Enhancing hydrophobicity and corrosion resistance of epoxy resin coatings using KH570-ZrO2 nanoparticles

Epoxy resin has excellent adhesion, mechanical strength, environmental adaptability and corrosion resistance. As a concrete coating, it can effectively seal internal pores, prevent the penetration of water and corrosive ions. However, the epoxy resin has a relatively high content of hydrophilic groups and lacks an effective physical barrier structure. In this work, KH570-ZrO 2 nanoparticles were synthesized by modifying zirconium oxide (ZrO 2 ) with 3-Methacryloxypropyltrimethoxysilane (KH570) and then mixed with epoxy resin to prepare epoxy coatings. The thermal properties, mechanical properties, hydrophobicity and corrosion resistance of the coatings were studied respectively. The results indicated that when the content of ZrO 2 particles was 3.0 wt% of the epoxy resin, the modified epoxy coating demonstrated the most notable enhancements in both thermal and mechanical properties. Moreover, it exhibited optimal hydrophobicity and corrosion resistance. The KH570-ZrO 2 nanoparticles constructed a micro-nano composite rough structure. Meanwhile, low surface energy organosilane segments were introduced. These two factors jointly decreased the contact. In addition, KH570-ZrO 2 particles are uniformly dispersed in the cross linked network. Through the “maze effect”, they extend the diffusion paths of environmental moisture, oxygen, and various ions, thereby effectively inhibiting the penetration of these media into the concrete matrix. Overall, this work successfully improved the mechanical, hydrophobic and corrosion resistant properties, offering an effective technique for enhancing the durability of protective coatings. • The effect of KH570-ZrO 2 on the hydrophobic properties and corrosion resistance of epoxy coatings was characterized. • The optimal ratio of KH570-ZrO 2 for enhancing the hydrophobicity and corrosion resistance of epoxy coatings was ascertained. • The mechanism by which KH570-ZrO 2 enhance the hydrophobic and corrosion resistance of epoxy coatings was revealed.