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Maximizing the functional properties of epoxy coatings using milled Al for enhanced mechanical strength and corrosion resistance

Ubair Abdus Samad

Ubair Abdus Samad

Center of Excellence for Research in Engineering Materials (CEREM), King Saud UniversityRiyadh, Saudi Arabia
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Samad, Ubair Abdus
, 
Jabair A. Mohammed

Jabair A. Mohammed

Center of Excellence for Research in Engineering Materials (CEREM), King Saud UniversityRiyadh, Saudi Arabia
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Mohammed, Jabair A.
, 
Mohammad Asif Alam

Mohammad Asif Alam

Center of Excellence for Research in Engineering Materials (CEREM), King Saud UniversityRiyadh, Saudi Arabia
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Alam, Mohammad Asif
, 
Saeed M. Al-Zahrani

Saeed M. Al-Zahrani

Department of Chemical Engineering, College of Engineering, King Saud UniversityRiyadh, Saudi Arabia
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Al-Zahrani, Saeed M.
, 
El-Sayed M. Sherif

El-Sayed M. Sherif

Center of Excellence for Research in Engineering Materials (CEREM), King Saud UniversityRiyadh, Saudi Arabia
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Sherif, El-Sayed M.
, 
Asiful H. Seikh

Asiful H. Seikh

Center of Excellence for Research in Engineering Materials (CEREM), King Saud UniversityRiyadh, Saudi Arabia
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Seikh, Asiful H.
 and 
Hany S. Abdo

Hany S. Abdo

Center of Excellence for Research in Engineering Materials (CEREM), King Saud UniversityRiyadh, Saudi Arabia
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Abdo, Hany S.
  
Dec 19, 2024
Maximizing the functional properties of epoxy coatings using milled Al for enhanced mechanical strength and corrosion resistance's Cover Image
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Article Category: Research Article
Published Online: Dec 19, 2024
Page range: 34 - 49
Received: Oct 07, 2024
Accepted: Nov 13, 2024
DOI: https://doi.org/10.2478/msp-2024-0042
Keywords
© 2024 the Ubair Abdus Samad et al., published by Sciendo
This work is licensed under the Creative Commons Attribution-NonCommercial-NoDerivatives 4.0 International License.

Figure 1

(a) SEM image of epoxy coating without any particles, (b) epoxy coating with the addition of 2 wt% MAl, (c) obtained EDX spectral scan with corresponding elemental percentages of epoxy coating added with 2 wt% MAl, (d–f) mapping for the C, O, and Al elements, and (g) the EDX spot scan spectrum of the agglomerated Al particles encircled in (f).
(a) SEM image of epoxy coating without any particles, (b) epoxy coating with the addition of 2 wt% MAl, (c) obtained EDX spectral scan with corresponding elemental percentages of epoxy coating added with 2 wt% MAl, (d–f) mapping for the C, O, and Al elements, and (g) the EDX spot scan spectrum of the agglomerated Al particles encircled in (f).

Figure 2

XRD spectra of (a) neat epoxy, (b) different percentages of MAl filled coatings, (c) as-received (un-milled) and MAl spectra, and (d) MAl-3 along with MAl powder (overlapping).
XRD spectra of (a) neat epoxy, (b) different percentages of MAl filled coatings, (c) as-received (un-milled) and MAl spectra, and (d) MAl-3 along with MAl powder (overlapping).

Figure 3

Temperature vs weight loss TGA curves for neat epoxy and modified coatings containing various proportions of MAl powder.
Temperature vs weight loss TGA curves for neat epoxy and modified coatings containing various proportions of MAl powder.

Figure 4

Graphical representation of the pendulum hardness, impact strength, and scratch resistance of MAl filled epoxy coatings.
Graphical representation of the pendulum hardness, impact strength, and scratch resistance of MAl filled epoxy coatings.

Figure 5

Indentation (L vs D) curves obtained for fabricated coatings.
Indentation (L vs D) curves obtained for fabricated coatings.

Figure 6

Hardness and modulus for the prepared epoxy coatings.
Hardness and modulus for the prepared epoxy coatings.

Figure 7

Nyquist plots for the coatings with different Al wt% after exposure to NaCl solution for (a) 1 h, (b) 7 days, (c) 14 days, (d) 21 days, and (e) 30 days. (f) Circuit model used to fit the obtained EIS data.
Nyquist plots for the coatings with different Al wt% after exposure to NaCl solution for (a) 1 h, (b) 7 days, (c) 14 days, (d) 21 days, and (e) 30 days. (f) Circuit model used to fit the obtained EIS data.

Figure 8

Resistance values (R S, R P1, and R P2) of epoxy coatings with varying concentrations of MAl nanoparticles (1, 2, and 3 wt%) after 21 and 30 days of immersion in 3.5 wt% NaCl solution.
Resistance values (R S, R P1, and R P2) of epoxy coatings with varying concentrations of MAl nanoparticles (1, 2, and 3 wt%) after 21 and 30 days of immersion in 3.5 wt% NaCl solution.

Figure 9

SEM images of 2 wt% Al coated samples (a) after 30 days of immersion along with (b–d) EDX elemental analysis.
SEM images of 2 wt% Al coated samples (a) after 30 days of immersion along with (b–d) EDX elemental analysis.

Modulus and hardness values obtained for the fabricated coatings_

Sample Hardness (GPa) Modulus (GPa)
Epoxy 0.120 3.3
MAl-1 0.144 3.69
MAl-2 0.149 3.79
MAl-3 0.141 3.62

Mechanical properties of produced epoxy coatings with different Al percentages_

S. Code DFT (µm) Hardness (MPa) Scratch test (kg) Impact resistance (lb/in2)
Epoxy [22] 100 ± 10 159 5.5 48
MAl-1 100 ± 10 162 6.5 50
MAl-2 100 ± 10 165 7 53
MAl-3 100 ± 10 171 6 51

Fitted parameters from the impedance data_

Sample code R S/Ω (cm2) Q1 R P1 (MΩ cm2) Q2 R P2 (MΩ cm2)
Y Q1 (F cm−2) N Y Q2 (F cm−2) n
MAl-1 (1 h) 157 0.000546 0.57 1,358 0.000668 0.87 2,374
MAl-2 (1 h) 162 0.000142 0.94 2,568 0.001874 0.82 3,075
MAl-3 (1 h) 151 0.000152 0.94 1,856 0.001246 0.70 2,539
MAl-1 (7 days) 144 0.0006847 0.93 2,048 0.004785 0.63 4,480
MAl-2 (7 days) 163 0.000159 0.93 2,998 0.001915 0.78 1,010
MAl-3 (7 days) 140 0.001249 0.97 2,135 0.004288 0.53 2,339
MAl-1 (14 days) 95 0.000792 0.90 3,756 0.000576 0.40 3,676
MAl-2 (14 days) 129 0.000119 0.56 2,555 0.000965 0.99 3,916
MAl-3 (14 days) 101 0.001220 0.97 2,870 0.000709 0.59 3,224
MAl-1 (21 days) 107 0.000861 0.94 1,206 0.003905 0.68 2,202
MAl-2 (21 days) 131 0.0001492 0.94 5,936 0.000885 0.14 2,702
MAl-3 (21 days) 110 0.0001710 0.93 5,321 0.002593 0.81 2,450
MAl-1 (30 days) 113 0.002131 0.91 1,051 0.006147 0.65 1,622
MAl-2 (30 days) 121 0.000972 0.99 3,143 0.001098 0.56 2,716
MAl-3 (30 days) 98 0.0001236 0.97 3,161 0.005593 0.67 1,916

Formulating ingredients of the prepared epoxy coatings fabricated with MAl particles_

Sample Resin (g) MIBK (ml) Xylene (ml) Silane MAl powder wt% Additives* PA-450 (g)
MAl-1 83.34 8 8 2.0 1.0 1.0 15.90
MAl-2 83.34 8 8 2.0 2.0 1.0 15.90
MAl-3 83.34 8 8 2.0 3.0 1.0 15.90

Recorded temperature at various percentages of weight loss_

S. code T d 15% (°C) T d 25% (°C) T d 50% (°C) T d 75% (°C) Residue (%)
Epoxy [22] 240.22 360.54 413.03 435.24 7.88
MAl-1 327.28 381.65 424.57 447.88 10.41
MAl-2 334.18 381.29 425.66 449.11 10.92
MAl-3 332.33 382.07 426.41 451.05 13.35
Language:
English
Publication timeframe:
4 times per year
Journal Subjects:
Materials Sciences, Materials Sciences, other, Nanomaterials, Functional and Smart Materials, Materials Characterization and Properties
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