Influence of Particle Shape of Al-pigments on High-temperature Degradation Behavior of Silicone Composite Coatings

doi:10.11902/1005.4537.2025.213

Journal of Chinese Society for Corrosion and protection

2026, Vol. 46

Issue (3): 777-786 DOI: 10.11902/1005.4537.2025.213

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Influence of Particle Shape of Al-pigments on High-temperature Degradation Behavior of Silicone Composite Coatings

ZHAO Tongjun¹^,², WANG Xingyao¹, CHEN Zehao¹, YANG Shasha¹, WANG Jinlong¹(

), CHEN Minghui¹, ZHU Shenglong², WANG Fuhui¹

^1.Corrosion and Protection Center, Northeastern University, Shenyang 110819, China
^2.Shi -Changxu Innovation Center for Advanced Materials, Institute of Metal Research, Chinese Academy of Sciences, Shenyang 110016, China

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ZHAO Tongjun, WANG Xingyao, CHEN Zehao, YANG Shasha, WANG Jinlong, CHEN Minghui, ZHU Shenglong, WANG Fuhui. Influence of Particle Shape of Al-pigments on High-temperature Degradation Behavior of Silicone Composite Coatings. Journal of Chinese Society for Corrosion and protection, 2026, 46(3): 777-786.

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Abstract

The influence of the particle shape of Al-pigments on the high-temperature degradation behavior of the organic silicone coatings on Ti-6Al-4V alloy was investigated in the precent article. First a coating (0F), as the calibrator was prepared by using TiO₂-particles as the pigment and with a ratio of TiO₂ to organic silicone resin of 3:2 (mass fraction). Then other two silicone composite coatings (2S) and (2F) were prepared by replacing 1/3 of the TiO₂-particles in the (0F) coating by 1% (mass fraction) of spherical Al-powder and 1 mass fraction of flake Al-powder, respectively. Then the variation of the microstructure, fracture morphology, and mechanical properties of the three coatings on Ti-6Al-4V alloy were comparatively examined during the heat exposure testing at 500 ℃, in terms of the effect of the partially replacing TiO₂ particles with spherical Al-particles (2S) and flake Al-particles (2F) on the thermal resistance, mechanical properties, and failure behavior of the organic silicone composite coatings. The results showed that the incorporation of flake-Al particles (2F) could significantly enhance the toughness of coating by inducing multiple crack deflections (namely, 60.89 kJ/m³, 65% higher than 0F coating). At elevated temperatures, their bridging effect could effectively dissipate the thermal mismatch strain energy, suppress the formation of through-cracks, allowing the coating to maintain structural integrity even after 100 h of heat exposure. In contrast, 0F and 2S coatings exhibited severe spalling due to the accumulation of thermal stress and resin degradation. These findings reveal that, the incorporation of flake Al-powder could significantly enhance the toughness of organic silicone coatings at high temperatures through a synergistic toughening mechanism (crack path extension and bridging effects), therewith providing a novel strategy for designing high-performance and heat-resistant coatings through regulating the particle shape of pigments.

Key words: heat-resistant silicone coating flake aluminum powder crack deflection toughness

Received: 05 July 2025 32134.14.1005.4537.2025.213

ZTFLH:

TG174

Corresponding Authors: WANG Jinlong, E-mail: Wangjinlong@mail.neu.edu.cn

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	Articles by authors
	ZHAO Tongjun
	WANG Xingyao
	CHEN Zehao
	YANG Shasha
	WANG Jinlong
	CHEN Minghui
	ZHU Shenglong
	WANG Fuhui

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https://www.jcscp.org/EN/10.11902/1005.4537.2025.213 OR https://www.jcscp.org/EN/Y2026/V46/I3/777

Table 1 Three types of silicone coatings formulations (mass fraction / %)

Fig.1 TEM image of submicron TiO₂ particles (a), SEM images of spherical aluminum powder (sphere-Al) (b) and flake aluminum powder (flake-Al) (c)

Fig.2 Surface SEM images (a1-c1) and cross-section SEM images (a2-c2) of the as-prepared 0F (a), 2S (b) and 2F (c) coatings

Fig.3 Mechanical properties of the as-prepared 0F, 2S and 2F coatings

Fig.4 Tensile fracture morphology of the as-prepared 0F (a), 2S (b) and 2F (c) coatings

Fig.5 Mass change curves of 0F, 2S and 2F coatings during heat exposure at 500 ℃: (a) full-time mass loss curves, (b) initial-stage mass changes within 8 h

Fig.6 XRD patterns of 0F, 2S and 2F coatings before and after heat exposure tests

Fig.7 FTIR spectra of the 0F, 2S and 2F coatings before (a) and after (b) heat exposure tests

Fig.8 Surface 3D morphologies of the (a, d) 0F, (b, e) 2S and (c, f) 2F coatings before and after heat exposure tests: (a-c) the as-prepared coatings, (d-f) coatings after the tests

Fig.9 Surface SEM images (a1-c1) and cross-section SEM images (a2-c2) of the 0F (a), 2S (b) and 2F (c) coatings after heat exposure tests

Fig.10 Schematic diagram illustrating the fracture mechanism of 0F (a), 2S (b) and 2F (c) coatings during heat exposure tests

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