Influence of Zinc Particle Shape on Cathodic Protection Performance and Mechanisms of Zinc-rich Coatings

doi:10.11902/1005.4537.2025.162

Journal of Chinese Society for Corrosion and protection

2026, Vol. 46

Issue (3): 938-944 DOI: 10.11902/1005.4537.2025.162

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Influence of Zinc Particle Shape on Cathodic Protection Performance and Mechanisms of Zinc-rich Coatings

WANG Die¹, DU Baoshuai¹, JIA Zeyang², FAN Zhibin¹, JIANG Bo¹, GAO Jin², DU Cuiwei²(

)

^1.Shandong Electric Power Research Institute, Jinan 250003, China
^2.Institute of Advanced Materials and Technology, University of Science and Technology Beijing, Beijing 100083, China

Cite this article:

WANG Die, DU Baoshuai, JIA Zeyang, FAN Zhibin, JIANG Bo, GAO Jin, DU Cuiwei. Influence of Zinc Particle Shape on Cathodic Protection Performance and Mechanisms of Zinc-rich Coatings. Journal of Chinese Society for Corrosion and protection, 2026, 46(3): 938-944.

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Abstract

To investigate the effect of the shape of zinc powder on the cathodic protection performance and mechanism of solvent-based zinc-rich coatings, three acrylic hybrid resin based coatings with zinc powder pigments composed of mixture of spherical zinc with 0%, 20%, and 100% flake zinc, namely replacing partially the spherical zinc of the pigment with the flake zinc, were prepared on Q235 carbon steel plate respectively. Then the corrosion performance of the Q235 steel with coatings was assessed via immersion test in 3.5%NaCl solution with open circuit potential (OCP) measurement and electrochemical impedance spectroscopy (EIS), as well as salt spray test. The results show that among others, the coating with pigment of spherical zinc and 20% flake zinc exhibits the best cathodic protection performance, i.e. the coating may provide significantly enhanced cathodic protectiveness for the steel substrate. It is concluded that the incorporation of flaky zinc powder can enhance the barrier properties of the coating, increase the zinc powder contact efficiency, and augment the number of effective electrical connections within the coating, thus extending its life-time of cathodic protection.

Key words: zinc-rich coatings cathodic protection coating failure

Received: 28 May 2025 32134.14.1005.4537.2025.162

ZTFLH:

TG174

Fund: State Grid Shandong Electric Power Company Science and Technology Project(52062623003J)

Corresponding Authors: DU Cuiwei, E-mail: dcw@ustb.edu.cn

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	WANG Die
	DU Baoshuai
	JIA Zeyang
	FAN Zhibin
	JIANG Bo
	GAO Jin
	DU Cuiwei

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https://www.jcscp.org/EN/10.11902/1005.4537.2025.162 OR https://www.jcscp.org/EN/Y2026/V46/I3/938

Table 1 Dosage of zinc powders of three pigments for resin based coatings

Fig.1 Surface (a1-c1) and cross-section (a2-c2) SEM images of A1 coating (a), A2 coating (b) and A3 coating (c)

Fig.2 Diagram of the open-circuit potential of the three coatings soaked in 3.5%NaCl solution

Fig.3 Nyquist (a) and Bode (b) plots of different periods of A1 (a1, b1), A2 (a2, b2), A3 (a3, b3) coating immersion for different time

Fig.4 Macroscopic morphologies pictures of A1 coating (a), A2 coating (b) and A3 coating (c) after 0 h (a1-c1), 168 h (a2-c2), 504 h (a3-c3) and 1176 h (a4-c4) salt spray time

Fig.5 Coating scratch appearance time: (a) 1.5 mm scratch, (b) 0.5 mm scratch

Fig.6 SEM images (a1-i1, a2-i2) and EDS spectrum (a3-i3) of A1 (a-c), A2, (d-f), A3 (g-h), coating after 7 d (a, d, g), 21 d (b, e, h) and 49 d (c, f, i) of salt spray test

Fig.7 Schematic diagram of the cathodic protection mechanism analysis of the coating: (a) coating failure process; (b) cathodic protection mechanisms of different coatings

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