Strategic PANI/silica surface functionalization of cenospheres for enhanced barrier performance in epoxy composite coatings for metals

IF 5.3 2区材料科学 Q1 MATERIALS SCIENCE, COATINGS & FILMS

Surface & Coatings Technology Pub Date : 2025-06-23 DOI:10.1016/j.surfcoat.2025.132429

S.S. Ananthapadmanabhan, Smrutiranjan Parida

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引用次数: 0

Abstract

Cenosphere (CNS), a common type of modern industrial waste, which can be used as inorganic fillers to improve weathering and anti-corrosion applications in organic coatings. However, the anti-corrosion applications of CNS have not been very successful due to their high porosity and low interface binding with matrix, leading to poor anti-corrosion performance in coatings. Here we investigate various strategic surface modifications to overcome these limitations in the use of CNS in composite coatings. When CNS was surface modified with polyaniline (pCNS) and silica (sCNS), long-term consistent corrosion performance, high impact and adhesion performance were obtained even at a coating thickness of ∼65 μm. From electrochemical impedance spectroscopy study, thin composite coating with pCNS exhibited a five-order increase in coating resistance (∼10¹⁰ Ω.cm²), and very high barrier properties, with ∼62 % less water uptake than the coatings with unmodified CNS. In the accelerated corrosion studies (ASTM B117), pCNS and sCNS coatings showed protection efficiencies of >92 % and 73 %, respectively. The epoxy-pCNS composite coating also showed exceptional mechanical properties, with a 62 % increase in adhesion strength and a 66 % increase in impact strength. The surface modifications chosen are strategic in that they can give electrostatic and passive protection along with barrier protection. Results show that these modifications successfully address the CNS limitations reported in literature, yielding an economical coating with sustainable, long-term anticorrosion performance. These strategies also convert the solid waste like CNS into a value-added material in coating formulation for metal corrosion protection.

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战略性聚苯胺/二氧化硅微球表面功能化以增强环氧金属复合涂层的阻隔性能

空心微球（CNS）是一种常见的现代工业废弃物，可作为无机填料改善有机涂料的耐候性和耐腐蚀性。然而，由于CNS的孔隙率高，与基体的界面结合度低，导致其在涂料中的防腐性能不佳，防腐应用并不成功。在这里，我们研究了各种策略的表面改性，以克服在复合涂层中使用CNS的这些限制。当用聚苯胺（pCNS）和二氧化硅（sCNS）对CNS进行表面改性时，即使涂层厚度为~ 65 μm，也能获得长期一致的腐蚀性能、高冲击性能和粘附性能。电化学阻抗谱研究表明，含有pCNS的薄复合涂层的涂层电阻增加了5个数量级（~ 1010 Ω.cm2），并且具有非常高的阻隔性能，吸水率比未改性CNS的涂层减少了~ 62%。在加速腐蚀研究（ASTM B117）中，pCNS和sCNS涂层的防护效率分别为92%和73%。环氧树脂- pcns复合涂层还表现出优异的机械性能，粘接强度提高62%，冲击强度提高66%。所选择的表面改性是战略性的，因为它们可以提供静电和被动保护以及屏障保护。结果表明，这些改性成功地解决了文献中报道的CNS限制，产生了具有可持续、长期防腐性能的经济涂层。这些策略还将CNS等固体废弃物转化为金属防腐涂料配方中的增值材料。

本文章由计算机程序翻译，如有差异，请以英文原文为准。

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来源期刊

Surface & Coatings Technology 工程技术-材料科学：膜

CiteScore

10.00

自引率

11.10%

发文量

921

审稿时长

19 days

期刊介绍： Surface and Coatings Technology is an international archival journal publishing scientific papers on significant developments in surface and interface engineering to modify and improve the surface properties of materials for protection in demanding contact conditions or aggressive environments, or for enhanced functional performance. Contributions range from original scientific articles concerned with fundamental and applied aspects of research or direct applications of metallic, inorganic, organic and composite coatings, to invited reviews of current technology in specific areas. Papers submitted to this journal are expected to be in line with the following aspects in processes, and properties/performance: A. Processes: Physical and chemical vapour deposition techniques, thermal and plasma spraying, surface modification by directed energy techniques such as ion, electron and laser beams, thermo-chemical treatment, wet chemical and electrochemical processes such as plating, sol-gel coating, anodization, plasma electrolytic oxidation, etc., but excluding painting. B. Properties/performance: friction performance, wear resistance (e.g., abrasion, erosion, fretting, etc), corrosion and oxidation resistance, thermal protection, diffusion resistance, hydrophilicity/hydrophobicity, and properties relevant to smart materials behaviour and enhanced multifunctional performance for environmental, energy and medical applications, but excluding device aspects.