A waterborne coating system for constructing inorganic-organic composite anti-corrosion and wear-resistant coating

In the fields of engineering and materials science, enhancing the corrosion resistance of engineered metal materials is extremely important. Most common anti -corrosion coatings often lack the capacity to resist external damages, which can lead to a failure in the coating 's physical shielding effect. In this study, we have developed an all -water -based, simple one-step spray method for preparing a modified phosphate -based organic -inorganic composite coating, designated as AP-S30@Al 2 O 3 @PTFE. The nanofillers of polytetrafluoroethylene (PTFE) and alumina (Al 2 O 3 ) were dispersed into inorganic binder aluminum phosphate (AP) modified by silica sol (S30). The effects of the incorporation of S30 and Al 2 O 3 as the second hard phase on their wettability, mechanical properties, microscopic morphology, abrasion resistance, and corrosion resistance of the composite coatings were investigated. The results showed that the AP-S30@Al 2 O 3 @PTFE coating significantly improved the corrosion resistance of the metal, with the open current density decreasing from 2.285x10 - 5 to 1.653x10 -7 mA & sdot;cm - 2 , and the open potential decreasing from -0.7533 to -0.2577 V. In addition, the composite coating provides a significant improvement in wear resistance. Thus, this cost-effective and eco-friendly method may offer significant contributions to the design and fabrication of strategic composite coatings, advancing their practical deployment in the protection of metal surfaces.