<p>This study develops and explores a self-stratifying coating system that incorporates both epoxy and acrylic resins. It examines the impact of film thickness and substrate type on self-stratification behavior, confirms predictions from the surface energy model, and identifies the surface tension gradient as the primary driving mechanism for stratification. Additionally, this research investigates the influence of FeSiCr powder on the stratification behavior of the coating. Results demonstrate that the self-stratifying coating, composed of a blend of epoxy and acrylic resins with FeSiCr powder, exhibits superior corrosion resistance compared to coatings formulated solely from a mixture of epoxy resin and FeSiCr powder. SEM-EDS analysis reveals that the enhanced corrosion resistance can be attributed to the accumulation of epoxy resin and FeSiCr at the bottom of the coating, while the acrylic resin forms an effective protective layer on the surface. Furthermore, the study examines the effects of FeSiCr powder content, solvent addition, and volatilization rate on the stratified structure and appearance of the coating. The findings indicate that at relatively low FeSiCr powder content, the layered structure of the coating remains largely intact, with the powder predominantly residing within the epoxy resin layer. However, increasing the powder content compromises the self-stratification structure, leading to a rougher coating surface. It is also observed that augmenting the quantity of the xylene/butyl acetate mixture reduces pit formation on the surface, while the use of MIBK solvent results in incomplete stratification and exacerbates surface roughness.</p>