Scanning Electron Microscopy of Carbon Nanotube–Epoxy Interfaces: Correlating Morphology to Sulfate Exposure

Epoxy resins are widely used as protective coatings in civil infrastructure, yet sulfate-rich environments accelerate their deterioration. This study evaluates the effectiveness of multi-walled carbon nanotubes (MWCNTs) in enhancing the sulfate resistance of epoxy resins. Neat and MWCNT-reinforced epoxy specimens (0.25 wt.% and 0.5 wt.%) were fabricated, heat cured at 100 °C and exposed to a solution of sulfuric acid and sodium chloride maintaining a pH of less than 3 for 0, 30, and 60 days. Analytical techniques, including scanning electron microscopy (SEM) and energy-dispersive spectroscopy (EDS), revealed distinct degradation patterns: the neat epoxy exhibited puncture damage and extensive salt deposition, while the MWCNT-reinforced specimens showed crack propagation mitigated by nanotube bridging. Heat curing introduced micro-voids that exacerbated sulfate ingress. The salt deposition surged to 200 times for the MWCNT-reinforced specimens compared to the neat ones, whereas crack width was higher in the MWCNT reinforced specimen compared to their neat counterparts, given that crack-bridging was observed. These findings highlight the potential of MWCNTs to improve epoxy durability in sulfate-prone environments, though the optimization of curing conditions and dispersion methods is critical.