This work aims to develop a novel eco-friendly waterborne epoxy anti-corrosion primer for rusty steel. The basalt flakes and polyaniline-modified TiO2 were used as pigment to replace zinc, and multi-organic acids were used as conversion agents based on the film-forming of waterborne epoxy emulsion. Their effects on the adhesion and anti-corrosion were studied using cross-cut test, electrochemical test station and neutral salt spray test, respectively. The microstructures of the coatings were also tested to analyze the anti-corrosion mechanism. The results show that Tannic + Citric + Gallic has the best rust conversion effect. The coating with 10% basalt flakes, 3% polyaniline-modified TiO2 has a uniform and dense diffusion barrier layer. The adhesion is the highest with grade 0. The corrosion resistance is the best with high corrosion impedance and high salt spray resistance time of 480 h. It provides a new option for the rusty steel structures to maintain against corrosion in practical engineering applications.
VeeranahTSeechurnY. Investigating coating adherence on S275JR carbon steel under cyclic corrosion. Surf Eng2025; 41: 695–710.
2.
CurryNA. Surface tolerance-painting rusty steel. 1st ed. Manchester, UK: The University of Manchester, 2023.
3.
LawalSLAfolaluSAJenTC, et al.Impact of environmental variables on corrosion rate of steel- an overview. In: 2023 International Conference on Science, Engineering and Business for Sustainable Development Goals (SEB-SDG), 2023. Omu-Aran.
4.
ChuYZSunWPMouPC, et al.Development of heavy-duty climbing robot with rust removing and recycling system for steel structures. Ind Robot2025; 52: 694–701.
5.
PokharkarKAZadeGPatilBP, et al.Impact of VTMS on coating performance of optimized CNSL and tannic acid-biomodified epoxy resin. Biomass Conv Bioref2025; 15: 2963–2982.
6.
ZhaoYHeYYanSM, et al.Eco-friendly design of α-zirconium phosphate modified by phytic acid for reinforcing the corrosion resistance of waterborne epoxy coating. Colloid Surface A2023; 656: 130472.
7.
ChangLZhengHPShaoYW, et al.Effect of phytic acid/rust conversion layer on corrosion protection of rusty mild steel. Surf Coat Tech2024; 492: 131243.
8.
LiJFGeSSWangJX, et al.Water-based rust converter and its polymer composites for surface anticorrosion. Colloid Surface A2018; 537: 334–342.
9.
FengLMYuanPY. Corrosion protection mechanism of aluminum triphosphate modified by organic acids as a rust converter. Prog Org Coat2020; 140: 105508.
10.
WangXZhuQJLiuXJ, et al.Rust conversion performance of phosphoric acid-gallic acid in vinyl chloride acrylic emulsion. Coat2021; 11: 52.
11.
SalazarSA. Investigation of the performance of anti-corrosive coating materials derived from bio-based feedstocks. 1st ed. Glassboro, NJ, USA: Rowan University, 2023.
12.
DagdagOHaldharRRKimSC, et al.Recent progress in epoxy resins as corrosion inhibitors: design and performance. J Adhes Sci Technol2022; 37: 923–944.
13.
PerevalovYYSafonovISMaslennikovNV, et al.Creation of Corrosion-Resistant Coatings Based on Zinc in an Electromagnetic Field on Steel Punching Rivets, In: 2023 IEEE 24th International Conference of Young Professionals in Electron Devices and Materials (EDM), Novosibirsk, Russian Federation, 2023.
14.
GerengiHSolomonMMMarasliM, et al.A comparative analysis of the corrosion characteristics of electro-galvanized steel coated with epoxy zinc-free and zinc-rich coatings in 5% NaCl. J Adhes Sci Technol2023; 37: 2795–2806.
15.
Al-NafaiIS. Novel zinc-rich organic coatings for offshore and infrastructure applications. 1st ed. Manchester, UK: The University of Manchester, 2022.
16.
HanXLiuTYuH, et al.Corrosion resistance of KH560-modified water-based epoxy cold-sprayed zinc coating. J Mater Sci2025; 60: 10478–10498.
17.
LiuXHHouPMZhaoX, et al.The polyaniline-modified TiO2 composites in water-based epoxy coating for corrosion protection of Q235 steel. J Coat Technol Res2019; 16: 71–80.
18.
MobinMAnsarF. Shoeb M.chitosan-polyaniline-TiO2 ternary nanocomposite coating as effective anti-corrosion material for low carbon steel in 3.5 wt% NaCl solution. J Adhes Sci Technol2023; 37: 3187–3205.
19.
AB AzizNAA. Surface Modification of graphene oxide by d-glucose in epoxy resin composites for anticorrosive coating. Kuala Lumpur, Malaysia: University of Malaya, 2023.
20.
FengAHYangXJHeDY, et al.Preparation and properties of waterborne epoxy anti-corrosion coatings modified by nano-SiO2 and flaky al. J Appl Polym Sci2025; 142: 1.
21.
AlbarqouniYBaniusEAbu BakarNH, et al.Enhancing epoxy coatings with spherical ZnO nanoparticles for improved hydrophobicity and corrosion resistance. J Adhes Sci Technol2025; 39: 3009–3029. https://orcid.org/0000-0002-5113-440X
22.
ThiruvothDDAnanthkumarM. Evaluation of cerium oxide nanoparticle coating as corrosion inhibitor for mild steel. Mater Today Proc2022; 49: 2007–2012.
23.
NguyenTVTrucVDNguyenTA, et al.Synergistic effect of oxide nanoparticles and inorganic inhibitor on anti-corrosion performance of epoxy coating. Anti-corros Method M2024; 71: 225–240.
24.
YanJShiJJZhangPG, et al.Preparation and properties of epoxy/basalt flakes anticorrosive coatings. Mater Corros2018; 69: 1669–1675.
FuXYWangJLXuZY, et al.Improvement of anti-corrosion of epoxy coating by synergistic modification of basalt scale with phytic acid. Anti-Corros Method M2025; 75: 653–663.
27.
LuoLDWangQHMaQ, et al.A novel basalt flake epoxy resin coating modified by carbon nanotubes. Coat2019; 9: 14.
28.
WangZTZhangLLiuX, et al.Basalt flake/epoxy resin nacre-inspired bulk composite fabricated by vacuum-assisted resin transfer molding technique. Mater Lett2025; 384: 138122.
29.
WangXLiangXWangB, et al.Corrosion resistance of graphene/basalt flake modified waterborne epoxy zinc-rich primer. Pigm Resin Technol2024; 53: 786–796.
30.
MohammadiIHaddadiSAIzadiM, et al.Chemically modified carbon nanotubes for commercial applications. 1st ed. Hoboken, NJ, USA: Wiley, 2023.
31.
WangZPHuBJYuHB, et al.Synergistic effects of 1-octyl-3-methylimidazolium hexafluorophosphate and cellulose nanocrystals on improving polyacrylate waterborne anti-corrosion coatings. Polymers (Basel)2023; 15: 10.
32.
PourZSGhaemyMBordbarS, et al.Effects of surface treatment of TiO2 nanoparticles on the adhesion and anticorrosion properties of the epoxy coating on mild steel using electrochemical technique. Prog Org Coat2018; 119: 99–108.
33.
ShaoHLCaoYBChenZH, et al.Gum arabic-assisted polyaniline nanofillers for improving anticorrosion performance of waterborne epoxy coating. ACS Appl Nano Mater2023; 6: 13270–13283.
34.
ChenYZhouRWuD, et al.Boosting interfacial adhesion in PBO fiber/epoxy composite by employing finely granular-structured polyaniline as an interfacial intensifier. Mater Today Commun2023; 35: 106066.
35.
LiuYZhuZWWenZM, et al.High anticorrosion performance of polyvinyl butyral/carbonized polyaniline/modified titanium dioxide composite coating. J Adhes Sci Technol2024; 38: 1585–1607.
36.
LiuXBMengFDLiuRP, et al.Enhancing the protective performance of organic coatings for marine applications with nepheline-epoxy resin composites. Anti-Corros Method M2025; 72: 224–235.
