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<p>This study investigates the synergistic effect of incorporating graphene oxide (GO) nanosheets and ZrO<sub>2</sub> nanoparticles into an epoxy coating to enhance corrosion protection and extend the service life of stainless steel in saline environments. The micromorphological, structural, thermal, hydrophobic, and mechanical properties of epoxy, ZrO<sub>2</sub>/epoxy, and GO/ZrO<sub>2</sub>/epoxy coatings were systematically investigated using FESEM, FTIR, XRD, thermogravimetric analysis, water contact angle measurements, and microhardness testing. Corrosion resistance was evaluated using potentiodynamic polarization (PDP) and electrochemical impedance spectroscopy (EIS). Compared with pure epoxy and ZrO<sub>2</sub>/epoxy coatings, the GO/ZrO<sub>2</sub>/epoxy nanocomposite exhibited superior corrosion protection, achieving a corrosion current density of 16.8 nA/cm<sup>2</sup>, a corrosion rate of 0.001 mpy, and a charge transfer resistance of 923000 Ω. The enhanced performance is attributed to the dual barrier effect of GO nanosheets, which provide impermeability and mechanical reinforcement, combined with reduced coating porosity and blocked corrosive pathways induced by ZrO<sub>2</sub> nanoparticles. Long-term corrosion behavior was evaluated after 72 h of immersion in saline solution. The hybrid coating maintained a low corrosion current density of 24.7 nA/cm<sup>2</sup>, corrosion rate of 0.0013 mpy, and charge transfer resistance of 913200 Ω, demonstrating excellent durability and confirming the long-term protective capability of the GO/ZrO<sub>2</sub>/epoxy nanocomposite coating system.</p>

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Synergistic effect of GO nanosheets and ZrO2 nanoparticles in epoxy coatings for improved electrochemical corrosion protection of stainless steel in saline solution

  • 期刊论文

  • 出版模式：

    开放获取

  • 发表日期：

    2026年5月13日

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  • Khalid Alshaybani,
  • Khaled M. Chahrour,
  • Hayrettin Ahlatçı,
  • Ahmed Abdel Nazeer

摘要

This study investigates the synergistic effect of incorporating graphene oxide (GO) nanosheets and ZrO2 nanoparticles into an epoxy coating to enhance corrosion protection and extend the service life of stainless steel in saline environments. The micromorphological, structural, thermal, hydrophobic, and mechanical properties of epoxy, ZrO2/epoxy, and GO/ZrO2/epoxy coatings were systematically investigated using FESEM, FTIR, XRD, thermogravimetric analysis, water contact angle measurements, and microhardness testing. Corrosion resistance was evaluated using potentiodynamic polarization (PDP) and electrochemical impedance spectroscopy (EIS). Compared with pure epoxy and ZrO2/epoxy coatings, the GO/ZrO2/epoxy nanocomposite exhibited superior corrosion protection, achieving a corrosion current density of 16.8 nA/cm2, a corrosion rate of 0.001 mpy, and a charge transfer resistance of 923000 Ω. The enhanced performance is attributed to the dual barrier effect of GO nanosheets, which provide impermeability and mechanical reinforcement, combined with reduced coating porosity and blocked corrosive pathways induced by ZrO2 nanoparticles. Long-term corrosion behavior was evaluated after 72 h of immersion in saline solution. The hybrid coating maintained a low corrosion current density of 24.7 nA/cm2, corrosion rate of 0.0013 mpy, and charge transfer resistance of 913200 Ω, demonstrating excellent durability and confirming the long-term protective capability of the GO/ZrO2/epoxy nanocomposite coating system.