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<p>Corrosion of metallic materials remains a persistent challenge in industrial environments, resulting in substantial economic losses and safety concerns. Developing efficient and durable protective coatings is, therefore, a key scientific and engineering priority. This study hypothesizes that incorporating zirconia (ZrO₂) nanoparticles into a Poly[(4-methyl-5-vinylthiazole)-co-glycidyl methacrylate] [Poly(VTZ-co-GMA)] matrix will enhance the coating’s structural integrity and electrochemical corrosion resistance on mild steel. Accordingly, Poly(VTZ-co-GMA) and its nanocomposites containing various loadings of ZrO₂ were synthesized via in-situ solution polymerization and systematically characterized using Fourier-transform infrared spectroscopy (FT-IR), X-ray diffraction (XRD), scanning electron microscopy (SEM), and transmission electron microscopy (TEM). Electrochemical behavior was evaluated using potentiodynamic polarization and electrochemical impedance spectroscopy (EIS) in a 3.5% NaCl solution. Results revealed that bare mild steel (MS) exhibited the highest corrosion rate (0.71190&#xa0;mm/yr), whereas Poly(VTZ-co-GMA) coatings substantially reduced corrosion (0.07092&#xa0;mm/yr) with an increase in polarization resistant (<i>R</i><sub><i>p</i></sub>) and a positive shift in corrosion potential (<i>E</i><sub><i>corr</i></sub>). Notably, the Poly(VTZ-co-GMA)/ZrO₂ (2.0 wt%) nanocomposite achieved the lowest corrosion rate (0.00354&#xa0;mm/yr), with high <i>R</i><sub><i>p</i></sub> (31.79 × 10<sup>4</sup> Ω), charge transfer resistance (<i>R</i><sub><i>ct</i></sub>) (2067 Ω·cm<sup>2</sup>), low double layer capacitance (<i>C</i><sub><i>dl</i></sub>) (1.023 × 10<sup>− 6</sup> F·cm<sup>− 2</sup>), and a protection efficiency exceeding 96%. The superior protection is attributed to the homogeneous dispersion of ZrO<sub>2</sub> nanoparticles, which improve the coating’s barrier performance and reduce ionic diffusion pathways. Overall, the study demonstrates that ZrO<sub>2</sub> incorporation into Poly(VTZ-co-GMA) offers a promising route for developing advanced nanocomposite coatings with enhanced structural stability and electrochemical corrosion resistance.</p>

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Electrochemical and structural evaluation of Poly(VTZ-co-GMA)/ZrO₂ nanocomposite coatings for corrosion protection of mild steel

  • 期刊论文

  • 发表日期：

    2025年12月20日

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  • O. Akbar Basha,
  • I. Pugazhenthi,
  • K. Mohammed Rehan,
  • S. Mohammed Safiullah

摘要

Corrosion of metallic materials remains a persistent challenge in industrial environments, resulting in substantial economic losses and safety concerns. Developing efficient and durable protective coatings is, therefore, a key scientific and engineering priority. This study hypothesizes that incorporating zirconia (ZrO₂) nanoparticles into a Poly[(4-methyl-5-vinylthiazole)-co-glycidyl methacrylate] [Poly(VTZ-co-GMA)] matrix will enhance the coating’s structural integrity and electrochemical corrosion resistance on mild steel. Accordingly, Poly(VTZ-co-GMA) and its nanocomposites containing various loadings of ZrO₂ were synthesized via in-situ solution polymerization and systematically characterized using Fourier-transform infrared spectroscopy (FT-IR), X-ray diffraction (XRD), scanning electron microscopy (SEM), and transmission electron microscopy (TEM). Electrochemical behavior was evaluated using potentiodynamic polarization and electrochemical impedance spectroscopy (EIS) in a 3.5% NaCl solution. Results revealed that bare mild steel (MS) exhibited the highest corrosion rate (0.71190 mm/yr), whereas Poly(VTZ-co-GMA) coatings substantially reduced corrosion (0.07092 mm/yr) with an increase in polarization resistant (Rp) and a positive shift in corrosion potential (Ecorr). Notably, the Poly(VTZ-co-GMA)/ZrO₂ (2.0 wt%) nanocomposite achieved the lowest corrosion rate (0.00354 mm/yr), with high Rp (31.79 × 104 Ω), charge transfer resistance (Rct) (2067 Ω·cm2), low double layer capacitance (Cdl) (1.023 × 10− 6 F·cm− 2), and a protection efficiency exceeding 96%. The superior protection is attributed to the homogeneous dispersion of ZrO2 nanoparticles, which improve the coating’s barrier performance and reduce ionic diffusion pathways. Overall, the study demonstrates that ZrO2 incorporation into Poly(VTZ-co-GMA) offers a promising route for developing advanced nanocomposite coatings with enhanced structural stability and electrochemical corrosion resistance.