In-situ phosphatization of waterborne acrylic latex coatings for long-term corrosion protection of metal without flash rust

• 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.