Synthesis and characterizations of hybrid nanocomposite coatings for enhanced anticorrosion performance

Most industries are facing problems with the corrosion of metals. Anticorrosive coatings can efficiently prevent metal corrosion. In this study, novel nanocomposite coating layers were prepared on low-carbon steel using electrostatic spray. Aluminum-rich epoxy–polyester (ALREPP) was prepared as a sacrificial metal and coated layer and functionalized with graphene oxide (GO/ALREPP) and silicon dioxide–graphene oxide (SiO₂-GO/ALREPP). In a water–alcohol solution, a sol–gel preparation method has been used to produce SiO₂-GO using tetraethoxysilane. Characterization of the prepared nanohybrid composites was conducted using X-ray diffraction (XRD), Fourier transform infrared spectroscopy (FTIR), UV–Vis spectroscopy, and field emission scanning electron microscopy (FESEM). Open-circuit potential (OCP), electrochemical impedance spectroscopy (EIS), Tafel polarization, and pull-off adhesion tests were utilized to examine the coated steel substrates’ mechanical properties and corrosion resistance. As demonstrated by the results, the anticorrosion protection effect of SiO₂-GO/ALREPP on the substrate was better than that of pure EPP and GO. The nanofiller’s uniform distribution decreased the corrosive electrolyte penetration into the coating material, exhibiting excellent anticorrosion performance and enhanced corrosion protection efficiency up to 99.9%.