MoS2 sheets are becoming more and more active in the field of anticorrosion coatings. In this work, different size of MoS2 were fabricated by a simple gradient centrifugation approach then introduced into epoxy coatings (EP). Composite coatings with smaller size and larger size of MoS2 were also prepared for comparison. Anticorrosion properties of the coatings were evaluated via electrochemical spectroscopy, salt spray tests and theoretical calculation in detail. The impedance arc of doping the 1.4±0.1 μm of EM2000 for EP was 4.8×107 Ω cm2 after 7d immersing, which is much higher than that of EM800/EP, EM1000/EP and EM3000/EP. Salt spray test and corrosion products analysis have also proved the proposed protection mechanism of EM2000/EP coating. Doping the optimized size of EM2000 could form nano-network covering the microcracks to impede the diffusion of corrosive medium. In addition, the theoretical calculation showed that the body-center adsorption of O2 show the weaker physisorption with adsorption energies of ∼ −0.64 eV and −0.14 eV for H2O and O2. Excellent barrier ability and enhanced dispersion of the optimized size of MoS2 sheets were responsible for the superior enhancement of the anticorrosion performance of EP coating.
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