Enhancing corrosion resistance of Epoxy-Based composite coatings on mild steel using functionalized aluminium oxide (Al₂O₃) nanoparticles

In this study the Al₂O₃ and functionalized Aluminium oxide [Al₂O₃F] were synthesised and characterized by Fourier transform infrared spectroscopy Transmission Electron Microscopy thermal gravimetric analysis and Scanning Electron Microscopy with Energy Dispersive X-Ray Analysis. Since corrosion of mild steel in aggressive environments is a persistent challenge, this work focuses on improving epoxy coatings using metal oxide nanoparticles. The corrosion behaviour of the epoxy, epoxy containing Al₂O₃, and Al₂O₃F was determined by electrochemical technique in 3.5 wt% NaCl solution. Surface changes of the coated substrates were analysed by pull-off test, salt spray test, and contact angle measurement. The results confirmed the superior performance of epoxy-Al₂O₃F coating over neat epoxy. Adding higher concentrations of Al₂O₃ and functionalized Al₂O₃ significantly improved the coating's protective performance. In summary, this research provides significant understanding for the development of advanced coatings with enhanced protective properties against corrosion, paving the way for practical applications in challenging environmental conditions.