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<p>With the rapid expansion of offshore wind power, enhancing the corrosion resistance of tower barrel materials in harsh marine environments has become critical. This study investigates a three-layer composite coating system—comprising a graphene-modified epoxy prime coat, micaceous iron oxide (MIO) intermediate coat, and polyurethane topcoat—applied to tinplate substrates. The corrosion behavior and protective performance were systematically evaluated through electrochemical tests (EIS, potentiodynamic polarization), surface characterization (XRD, XPS, SEM), and mechanical property assessments. Results demonstrated that the graphene-modified epoxy prime coat significantly improved corrosion resistance. Compared with the unmodified coating, the initial corrosion potential (0&#xa0;h) of graphene modified epoxy resin increased by 0.68&#xa0;V, and even after 1440 hours of corrosion, the corrosion current density remained at a lower level of 6.86 × 10<sup>-7</sup>A·cm<sup>-2</sup>. The composite system effectively mitigated the formation of porous corrosion products (Fe<sub>2</sub>O<sub>3</sub>, Fe<sub>3</sub>O<sub>4</sub>, α-FeOOH, γ-FeOOH) and maintained adhesion strength even after 1440 hours of salt spray exposure. Mechanical tests revealed a 25% decline in the steel’s elastic modulus post-corrosion, yet the coating system slowed degradation. Molecular dynamics simulations further elucidated the permeation of Cl<sup>-</sup> ions and the corrosion mechanism at the coating-substrate interface. This work highlights the efficacy of graphene-enhanced coatings in extending the service life of offshore wind infrastructure, offering theoretical and experimental insights for advancing marine anti-corrosion technologies.</p>

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Research on Corrosion Resistance of Offshore Wind Turbine Tower with Multi-layer Composite Coatings

  • 期刊论文

  • 发表日期：

    2026年6月3日

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  • Fu You,
  • Banghua Liu,
  • Di Zhang,
  • Xin Zhang,
  • Yunpu Tai,
  • Hongyi Liu,
  • Jingke Pei,
  • Qiding Ran,
  • Huanqin Peng,
  • Rui Zuo,
  • Mingpeng He,
  • Yuanjie Li,
  • Guanggen Zeng

摘要

With the rapid expansion of offshore wind power, enhancing the corrosion resistance of tower barrel materials in harsh marine environments has become critical. This study investigates a three-layer composite coating system—comprising a graphene-modified epoxy prime coat, micaceous iron oxide (MIO) intermediate coat, and polyurethane topcoat—applied to tinplate substrates. The corrosion behavior and protective performance were systematically evaluated through electrochemical tests (EIS, potentiodynamic polarization), surface characterization (XRD, XPS, SEM), and mechanical property assessments. Results demonstrated that the graphene-modified epoxy prime coat significantly improved corrosion resistance. Compared with the unmodified coating, the initial corrosion potential (0 h) of graphene modified epoxy resin increased by 0.68 V, and even after 1440 hours of corrosion, the corrosion current density remained at a lower level of 6.86 × 10-7A·cm-2. The composite system effectively mitigated the formation of porous corrosion products (Fe2O3, Fe3O4, α-FeOOH, γ-FeOOH) and maintained adhesion strength even after 1440 hours of salt spray exposure. Mechanical tests revealed a 25% decline in the steel’s elastic modulus post-corrosion, yet the coating system slowed degradation. Molecular dynamics simulations further elucidated the permeation of Cl- ions and the corrosion mechanism at the coating-substrate interface. This work highlights the efficacy of graphene-enhanced coatings in extending the service life of offshore wind infrastructure, offering theoretical and experimental insights for advancing marine anti-corrosion technologies.