Optimization of Hybrid Modified Epoxy Nanocomposite Coatings via ‎Response Surface Methodology (RSM) for Maximizing Corrosion ‎Resistance

Abstract

The paper explores systematic optimization of hybrid epoxy nanocomposite coatings that are reinforced with functionalized zinc oxide nanoparticles and graphene oxide sheets to develop maximum corrosion resistance on cold-rolled steel. In response to the objectives, a three-factor, three-level Box-Behnken Design under Response Surface Methodology was used to determine how the functionalized zinc oxide concentration, graphene oxide concentration, and curing temperature affect the coating resistance as measured by Electrochemical Impedance Spectroscopy. Microstructural characterization using Field Emission Scanning Electron Microscopy and X-ray Diffraction proved the successful silane-functionalization of zinc oxide and the high amount of graphene oxide exfoliation that combined to create a complex tortuous path of corrosive elements. Statistical analysis showed that the quadratic model was very significant with a value of which showed that the two variables of nanofillers and curing process interacted synergistically. Optimization analysis revealed that the optimal formulation factors were 2.25 weight percentage functionalized zinc oxide and 0.85 weight percentage graphene oxide at a curing temperature of 95°C , yielding a maximized value of coating resistance of  . This is an order of magnitude better than neat epoxy, which confirms the effectiveness of hybrid nanomaterials and statistical modeling when it comes to creating better industrial protective coats.