New Hexafunctional Epoxy Prepolymer: Innovation Structure for Corrosion Inhibition

The corrosion of metals is a pervasive issue across various industries, leading to significant economic losses. The development of new protective agents, particularly organic inhibitors, is a promising approach for mitigating corrosion. This study introduces a novel hexafunctional phosphorus epoxy resin, HGTMDAP, as an innovative corrosion inhibitor for metal surfaces in acidic environments. HGTMDAP was synthesized via a two-step reaction involving methylene dianiline and phosphorus trichloride, followed by epichlorohydrin addition. Its structure was confirmed using FTIR, ¹H, and ¹³C NMR techniques. The corrosion inhibition performance was assessed through electrochemical evaluations (EIS, PDP), SEM/EDX analysis for surface characterization, and theoretical simulations (DFT, MC, and MD) to elucidate the adsorption mechanism and interaction with metal surfaces. The HGTMDAP resin demonstrated exceptional corrosion inhibition efficiency, reaching 96.3% at an optimal concentration of 10^–3 M. Electrochemical studies validated its role as a mixed-type inhibitor, forming a protective film on the metal surface. Theoretical simulations supported the experimental findings, revealing strong adsorption and interaction mechanisms at the molecular level. This comprehensive approach underscores the potential of HGTMDAP as a highly effective corrosion inhibitor under acidic conditions.