Metal corrosion is a global problem in industries such as construction, petroleum, and production. One common corrosion prevention is the application of polymeric coatings, acting as a physical barrier to inhibit/delay the permeation of the corrosive media. Thus, there is an opportunity to search for efficient and high-performance coatings. Composites usually performed better than the pristine matrix (e.g., polymer). Therefore, this study aimed to create a novel polymeric composite coating by insulating the metal from the corrosive environment with an inert matrix and macro fillers to make a tortuous path. Herein, Nylon 12 (PA-12) particles were dispersed as the fillers into a poly (vinylidene fluoride-co-hexafluoropropylene) (PVDF-HFP) matrix. PVDF-HFP has fluorine atoms which endow the polymer with superior chemical resistance as well as poor adhesion properties. In contrast, PA-12 can absorb water thereby changing its size and can improve the adhesion owing to the amide groups willing to interact with the metal surface. The corrosion resistance was evaluated by Electrochemical impedance analysis (EIS) and Potentiodynamic Polarization in a 3.5 wt% NaCl test solution with Mild Steel (MS) as a substrate. Results from electrochemical measurements indicated that small amounts of PA-12 (ranging from 0 to1 wt.%) are needed to enhance, by a synergistic effect, the overall protection performance of the PVDF-HFP composite coatings. After seven days of immersion, the PVDF-HFP/PA 12 dip-coated samples (thickness &lt; 1 mil) were able to protect MS from corrosion attack. The results were supported by Microscopy, Dielectric spectroscopy, and mechanical testing (ASTM D3359-Adhesion and ASTM D3363-Hardness). The coatings with an optimum PA-12 loading increased the resistance of the coating with time and the corrosion inhibition, reduced the corrosion rate and dielectric constant, and increased the adhesion of the film with the substrate.

Enhanced corrosion resistance of PVDF-HFP/PA-12 composite coatings

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