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<p>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 ANPEO<sub>10</sub>-P<sub>1</sub> 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 (∣<i>Z</i>∣<sub>0.01Hz</sub>≤10<sup>6</sup> Ω·cm<sup>2</sup>) on Q235 carbon steel. On 5052 aluminum alloy, the St-BA coating maintained ∣<i>Z</i>∣<sub>0.01Hz</sub>&gt;gt;10<sup>8</sup> Ω·cm<sup>2</sup> 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.</p>

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

  • 期刊论文

  • 发表日期：

    2026年1月1日

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  • Rui Yuan,
  • Zhi-xing Tang,
  • Min-di Xiao,
  • Min-zhao Cai,
  • Zi-long Zhao,
  • Lin Gu

摘要

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>gt;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.