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Journal of Chinese Society for Corrosion and protection  2025, Vol. 45 Issue (6): 1549-1562    DOI: 10.11902/1005.4537.2025.046
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Long-term Corrosion Resistance of Carbon Steel and Al-alloy with Single Component Fluorocarbon Modified Epoxy Coating
WANG De1,2, ZHANG Fan3, WANG Xingqi2, ZHANG Hexin1, ZHAO Chengzhi1, YANG Yange2()
1 School of Materials Science and Chemical Engineering, Harbin Engineering University, Harbin 150001, China
2 Shi -changxu Innovation Center for Advanced Materials, Institute of Metal Research, Chinese Academy of Sciences, Shenyang 110016, China
3 Shenyang Rustprooft Packaging Materials Co. Ltd. , Shenyang 110000, China
Cite this article: 

WANG De, ZHANG Fan, WANG Xingqi, ZHANG Hexin, ZHAO Chengzhi, YANG Yange. Long-term Corrosion Resistance of Carbon Steel and Al-alloy with Single Component Fluorocarbon Modified Epoxy Coating. Journal of Chinese Society for Corrosion and protection, 2025, 45(6): 1549-1562.

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Abstract  

In this paper, the long-term anticorrosion performance in 3.5%NaCl solution of 10# mild steel and LY12 Al-alloy coated with the same single-component fluorocarbon-modified epoxy coating, was comparatively studied by means of electrochemical tests such as open-circuit potential (OCP), electrochemical impedance spectroscopy (EIS) and potentiodynamic polarization curve, and macro/micro morphology characterization as well as adhesion test and water contact angle test. The results showed that the modified epoxy coating shows better corrosion resistance when applied on LY12 Al-alloy rather than applied on 10# mild steel by long-term immersion in 3.5%NaCl solution for 3500 h. The failure of the modified epoxy coating on the surface of the two substrates can be divided into four and three stages respectively, and the failure process is different. The corrosion of the coating/metal interface is the key to determine the failure rate of the coating. Low coating adhesion and high water contact angle for the coating on Al-alloy and high coating adhesion and low water contact angle for the coating on carbon steel substrate are the main reasons for the different failure courses of coatings.
Key words:  epoxy coating      carbon steel      Al-alloy      corrosion resistance      electrochemical impedance spectroscopy     
Received:  14 February 2025      32134.14.1005.4537.2025.046
ZTFLH:  TG174  
Fund: National Key Research and Development Program(2022RDC2012502)
Corresponding Authors:  YANG Yange, E-mail: ygyang@imr.ac.cn
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WANG De
ZHANG Fan
WANG Xingqi
ZHANG Hexin
ZHAO Chengzhi
YANG Yange

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https://www.jcscp.org/EN/10.11902/1005.4537.2025.046     OR     https://www.jcscp.org/EN/Y2025/V45/I6/1549

Fig.1  Schematic diagram of the device for electrochemical testing
Fig.2  OCP curve of epoxy-coated 10# steel (a) and LY12 Al-alloy (b) with immersion time
Fig.3  Nyquist (a1-d1), modules (a2-d2) and phase angle (a3-d3) of the four stages of coated 10# steel surface: stage I (0-24 h), stage II (24-816 h), stage III (816-1968 h), stage IV (1968-3500 h)
Fig.4  Nyquist (a1-c1), modules (a2-c2) and phase angle (a3-c3) of the three stages of coated LY12 Al-alloy surface: stage I (0-24 h), stage II (24-816 h), stage III (816-3500 h)
Fig.5  Equivalent circuit model for fitting impedance spectrum data of coated 10# steel and LY12 Al-alloy: (a) R(QR), (b) R(Q(R(QR))), (c) R(Q(R(Q(RW))))
Fig.6  |Z|0.01 Hz curve of coated 10# steel (a) and LY12 Al-alloy (b) with immersion time
Fig.7  Variation of electrochemical parameters for coated 10# steel and LY12 Al-alloy with immersion time: (a) Rc, (b) Qc, (c) Rct, (d) Qdl
Time / hRs / Ω·cm2Qc / F·cm-2n1Rc / Ω·cm2Qdl / F·cm-2n2Rct / Ω·cm2W / Ω·cm2σ2
02.96 × 10-42.34 × 10-100.9483.76 × 1010----9.328 × 10-3
21.40 × 10-22.03 × 10-100.9662.79 × 1061.33 × 10-90.4639.80 × 107-9.612 × 10-4
42.89 × 10-43.16 × 10-90.9482.50 × 1062.92 × 10-80.7153.62 × 106-1.237 × 10-3
61.02 × 10-33.42 × 10-100.9406.44 × 1061.28 × 10-80.7836.88 × 106-9.641 × 10-4
121.02 × 10-33.42 × 10-100.9406.44 × 1061.28 × 10-80.7836.88 × 106-4.831 × 10-4
2437.13.28 × 10-100.9469.43 × 1058.66 × 10-80.5862.34 × 106-1.619 × 10-4
481283.35 × 10-100.9471.02 × 1062.14 × 10-70.4871.62 × 106-2.537 × 10-4
7249.23.53 × 10-100.9441.08 × 1067.88 × 10-70.4121.55 × 106-1.001 × 10-4
9640.73.50 × 10-100.9442.60 × 1066.98 × 10-70.4806.76 × 106-5.418 × 10-5
1201093.35 × 10-100.9473.32 × 1066.80 × 10-70.4361.26 × 107-6.914 × 10-5
14468.63.56 × 10-100.9433.74 × 1066.48 × 10-70.3889.29 × 106-3.642 × 10-5
1926843.76 × 10-100.9424.10 × 1052.64 × 10-70.0859.36 × 106-8.478 × 10-4
2407.42 × 10-33.47 × 10-100.9361.20 × 1061.63 × 10-70.3721.25 × 1061.75 × 10-61.923 × 10-4
2881.00 × 10-23.24 × 10-100.9419.01 × 1051.68 × 10-70.3051.47 × 1061.69 × 10-62.082 × 10-4
3363.35 × 10-33.16 × 10-100.9442.28 × 1051.08 × 10-70.2131.87 × 1061.99 × 10-61.623 × 10-4
3841.00 × 10-23.75 × 10-100.9398.34 × 1059.90 × 10-70.3001.41 × 1061.18 × 10-62.102 × 10-5
48030.13.45 × 10-100.9439.43 × 1056.46 × 10-70.3011.90 × 1061.96 × 10-63.349 × 10-5
8164.27 × 10-52.58 × 10-100.9525.61 × 1051.59 × 10-70.1992.04 × 1061.49 × 10-61.492 × 10-4
108076.94.53 × 10-100.9331.13 × 1051.24 × 10-60.3037.79 × 105-4.257 × 10-4
129616.15.98 × 10-100.9181.02 × 1052.88 × 10-60.2655.61 × 105-1.950 × 10-4
15601597.49 × 10-80.7211.10 × 1039.78 × 10-50.4314.20 × 104-3.122 × 10-3
19682944.70 × 10-80.7849.51 × 1029.79 × 10-50.4304.24 × 104-3.152 × 10-3
244871.54.60 × 10-70.6107.77 × 1021.04 × 10-40.5777.37 × 106-3.015 × 10-3
280860.28.07 × 10-70.5824.73 × 1021.47 × 10-40.6931.27 × 104-1.025 × 10-3
314435.61.01 × 10-60.5555.36 × 1022.00 × 10-40.7071.47 × 104-6.570 × 10-4
333661.91.06 × 10-60.5723.91 × 1022.74 × 10-40.6961.25 × 104-9.363 × 10-4
350066.81.23 × 10-60.5703.27 × 1023.30 × 10-40.6981.27 × 104-9.130 × 10-4
Table 1  Electrochemical fitting parameters obtained in 3.5%Nacl solution after coating the surface of 10# steel
Time / hRs / Ω·cm2Qc / F·cm-2n1Rc / Ω·cm2Qdl / F·cm-2n2Rct / Ω·cm2W / Ω·cm2σ2
01.00 × 1023.01 × 10-100.9548.63 × 1066.82 × 10-90.8134.00 × 1075.12 × 10-72.87 × 10-3
21.00 × 10-21.00 × 10-90.8712.64 × 1071.88 × 10-90.8758.28 × 1072.50 × 10-81.27 × 10-3
41.00 × 1031.61 × 10-90.8434.13 × 1067.30 × 10-100.9357.10 × 1071.92 × 10-88.37 × 10-4
61.00 × 1022.55 × 10-90.8082.01 × 1067.94 × 10-90.8251.93 × 1071.56 × 10-77.44 × 10-3
121.00 × 10-23.43 × 10-90.7873.25 × 1062.34 × 10-90.9005.82 × 1067.80 × 10-83.23 × 10-3
246.68 × 10-21.62 × 10-90.8491.82 × 1075.44 × 10-90.7507.17 × 1071.02 × 10-74.44 × 10-3
483.31 × 1041.85 × 10-90.8374.82 × 1053.95 × 10-90.8676.10 × 1079.43 × 10-82.72 × 10-3
721.00 × 10-21.41 × 10-90.8593.48 × 1065.27 × 10-90.8108.01 × 1075.70 × 10-83.81 × 10-3
961.00 × 10-26.38 × 10-110.9191.97 × 1057.70 × 10-90.7641.28 × 1085.10 × 10-82.65 × 10-3
1201.00 × 1025.71 × 10-100.9271.51 × 1066.42 × 10-90.8081.34 × 1085.94 × 10-88.24 × 10-4
1681.00 × 1035.59 × 10-100.9326.67 × 1057.84 × 10-90.7869.65 × 1076.85 × 10-82.77 × 10-3
1923.47 × 10-26.58 × 10-100.9216.92 × 1059.09 × 10-90.8256.83 × 1071.01 × 10-51.96 × 10-3
2401.00 × 10-25.82 × 10-100.9291.78 × 1061.20 × 10-80.7739.06 × 1077.26 × 10-83.45 × 10-3
2881.00 × 10-24.86 × 10-100.9431.68 × 1049.68 × 10-90.8498.30 × 1073.92 × 10-81.14 × 10-2
3361.00 × 10-24.57 × 10-90.9491.95 × 1051.24 × 10-80.8046.17 × 1077.65 × 10-87.50 × 10-4
3841.00 × 1033.70 × 10-100.9641.97 × 1051.32 × 10-80.7741.09 × 1086.77 × 10-84.46 × 10-4
4321.00 × 10-23.36 × 10-100.9702.02 × 1072.79 × 10-80.7207.56 × 1072.27 × 10-72.33 × 10-3
4801.00 × 1033.66 × 10-100.9622.81 × 1051.68 × 10-80.7761.00 × 1082.61 × 10-76.33 × 10-4
5761.00 × 10-24.06 × 10-80.9561.57 × 1051.71 × 10-80.7705.11 × 1071.56 × 10-71.51 × 10-3
6961.27 × 10-23.48 × 10-100.9671.04 × 1051.50 × 10-80.7735.91 × 1071.30 × 10-61.60 × 10-3
8161.00 × 10-22.16 × 10-101.0006.62 × 1051.40 × 10-80.7378.80 × 1079.73 × 10-82.68 × 10-3
10801.00 × 10-23.73 × 10-100.9608.76 × 1042.15 × 10-80.8162.28 × 1078.00 × 10-81.22 × 10-3
12961.00 × 10-25.87 × 10-100.9213.42 × 1055.38 × 10-80.8591.72 × 1078.74 × 10-95.80 × 10-3
15601.00 × 10-28.39 × 10-100.8964.80 × 1056.94 × 10-80.8951.02 × 1083.31 × 10-75.05 × 10-3
19681.00 × 1031.72 × 10-90.8485.02 × 1049.05 × 10-80.8776.07 × 1065.18 × 10-71.82 × 10-3
24481.00 × 1034.46 × 10-90.7822.40 × 1041.01 × 10-70.8501.12 × 1073.12 × 10-76.10 × 10-3
28081.00 × 1032.10 × 10-80.6752.21 × 1041.34 × 10-70.8893.80 × 1061.66 × 10-68.04 × 10-3
31441.00 × 1037.92 × 10-90.7452.31 × 1042.94 × 10-70.8814.00 × 1062.42 × 10-68.75 × 10-3
33361.00 × 10-21.66 × 10-90.6922.46 × 1043.49 × 10-70.8642.74 × 1063.05 × 10-69.65 × 10-3
35001.00 × 10-21.70 × 10-80.6932.01 × 1044.08 × 10-70.8451.79 × 1067.18 × 10-89.28 × 10-3
Table 2  Electrochemical fitting parameters obtained in 3.5%Nacl solution after coating the surface of LY12 Al-alloy
Fig.8  Potentiodynamic polarization curves of coated 10# steel (a) and LY12 Al-alloy (b) before and after 3500 h immersion
Fig.9  Adhesion test results of coated 10# steel and LY12 Al-alloy before and after 3500 h immersion
Fig.10  Water contact angle test results of coated 10# steel (a) and LY12 Al-alloy (b) before (a1, b1) and after 3500 h immersion (a2, b2)
Fig.11  Evolution of macroscopic morphologies of coated 10# steel during 3500 h immersion
Fig.12  Evolution of macroscopic morphologies of coated LY12 Al-alloy during 3500 h immersion
Fig.13  Optical micrographs of coated 10# steel (a) and LY12 Al-alloy (b) before (a1, b1) and after 3500 h immersion (a2, b2)
Fig.14  Microscopic morphologies of epoxy-coated 10# steel (a) and LY12 Al-alloy (b) before (a1, b1) and after immersion for 3500 h (a2, b2)
Fig.15  Elemental distribution of epoxy-coated 10# steel (a) and LY12 Al-alloy (b) after immersion for 3500 h
Fig.16  Failure process of 10# steel and LY12 Al-alloy with epoxy coating: (a1-d1) rapid water absorption, slow corrosion, accelerated corrosion, complete failure; (a2-c2) rapid water absorption, stable corrosion, slow corrosion
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