| 引用本文: | 许吉,白久航,凌志远,朱能杰,严威威,蓝席建.转锈缓蚀低表面处理涂料制备及性能[J].中国表面工程,2024,37(6):440~449 |
| XU Ji,BAI Jiuhang,LING Zhiyuan,ZHU Nengjie,YAN Weiwei,LAN Xijian.Fabrication and Performance of Low Surface Treatment Coating with Rust Conversion and Corrosion Inhibition[J].China Surface Engineering,2024,37(6):440~449 |
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| 摘要: |
| 海洋环境金属构筑物表面易腐蚀、维护成本高以及保养困难，而普通低表面处理涂料功能单一，无法长效防腐，且缓蚀剂与水性涂料配方体系难以兼容。引入适量咪唑啉缓蚀剂与过量的自交联环氧发生预固化反应，提升涂层交联密度的同时具备缓蚀钝化功能，加上乙二胺四乙酸（EDTA）与金属底材的络合作用，制得一种具有高效强渗透、转锈和缓蚀功能的水性涂层材料。通过扫描电子显微镜（SEM）、激光共聚焦扫描显微镜（LSCM）、X 射线衍射仪（XRD）、拉曼光谱仪（Raman） 和 X 射线光电子能谱（XPS）等手段对转锈缓蚀低表面处理涂料的转锈性能和缓蚀机制进行初步探索。结果表明，金属基材表面的锈蚀产物在转锈剂和缓蚀剂的双重作用下快速形成稳定的“沉淀型”转化膜和钝化膜。拉曼和 XRD 显示，锈转化率达到 72.4%，转锈膜和钝化膜的协同保护使涂层具有长效防腐性能，3.5% NaCl 盐水浸泡试验 168 h 后附着力衰减值仅为 3.3%， 耐中性盐雾 500 h 仍具有良好的防腐效果。新型低表面处理转锈缓蚀涂料施工便捷、可有效降低金属构筑物表面处理等级， 同时减少涂层打磨带来的环境污染，提高施工效率，降低海洋环境下船舶和海洋平台等的运维成本，对于难以彻底表面处理的海洋环境金属材料的长寿命服役需求有着优异的工程应用前景。 |
| 关键词: 涂料 防腐 转锈剂 缓蚀剂 表面处理 |
| DOI：10.11933/j.issn.1007-9289.20231221002 |
| 分类号:TQ630 |
| 基金项目:国家重点研发计划重点专项（2022YFC3102503）；宁波市科技创新 2025 重大专项（2020Z053）；海洋新材料船舶应用研究（2022Y0011-3） |
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| Fabrication and Performance of Low Surface Treatment Coating with Rust Conversion and Corrosion Inhibition |
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XU Ji1，BAI Jiuhang1，2，LING Zhiyuan3，ZHU Nengjie1，YAN Weiwei1，4，LAN Xijian1
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1.Key Laboratory of Advanced Marine Materials, Ningbo Institute of Materials Technology and Engineering,Chinese Academy of Sciences, Ningbo 315201 , China ；2.School of Materials Science and Engineering, Jiangxi University of Science and Technology,Ganzhou 34100, China ；3.Cosco Shipping Energy Transportation Co., Ltd., Shanghai 200080 , China ；4.School of Materials Science and Chemical Engineering, Ningbo University, Ningbo 315211 , China
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| Abstract: |
| In the marine environment, the surfaces of metal structures are prone to corrosion, which leads to the common challenges of high maintenance costs and difficult upkeep. Conventional low surface treatment coatings typically offer limited functionality and mostly target superficial enhancements. These coatings often fall short in providing adequate long-term anti-corrosion protection. Whereas rust converters and corrosion inhibitors are effective solutions for treating surface rust and the corrosion protection of substrate surfaces, they encounter issues related to poor paint penetration and difficult compatibility with waterborne coating systems. This study focuses on the development of a novel low surface treatment coating that is capable of integrating long-term anti-corrosion properties, effective low surface treatment functionalities, and enhanced penetration capabilities. The novel coating formulation aims to harmonize the interplay between the rust converter, corrosion inhibitor, and waterborne coating to achieve synergistic, multifunctional benefits. By introducing a proper amount of imidazole corrosion inhibitor and an excessive self-crosslinking epoxy to initiate a pre-curing reaction, the coating’s crosslinking density and adhesion strength between the coating and substrate are significantly enhanced, which also breaks through the difficult challenge of compatibility between the corrosion inhibitor and waterborne coating formulation system. Moreover, through the complexation of EDTA with the metal substrate, the coating can form a stable “precipitation-type” passivation film to protect the substrate from corrosion. Furthermore, by adding a suitable amount of rust converter and a coupling agent, efficient rust conversion and strong penetration can be achieved. This innovative coating system represents a holistic approach by which to combat corrosion in marine environments, offering enhanced durability, multifunctional efficacy, and improved substrate protection via a carefully designed formulation strategy. The rust conversion performance and corrosion inhibition mechanism of the low surface treatment coatings were subjected to preliminary investigation via various analytical techniques, including scanning electron microscopy (SEM), laser scanning confocal microscopy (LSCM), X-ray diffraction (XRD), Raman spectrometry, and X-ray photoelectron spectroscopy (XPS). The results of microstructure and composition analyses before and after rust transformation reveal that the corrosion products on the rust surface of the metal substrate are effectively converted into a dense rust conversion film and passivation film under the dual action of the rust conversion agent and corrosion inhibitor, which successfully impedes the further occurrence of corrosion. The results of a quantitative XRD analysis show that the conversion rate of corrosion products reaches 72.4%, indicating that the coating has excellent rust transfer efficiency. The collaborative protection of the rust conversion film and passivation film gives the coating long-lasting anticorrosive performance. The test of neutral salt spray resistance shows that it still has a favorable anti-corrosion effect after 500 h of neutral salt spray resistance, indicating that the coating has excellent anti-corrosion properties. Moreover, these results prove that the two corrosion inhibitors both play a role in corrosion protection, indicating that they have excellent compatibility in waterborne coatings. The adhesion of the coating is effectively enhanced via the combination of the low surface treatment, strong penetration of the coupling agent, and improvement of the density inside and adhesion at the interface between the coating and substrate. Following a 168 h, 3.5% NaCl salt immersion test, the adhesion attenuation value is only 3.3%, effectively addressing the issues related to poor adhesion and difficult penetration encountered with the traditional low surface treatment coating. This novel low surface treatment coating for rust conversion and corrosion inhibition offers notable advantages in its ease of application, and it significantly enhances construction efficiency while concurrently reducing operational and maintenance expenses for ships and offshore platforms that operate within marine environments. With its promising engineering application prospects, this coating holds potential for extending the service lives of metal surfaces exposed to marine conditions. Hence, this coating addresses critical challenges in marine infrastructure maintenance and sustainability. |
| Key words: coating anti-corrosion rust conversion agent corrosion inhibitor surface treatments |
