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Graphene-based epoxy coatings push corrosion resistance limits for steel reinforcement
A comprehensive review highlights the advancements of graphene nanofillers in epoxy coatings, offering over 99 % corrosion resistance in chloride-rich environments. The study examines performance mechanisms, long-term durability, and practical synthesis methods.
Epoxy coatings are widely used to protect steel reinforcement in corrosive environments, yet their susceptibility to defects allows water and ions to penetrate, leading to corrosion. A recent review examines how graphene (G) and its derivatives—graphene oxide (GO) and reduced graphene oxide (rGO)—can improve the barrier properties of epoxy coatings. However, challenges such as micro-galvanic corrosion from nanofiller agglomeration require careful optimisation.
The study evaluates the corrosion resistance performance of graphene-enhanced epoxy coatings in chloride-rich environments, categorising results into short-term (≤24 h) and long-term (>24 h) exposures. Graphene-based coatings consistently outperformed neat epoxy, with many achieving corrosion resistance efficiencies above 99 %. For long-term durability, functionalised or oriented graphene fillers delivered stronger interfacial adhesion and reduced delamination index values, mitigating degradation risks over time.
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Balancing performance and scalability
Key factors influencing corrosion resistance include nanofiller loading, dispersion techniques, and synthesis methods. In situ polymerisation emerged as the most effective method for producing uniform, low-porosity coatings, while solution mixing offers a scalable and cost-effective alternative. Advanced characterisation techniques such as SEM, TEM, and AFM are widely used to assess nanofiller dispersion but often require complementary methods to overcome resolution and depth limitations.
This review underscores the potential of graphene nanofillers to redefine epoxy coatings for steel protection. By balancing performance, durability, and scalability, these innovations open new pathways for corrosion-resistant materials in infrastructure and marine applications.
Source: Sanya, O. T. & Panesar, D. K., Mechanistic advances in graphene-based nanofiller epoxy coatings for corrosion protection of reinforcing steel: Performance and practical outlook. Progress in Organic Coatings, 213, 109900 (2025).
