Microcapsules show great potential in metal anticorrosive coating in recent years. In the following paper, first, urea-formaldehyde (UF) microcapsules containing cerium nitrate were synthesized under different parameter conditions. Three different quantities of the microcapsules were introduced to the epoxy coatings and applied on the AZ31B substrate to meet the increasing demands for anticorrosive coatings. An analysis of the scanning electron microscopy surface morphology of UF microcapsules synthesized by nine different parameter conditions shows that the ratio of formaldehyde to urea is 1.5:1, and 2 wt.% of emulsifier, 25 wt.% of cerium nitrate, and 150 r/min of rotation speed are the best choice for the synthesis of microcapsules, resulting in spherical particles with an average particle size of about 25 μm. The characteristics of microcapsules were studied by optical microscope, Fourier transform infrared, and thermogravimetric analysis. The result of electrochemical impedance spectroscopy indicated that the 2 wt.% microcapsule content in the defective coating shows better corrosion protection performance than neat epoxy coating and cerium nitrate inhibitor coating.
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