Enhanced UV aging resistance and corrosion protection of low-zinc epoxy zinc-rich coatings via Ti3C2Tx-Zn composite network

Purpose This study aims to improve the comprehensive performance of low-zinc epoxy zinc-rich coatings (EZRCs) under UV aging and salt spray corrosion environments by incorporating Ti3C2Tx nanosheets into a 60 Wt.% zinc system to construct a Ti3C2Tx-Zn composite conductive/barrier network. Design/methodology/approach Ti3C2Tx nanosheets were added at different loadings, and the effects on coating structure and protective behavior were evaluated using scanning electron microscopy, X-ray diffraction, FT-IR and electrochemical techniques. Corrosion performance was further analyzed through polarization curves and electrochemical impedance spectroscopy during salt spray exposure. Findings The results demonstrate that Ti3C2Tx was uniformly dispersed in the coating and synergistically interacted with zinc particles, significantly enhancing coating compactness and conductivity. At an optimal loading of 0.6 Wt.%, the coating exhibited the best overall performance, showing improved mechanical properties, UV aging resistance and corrosion protection. The corrosion current density decreased to 7.59 × 10–8A·cm-2, while the corrosion potential increased to −0.46V. The optimized coating achieved an initial low-frequency impedance modulus of 1.67 × 106 Ω·cm2 and maintained a high impedance of 1.45 × 104 Ω·cm2 after 60 d of salt spray exposure, demonstrating excellent long-term protective ability. Originality/value This study proposes a novel strategy for enhancing the durability and corrosion resistance of low-zinc EZRCs by constructing a Ti3C2Tx-Zn composite conductive/barrier network. The findings provide valuable insights into the structural optimization and long-term protective mechanisms of such coatings.