Enhancement of hydrophobic, resistive barrier and anticorrosion performance of epoxy coating with addition of Clay-Modified Green Silico-Graphitic Carbon

Under this study, a straightforward method for producing clay-modified silico-graphitic carbon (CGSGC) was developed and applied to create CGSGC/epoxy coatings for carbon steel (CS). The CGSGC was synthesized using a mixture of 25 % pond clay, and 75 % remnant agricultural biomass by mass via pyrolysis route. The aim was to evaluate the barrier and anti-corrosion properties of these coatings. The results demonstrated that adding 0.1 wt.% of CGSGC in the epoxy (EP) matrix enhanced its anti-corrosion inhibition capabilities by 99.8 % when compared with standard EP coating. The 0.1 wt.% CGSGC/EP mixed coating also exhibited robust hydrophobicity with WCA of 142.2° and thermal stability up to 250 °C with 2–3 % coating weight reduction. The microhardness of the optimized sample shows a 59.18 % improvement compared to standard EP coating. SEM images revealed improved EP compactness and reduction in microstructural defects (holes and cracks), with the incorporation of 0.1 wt.% CGSGC. 3D profilometry showed a smoother surface for the 0.1 wt.% CGSGC/EP coating. Similar such materials, while being abundantrly and renewably available, can be a safer alternative to conventional hazardous chemicals for protecting carbon steel from corrosion; not to mention the carbon credit benefits they entail.