Synthesis and characterization of anticorrosion zirconia/acrylic nanocomposite resin coatings for steel

For long-term performance in outdoor applications, compatible inorganic fillers with reliable corrosion inhibiting abilities are incorporated within acrylic coatings for metallic structures that are susceptible to atmospheric degradation. However, challenges still abound on the selection criteria for appropriate fillers suitable for most coatings. In this work, zirconia nanoparticles (ZrO2NPs) were prepared from zirconium ethoxide via sol-gel technique. Zirconia-modified acrylic nanocomposite resins were subsequently prepared by incorporating ZrO2NPs within different grams of an acrylic base resin. In-depth characterization was conducted for both prepared ZrO2NPs and the synthesized zirconia-modified acrylic coatings. The inorganic/organic hybrid resin coating was applied on Q235 steel to prevent its corrosion in 3.5. wt% NaCl solution. The presence of ZrO2NPs within these acrylic coatings further blocked inherent pathways to which corrosive ions and molecules could have permeated the coating; hence, delaying steel corrosion. The optimum amount of ZrO2NP fillers required to prepare an anticorrosion acrylic resin coating with efficient barrier properties has been identified. These particles further strengthened the gross mechanical properties of the coatings in terms of bulk structural reinforcement while also enhancing their barrier performances. This work highlights the relationship between coating content and the failure mechanisms in degrading acrylic coatings within saline medium. These modified acrylic resin coatings may have a future as outdoor protective coatings against atmospheric corrosion for metal structures.