Corrosion resistance of tannic acid, d-limonene and nano-ZrO2 modified epoxy coatings in acid corrosion environments

doi:10.1016/j.jmst.2020.03.081

Abstract

Abstract:

The protection of rusted carbon steel in acid corrosion environments is of great significance for equipment to keep safe operation. In this work, we presented a method to protect the rusted steel by rust conversion treatment and epoxy coating. Tannic acid was selected as rust conversion agent. Tannic acid, d-limonene and nano-ZrO₂ were used to improve the corrosion resistance of epoxy coatings. The Raman spectra, X-ray diffraction and 3D confocal images were used to characterize the rust conversion reaction. Adhesion test showed that the loss of wet adhesion of the optimal coating was relatively low due to the addition of tannic acid, limonene and nano-ZrO₂. The corrosion resistance of five different coatings was investigated by scanning electron microscopy (SEM) and electrochemical analysis. Results show that after 264 h acid immersion, the low frequency resistance of the optimal coating consisting of rust conversion treatment and additives is 10⁷ Ω cm², three orders magnitude higher than that of the pristine coating. Moreover, SEM indicates that the optimal coating possesses a smooth surface and an unbroken interface between substrate and coating. Accordingly, the corrosion-resistant mechanism of the hybrid coating is proposed.

Key words: Epoxy coatings, Corrosion resistance, Rust treatment, Tannic acid, Synergistic inhibition effect

Junwei Chang, Zhenyu Wang, En-hou Han, Xinlei Liang, Gang Wang, Zuyao Yi, Na Li. Corrosion resistance of tannic acid, d-limonene and nano-ZrO₂ modified epoxy coatings in acid corrosion environments[J]. J. Mater. Sci. Technol., 2021, 65: 137-150.

Figures/Tables 20

Table 1 The composition of five coatings.

Samples	Rust treatment	Composition
1	None	99.5 wt% epoxy resin E51 + 0.5 wt% BYK-108 dispersant
2	Tannic acid	Coating 1
3	Tannic acid	Coating 1 + 3 wt% tannic acid
4	Tannic acid	Coating 1 + 3 wt% tannic acid + 3 wt% limonene
5	Tannic acid	Coating 1 + 3 wt% tannic acid + 3 wt% limonene + 3 wt% ZrO₂

Fig. 1. Photographs of rusted carbon steel before (a) and after (b) tannic acid treatment.

Fig. 2. SEM images of rusted carbon steel before (a, b) and after (c, d) tannic acid treatment.

Fig. 3. 3D confocal images of rusted carbon steel before (a) and after (b) tannic acid treatment.

Fig. 4. Raman spectra (a) and XRD patterns (b) of rusted carbon steel before and after tannic acid treatment.

Fig. 5. Adhesions of coatings 1, 2, 3, 4, and 5 after different immersion time.

Fig. 6. SEM images of surface morphologies for different samples after 264 h acid immersion at 60 °C: (a) coating 1; (b) coating 2; (c) coating 3; (d) coating 4; (e) coating 5.

Fig. 7. Cross-section morphology and corresponding element mapping of different coatings after 264 h immersion: (a) coating 1; (b) coating 2; (c) coating 3; (d) coating 4; (e) coating 5.

Fig. 8. Potentiodynamic polarization curves of five coatings after immersion in hybrid acid solution for 264 h.

Table 2 Polarization parameters for five different coatings immersed in hybrid acid solution for 264 h.

Samples	E_corr (mV vs. SCE)	I_corr (μA cm^-2)
1	-596.1 ± 0.7	2.260 ± 0.010
2	-588.6 ± 0.6	0.785 ± 0.008
3	-585.4 ± 0.5	0.523 ± 0.006
4	-577.9 ± 0.6	0.191 ± 0.007
5	-569.3 ± 0.5	0.111 ± 0.005

Fig. 9. EIS diagram of coating 1 for different immersion time. (a-c) Nyquist diagrams: (a) 0-12 h, (b) 24-72 h, (c) 96-264 h; (d) Bode modulus plots; (e) Bode phase angle plots.

Fig. 10. EIS diagram of coating 2 for different immersion time. (a, b) Nyquist diagrams: (a) 0-96 h, (b) 120-264 h; (c) Bode modulus plots; (d) Bode phase angle plots.

Fig. 11. EIS spectra of coating 3 for different immersion time. (a, b) Nyquist diagrams: (a) 0-24 h, (b) 48-264 h; (c) Bode modulus plots; (d) Bode phase angle plots.

Fig. 12. EIS diagram of coating 4 for different immersion time. (a) Nyquist diagrams; (b) Bode modulus plots; (c) Bode phase angle plots.

Fig. 13. EIS diagram of coating 5 for different immersion time. (a) Nyquist diagrams; (b) Bode modulus plots; (c) Bode phase angle plots.

Fig. 14. Impedance at 0.01 Hz (a) and breakpoint frequency (?b) (b) of different coatings exposed to the mix acid solution.

Fig. 15. Schematic diagrams of corrosion protection mechanism for coating 1 (a), coating 2 (b), coating 3 (c), coating 4 (d), and coating 5 (e).

Scheme 1. Interaction between tannic acid and d-limonene.

Scheme 2. Interaction between tannic acid and nano-ZrO2 particle.

Scheme 3. Interaction between d-limonene and nano-ZrO2 particle.

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Corrosion resistance of tannic acid, d-limonene and nano-ZrO₂ modified epoxy coatings in acid corrosion environments

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