The difficulty in preparing such coatings was mainly due to problems with the control of the assembled phase during interfacial reactions. Herein, the interactions between the filler and the polymer were found to be a key factor governing anticorrosion performance, which has scarcely been previously reported. The advantage of graphene as a filler in anticorrosion coatings lies in its dispersibility and miscibility with both the casting solvent and the polymer.
Electrochemically exfoliated graphene EC-graphene with appropriate surface functionalities that allow high miscibility with waterborne polyurethane PU and hydrophobic epoxy has been found to be an ideal filler that outperforms other graphene materials such as graphene oxide GO and reduced graphene oxide rGO. Furthermore, a bilayer coating with EC-graphene additives for PU over epoxy has been found to reduce the corrosion rate CR to 1.
Furthermore, we have shown that by controlling the amount of graphene loaded in the polymer galvanic corrosion favored by the formation of an interconnected graphene percolation network can successfully be limited. The present study, together with a facile and eco-friendly method of nanocomposite synthesis, may pave the way toward practical applications in the development of graphene-based anticorrosion coatings.
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