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Functionalised aluminium oxide enhances corrosion resistance of epoxy coatings on mild steel
A study demonstrates how functionalised aluminium oxide nanoparticles (Al₂O₃F) improve the corrosion resistance of epoxy coatings, paving the way for advanced protective applications in aggressive environments.
Corrosion of mild steel in aggressive environments remains a critical challenge, often leading to structural degradation and economic loss. This study addresses the issue by improving epoxy-based coatings using aluminium oxide (Al₂O₃) nanoparticles and their functionalised variant, Al₂O₃F. These nanoparticles were synthesised and characterised using advanced techniques, including Fourier transform infrared spectroscopy (FT-IR), transmission electron microscopy (TEM), and scanning electron microscopy (SEM) with energy dispersive X-ray analysis (EDX).
Electrochemical testing in 3.5 wt% NaCl solution revealed superior corrosion resistance in epoxy-Al₂O₃F coatings compared to neat epoxy. Functionalisation of Al₂O₃ allowed better dispersion in the epoxy matrix, preventing nanoparticle agglomeration and creating a robust barrier against corrosive agents like chloride ions and water. The study also demonstrated improved tensile strength, contact angle, and salt spray resistance in coatings with higher concentrations of Al₂O₃F.
Reading tip: Epoxy resins
Due to their outstanding properties, epoxy resins are more widely used in the coating industry than almost any other class of binder. In their new reference book “”Epoxy Resins“”, the authors Dornbusch, Christ and Rasing explain the basics of the chemistry of the epoxy group and use specific formulations to explain the use of epoxy and phenoxy resins in industrial coatings – including corrosion protection, floor coatings, powder coatings and internal can coatings.
Advanced coatings for challenging environments
This research highlights the potential of functionalised Al₂O₃ nanoparticles in enhancing the protective properties of epoxy coatings. By improving corrosion resistance, these coatings offer practical solutions for applications in aggressive environmental conditions, such as marine infrastructure and industrial pipelines.
Source: Ola, S. K., Chopra, I., Ola, T., & Dhayal, V., Enhancing corrosion resistance of epoxy-based composite coatings on mild steel using functionalised aluminium oxide (Al₂O₃) nanoparticles. Scientific Reports, Article 5514 (2026)
