In a significant stride towards developing eco-friendly and highly effective anti-corrosive coatings, researchers from Jishou University have unveiled a novel formulation that could revolutionize the energy sector’s approach to protecting infrastructure. The study, led by ZHANG Feng and colleagues from the College of Chemistry and Chemical Engineering, explores the potential of water-borne epoxy resin latex combined with flaky Zn-Al-Mg-Ce alloy powder to create coatings with exceptional corrosion resistance.
Corrosion is a persistent challenge in the energy sector, leading to substantial maintenance costs and potential safety hazards. Traditional anti-corrosive coatings often rely on toxic materials, making them environmentally unfriendly. The research published in ‘Cailiao Baohu’ (which translates to ‘Materials Protection’) offers a promising alternative. “Our goal was to develop a coating that not only performs exceptionally well but also minimizes environmental impact,” said ZHANG Feng, the lead author of the study.
The team investigated the effects of various factors, including the type of anti-corrosive pigments, pigment volume concentration (PVC), silane coupling agent, and dispersant, on the coating’s performance. They found that the coating with flaky Zn-Al-Mg-Ce alloy powder exhibited superior corrosion resistance compared to those with spherical and lamellar Zn-Al alloy. Notably, at a PVC of 28%, the coating demonstrated the best overall performance.
The optimal formulation, containing 12.0% flaky Zn-Al-Mg-Ce alloy, 28% PVC, 3.2% silane coupling agent, and 1.5% wetting dispersant, showed remarkable properties. It achieved an adhesion grade of 1, a hardness of 4H, and endured a neutral salt spray test for 600 hours. The corrosion rate of the coated substrate decreased to an impressive 0.064% of the uncoated substrate, and the water resistance test lasted for 780 hours without any foaming or falling off.
The implications of this research for the energy sector are profound. “This coating could significantly extend the lifespan of infrastructure, reducing maintenance costs and enhancing safety,” said ZHANG Feng. The use of environmentally friendly materials also aligns with the growing emphasis on sustainability in the energy industry.
The study’s findings could pave the way for future developments in anti-corrosive coatings, particularly in the energy sector. As the industry continues to seek innovative solutions to combat corrosion, this research offers a promising path forward. The team’s work, published in ‘Cailiao Baohu’, underscores the importance of ongoing research and development in materials science to address real-world challenges.