In-situ phosphatization and enhanced corrosion properties of films made of phosphate functionalized nanoparticles

Multifunctional Waterborne Polyurethane Microreactor-Based Approach to Fluorocarbon Composite Latex Coatings with Double Self-Healing and Excellent Synergistic Performances

In this article, chlorotrifluoroethylene (CTFE)-based fluorocarbon composite latexes and their coatings are successfully fabricated by an environmentally friendly preparation method based on a new multifunctional waterborne polyurethane (MFWPU) dispersion. It is worth noting that the MFWPU acts as the sole system stabilizer as well as microreactor and simultaneously endows the composite coating with excellent double self-healing performance and adhesion. Moreover, the introduction of a dynamic disulfide bond in the polyurethane dispersion entrusts the coating with excellent scratch self-healing performance. Simultaneously, carbon-carbon double bonds in the polyurethane dispersion increase the compatibility between the core polymer and shell polymer. The fluorine-containing chain segments can be distributed in the coating evenly during the self-assembly film-forming process of composite particles so that the original element composition of the worn coating surface can restore the original element composition after heating, and the coating presents a regeneration ability, which further and verifies the usefulness of the double self-healing model of the coating. Afterward, efficient recovery and durability, which are two contradictory properties of scratch self-healing polymers, are optimized to obtain a composite coating with excellent comprehensive performance. The research results regarding the composite system may provide a valuable reference for the structural design and application of waterborne fluorocarbon functional coatings in the future.

Strategies to incorporate a fluorinated acrylate monomer into polymer particles: from particle morphology to film morphology and anticorrosion properties

Four strategies to incorporate a fluorinated monomer (perfluoro octyl acrylate, POA) into a waterborne polymeric dispersion are investigated. Due to the very low water solubility of the POA monomer, three of the strategies use miniemulsion droplets containing the whole POA monomer in the initial charge. The rest of the comonomers of the formulation (methyl methacrylate, MMA, and n-butyl acrylate, BA) are partially incorporated in the initial miniemulsion or fed to the reactor as a preemulsion. In the fourth strategy, a conventional seeded semibatch emulsion polymerization is carried out using cyclodextrin in the seed and feeding the POA/MMA/BA preemulsion to the reactor. Each process strategy led to a distinct particle morphology and hence a particular film morphology. We found that the strategy that produced core–shell particles with the core composed by pure polyPOA yielded the films that showed the best corrosion protection as measured in salt-spray test (1200 h standing without damage).

Taking Advantage of Phosphate Functionalized Waterborne Acrylic Binders to Get Rid of Inhibitors in Direct-to-Metal Paints

In this paper, two phosphate functionalized acrylic binders are formulated to yield direct-to-metal paints without using corrosion inhibitors. The difference between both binders is the addition of polystearylacrylate crystalline nanodomains in one of them, and an amorphous methyl methacylate-co-butyl acrylate copolymer in the other. The water sensitivity, mechanical stability, adhesion, and the performance of the paints against corrosion (high humidity resistance, accelerated weathering, and salt-spray tests) are assessed and compared with a DTM paint formulated from a commercial binder. The performance of both phosphate functionalized paints formulated without corrosion inhibitors in high humidity and weathering tests is superior to the commercial DTM paint formulated without corrosion inhibitors and similar to the DTM paint formulated with them. Furthermore, the paint based on the amorphous copolymer binder provides significantly good performance in the salt spray test (even superior to that of the DTM paint formulated with corrosion inhibitors).

Improved Corrosion Protection of Acrylic Waterborne Coating by Doping with Microencapsulated Corrosion Inhibitors

Herein, a waterborne acrylic coating doped with pH sensitive colophony microcapsules containing corrosion inhibitors was studied on carbon steel plates. The changes in the physical properties of the coatings were studied. The microcapsule coating specimens maintained more noble Ecorr values compared to the control in deionized water and simulated concrete pore solutions with −513 and −531 mVSCE, respectively. Additionally, the microcapsule polarization results for both pH 12.6 and 6.2 electrolyte solutions showed lower icorr values of 1.20 × 10−6 and 3.24 × 10−6 A·cm−2, respectively, compared to the control sample (1.15 × 10−5 and 4.21 × 10−5 A·cm−2). Therefore, the microcapsule coating provided more protection from chloride attack on the substrate as well as the deleterious effects of low pH on carbon steel. The electrochemical impedance spectroscopy analysis corroborated the DC polarization results, showing increased corrosion resistance for the microcapsule coated specimens compared to the control. Moreover, the Rpore and Rct are much higher than the control, indicating the protection of the inhibitors. The Ceff,dl also shows lower values for the microcapsule coating than the control, showing a more protective and less doped double layer.

Assessing the Effect of CeO2 Nanoparticles as Corrosion Inhibitor in Hybrid Biobased Waterborne Acrylic Direct to Metal Coating Binders

CeO₂ nanoparticles were incorporated in waterborne binders containing high biobased content (up to 70%) in order to analyze the anticorrosion performance for direct to metal coatings. Biobased binders were synthesized by batch miniemulsion polymerization of 2-octyl acrylate and isobornyl methacrylate monomers using a phosphate polymerizable surfactant (Sipomer PAM200) that lead to the formation of phosphate functionalized latexes. Upon the direct application of such binders on steel, the functionalized polymer particles were able to interact with steel, creating a thin phosphatization layer between the metal and the polymer and avoiding flash rust. The in situ incorporation of the CeO₂ nanoparticles during the polymerization process led to their homogeneous distribution in the final polymer film, which produced outstanding anticorrosion performance according to the Electrochemical Impedance Spectroscopy measurements. In fact, steel substrates coated with the hybrid polymer film (30-40 µm thick) showed high barrier corrosion resistance after 41 days (~1000 h) of immersion in NaCl water solution and active inhibition capabilities thanks to the presence of the CeO₂ nanoparticles. This work opens the door to the fabrication of sustainable hybrid anticorrosion waterborne coatings.

Crosslinking in Semi-Batch Seeded Emulsion Polymerization: Effect of Linear and Non-Linear Monomer Feeding Rate Profiles on Gel Formation

Waterborne latex is often called a product-of-process. Here, the effect of semi-batch monomer feed rate on the kinetics and gel formation in seeded emulsion polymerization was investigated for the copolymerization of n-butyl methacrylate (n-BMA) and ethylene glycol dimethacrylate (EGDMA). Strikingly, the gel fraction was observed to be significantly influenced by monomer feed rate, even while most of the experiments were performed under so-called starve-fed conditions. More flooded conditions from faster monomer feed rates, including seeded batch reactions, counterintuitively resulted in significantly higher gel fraction. Chain transfer to polymer was intentionally suppressed here via monomer selection so as to focus mechanistic insights to relate only to the influence of a divinyl monomer, as opposed to being clouded by contributions to topology from long chain branching. Simulations revealed that the dominant influence on this phenomenon was the sensitivity of primary intramolecular cyclization to the instantaneous unreacted monomer concentration, which is directly impacted by monomer feed rate. The rate constant for cyclization for these conditions was determined to be first order and 4000 s-1, approximately 4 times that typically observed for backbiting in acrylates. This concept has been explored previously for bulk and solution polymerizations, but not for emulsified reaction environments and especially for the very low mole fraction divinyl monomer. In addition, while gel fraction could be dramatically manipulated by variations in linear monomer feed rates, it could be markedly enhanced by leveraging non-linear feed profiles built from combination sequences of flooded and starved conditions. For a 2 h total feed time, a fully linear profile resulted in 30% gel while a corresponding non-linear profile with an early fast-feed segment resulted in 80% gel.