An Exploratory Study on Graphene‐Based Hybrid Epoxy Coatings for Corrosion Resistance and Self‐Healing

ABSTRACT Corrosion of metallic process equipment in chemical, marine, and offshore industries leads to significant maintenance costs and safety concerns. Conventional epoxy coatings, though widely applied, often deteriorate under harsh conditions due to microcracking, moisture ingress and lack of self‐healing capability. This study develops multifunctional epoxy nanocomposite coatings incorporating electrochemically exfoliated graphene (EG) and functionalized nanoparticles, namely, iron oxide (f‐Fe₃O₄) and zeolite (f‐Zeo), to enhance durability and reduce lifecycle costs of process systems. EG was synthesized using an eco‐friendly electrochemical exfoliation method in 0.3 M Na₂SO₄ at applied voltages of 5 and 10 V, with higher voltage producing thinner, well‐delaminated flakes confirmed by FESEM. Binary and ternary nanoparticle hybrids were dispersed in epoxy and evaluated for adhesion (ASTM D3359), UV‐triggered self‐healing, and corrosion protection under cyclic salt exposure. The EG/f‐Zeo hybrid achieved the best overall performance, with stable dispersion, strong adhesion, and corrosion inhibition efficiency of 92.26%. UV‐induced self‐healing was evident in all EG‐containing systems, highlighting its role as a photothermal agent for damage repair. In contrast, ternary hybrids exhibited reduced effectiveness due to agglomeration. These results provide practical insights for designing smart, corrosion‐resistant coatings tailored for chemical process infrastructure, supporting sustainable operations in aggressive industrial environments.