Enhancing anticorrosive properties of low-zinc composite epoxy coatings with graphene

Traditional zinc-rich coatings face challenges such as high zinc powder content, brittle film formation, poor adhesion, high porosity, and low zinc powder utilization. In this study, graphene was introduced into an epoxy coating with a 30% zinc powder content to develop a graphene-modified low-zinc coating with exceptional corrosion resistance and mechanical properties. The primary objective was to determine the optimal graphene addition for enhanced corrosion resistance and mechanical performance. Characterization of the coating included assessing pull-off adhesion, flexibility, impact resistance, saltwater resistance, and resistance to acids and alkalis. Concurrently, the corrosion resistance of coatings was thoroughly examined through electrochemical testing and salt spray experiments. Our findings indicate that the coating demonstrated optimal overall performance with a graphene content of 1%, achieving superior corrosion resistance as well as enhanced physical and mechanical properties.