Key Takeaways & Executive Findings
- •• Reactive phosphate emulsifier ANPEO10-P1 enables in-situ phosphatization, providing long-term corrosion protection without flash rust. • MMA-BA coating achieved exceptional durability on Q235 carbon steel, withstanding 1224 h (51 d) of immersion before failure. • St-BA coating maintained high impedance (>108 Ω·cm2) on 5052 aluminum alloy for 480 h (20 d), outperforming commercial coatings. • The synthesized latexes achieved ~99% conversion and ~50% solid content, demonstrating efficient and scalable production.
Abstract
Waterborne acrylic coatings are widely utilized due to their cost-effectiveness, high transparency, strong resistance to weather and chemicals, impressive mechanical properties, and excellent adhesion to various substrates. In these coatings, a reactive emulsifier containing phosphate groups can be integrated into the molecular chain during polymerization, which enhances the coating's compactness and corrosion resistance. This work focuses on the synthesis of styrene-butyl acrylate (St-BA) latex and methyl methacrylate-butyl acrylate (MMA-BA) latex using the reactive phosphate emulsifier ANPEO10-P1 through seed emulsion polymerization, achieving a conversion rate of approximately 99% and a solid content close to 50%. The resulting coatings from St-BA and MMA-BA latexes demonstrated long-term corrosion protection for carbon steel and aluminum alloy due to in-situ phosphatization, effectively preventing flash rust. Notably, the MMA-BA coating exhibited remarkable durability, enduring immersion for up to 1224 h (51 d) on Q235 carbon steel before reaching the failure threshold (|Z|0.01Hz£106 Ω·cm2) on Q235 carbon steel. On 5052 aluminum alloy, the St-BA coating maintained |Z|0.01Hz>108 Ω·cm2 for 480 h (20 d). Furthermore, the corrosion resistance of St-BA and MMA-BA coatings on Q235 steel sheet and 5052 aluminum alloy surpassed that of commercially available MMA-BA and St-BA coatings after immersion in a 3.5 wt% NaCl aqueous solution. This work also delves into the anticorrosion mechanism of MMA-BA and St-BA coatings.
1. Introduction
Metal corrosion is a significant issue in various industries, resulting in substantial economic losses and safety concerns [1]. As a result, corrosion inhibition has garnered significant attention and extensive research. Different approaches have been employed to safeguard metals from corrosion, including surface coating technology [2, 3], development of new alloys [4, 5], cathodic protection [6], and other methods. Among these strategies, surface coating technology stands out as a widely utilized and cost-efficient technique [7]. It is commonly employed in industrial settings to create a protective barrier between metals and corrosive environments. By applying a protective coating to the metal surface, its corrosion resistance can be greatly enhanced, leading to improved durability [8, 9]. This approach effectively shields the metal from the corrosive medium, ultimately reducing the corrosion process.
Waterborne coatings are well-known for their environmental benefits and ability to lower volatile organic compounds (VOC) emissions, making them a preferred option across different industries [10, 11]. Among waterborne coatings, waterborne acrylic coatings stand out in the realm of metal corrosion protection due to their cost-effectiveness, durability against weather conditions, resistance to chemicals, and mechanical properties [12]. Nevertheless, waterborne acrylic latexes have clear drawbacks when compared to solvent-based coatings in terms of coating density and flash rust [13 −15]. Additionally, the traditional non-reactive emulsifier used in waterborne acrylic coatings is susceptible to desorption and migration, which can negatively impact product performance.
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YUAN Rui, TANG Zhi-xing, XIAO Min-di, CAI Min-zhao, ZHAO Zi-long, GU Lin (2026). In-situ phosphatization of waterborne acrylic latex coatings for long-term corrosion protection of metal without flash rust. Journal of Central South University. https://doi.org/10.1007/s11771-025-6116-y
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Frequently Asked Questions
What is the main innovation of this study?
The study introduces a reactive phosphate emulsifier (ANPEO10-P1) that enables in-situ phosphatization in waterborne acrylic latex coatings, providing long-term corrosion protection without flash rust.
How long did the MMA-BA coating protect Q235 carbon steel?
The MMA-BA coating endured immersion for up to 1224 hours (51 days) on Q235 carbon steel before reaching the failure threshold.
What performance did the St-BA coating achieve on aluminum alloy?
On 5052 aluminum alloy, the St-BA coating maintained a high impedance (>108 Ω·cm2) for 480 hours (20 days), indicating excellent corrosion resistance.
How do these coatings compare to commercial ones?
The synthesized St-BA and MMA-BA coatings outperformed commercially available counterparts in corrosion resistance after immersion in 3.5 wt% NaCl solution.
What are the key benefits of using reactive phosphate emulsifiers?
Reactive phosphate emulsifiers are chemically incorporated into the polymer chain, reducing desorption issues and enhancing coating compactness and corrosion resistance through phosphate passivation film formation.
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