中国腐蚀与防护学报, 2023, 43(4): 922-928 DOI: 10.11902/1005.4537.2022.279

研究报告

环氧树脂/有机硅氧烷改性阳离子丙烯酸乳液复合涂层的研究

邹文杰, 丁立, 张雪姣, 陈均,

安徽工业大学化学与化工学院 马鞍山 243002

Epoxy/Organosiloxane Modified Cationic Acrylic Emulsion Composite Coating

ZOU Wenjie, DING Li, ZHANG Xuejiao, CHEN Jun,

School of Chemistry and Chemical Engineering, Anhui University of Technology, Ma'anshan 243002, China

通讯作者: 陈均,E-mail:junchen@ahut.edu.cn,研究方向为金属表面处理

收稿日期: 2022-09-09   修回日期: 2022-10-24  

基金资助: 国家自然科学基金.  U1460106

Corresponding authors: CHEN Jun, E-mail:junchen@ahut.edu.cn

Received: 2022-09-09   Revised: 2022-10-24  

Fund supported: National Natural Science Foundation of China.  U1460106

作者简介 About authors

邹文杰,男,1993年生,硕士生

摘要

利用合成的有机硅氧烷改性的阳离子型丙烯酸 (SMCWA) 乳液中的胺基能够固化环氧树脂的原理,在碳钢板表面制备耐腐蚀环氧树脂/SMCWA乳液复合涂层。利用激光纳米粒度仪对SMCWA乳液粒径进行表征,使用Fourier变换红外光谱仪 (FT-IR) 和扫描电子显微镜 (SEM) 对复合涂层进行结构和形貌分析,利用CuSO4点滴、电化学测试和中性盐雾实验研究复合涂层的耐蚀能力。结果表明,合成的SMCWA乳液粒径小,分布均匀。相较于空白SMCWA乳液涂层,环氧树脂/SMCWA乳液复合涂层的致密性和耐腐蚀性均得到增强,其中环氧树脂/SMCWA乳液质量比为9.5/0.5的复合涂层,CuSO4点滴时间提高了116 s,电化学阻抗提高了4倍,腐蚀电流密度下降了一个数量级,耐盐雾能力大幅增强。

关键词: 碳钢板 ; 有机硅氧烷改性 ; 阳离子型丙烯酸乳液 ; 环氧树脂 ; 防腐性能

Abstract

Based on the principle that the amine group in the synthesized organosiloxane-modified cationic acrylic (SMCWA) latex can cure epoxy resin, the corrosion-resistant epoxy resin/SMCWA latex composite coating were prepared on the surface of carbon steel plate. The SMCWA latex was characterized by laser nanometer particle size analyzer. The structure and morphology of the composite coatings were analyzed by FT-IR and SEM. The corrosion resistance of the composite coating was studied by copper sulfate spot test, electrochemical test and neutral salt spray test. The results show that the synthesized stable SMCWA latex has small particle size and uniform particle size distribution. Compared with the blank SMCWA latex coating, the compactness and corrosion resistance of the epoxy resin/SMCWA latex composite coating have been greatly enhanced. When the composite coating prepared with the mass ratio of epoxy resin to SMCWA is 9.5/0.5, as a result, the life-time of copper sulfate corrosion resistance is increased by 116 s; the AC impedance is increased by 4 times, and the corrosion current density is decreased by an order of magnitude in 3.5%NaCl; and the neutral salt spray resistance is also greatly enhanced for the prepared composite coating.

Keywords: carbon steel plate ; organosiloxane modification ; cationic acrylic emulsion ; epoxy resin ; corrosion resistance

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邹文杰, 丁立, 张雪姣, 陈均. 环氧树脂/有机硅氧烷改性阳离子丙烯酸乳液复合涂层的研究. 中国腐蚀与防护学报[J], 2023, 43(4): 922-928 DOI:10.11902/1005.4537.2022.279

ZOU Wenjie, DING Li, ZHANG Xuejiao, CHEN Jun. Epoxy/Organosiloxane Modified Cationic Acrylic Emulsion Composite Coating. Journal of Chinese Society for Corrosion and Protection[J], 2023, 43(4): 922-928 DOI:10.11902/1005.4537.2022.279

近年来,碳钢板凭借自身强度高、硬度大的特点被广泛应用,但是碳钢极易与环境成分发生反应,从而因腐蚀导致大量经济损失和引发安全问题[1, 2]。有机硅改性的丙烯酸树脂涂层在碳钢板防腐方面的应用日益突出[3, 4],其中阳离子型有机硅氧烷改性的丙烯酸 (SMCWA) 乳液一方面经济环保,另一方面改善了传统丙烯酸树脂涂层在耐水性、耐候性和耐热性等方面的不足[5~8]。SMCWA乳液与碳钢板基底能够形成Si-O-Me键,提高与金属基底的结合,从而提高金属耐腐蚀性能,而且其能够自交联,使有机的膜层变得更加致密、疏水和耐腐蚀[9~13]。改性水性丙烯酸树脂涂层应用于碳钢板的防腐方面,环保经济、防腐性能较好,因此对其研究越来越深入,应用也更加广泛[14, 15]。目前,国外对可聚合胺基硅烷改性丙烯酸乳液的报道较少,国内的有关改性丙烯酸阴离子乳液的报道较多[16],对于可聚合胺基硅烷改性阳离子型丙烯酸乳液的研究处于成长阶段。改性乳液聚合采用半连续的聚合方法,先将一部分单体、乳化剂和引发剂加入到反应容器中,再将剩余的单体和引发剂滴加到反应器中。与其他聚合方法相比,该操作更加简单,由于采用滴加的方式,对反应过程能够更好的控制[17~20]。Chen等[21]通过半连续种子乳液聚合成功制备了二乙烯基硅烷改性的自交联聚丙烯酸酯胶乳。乳液具有良好的力学稳定性和化学稳定性,分散体呈蓝色、半透明,粒径小。制备的聚丙烯酸酯胶体膜具有突出的热稳定性和疏水性。Su等[5]通过可逆加成-断裂转移聚合开发了一种新的阳离子丙烯酸酯改性环氧树脂乳液,用于水性喷墨。该乳液兼具聚丙烯酸酯和环氧树脂的优点,具有高电势和高水接触角。该乳液成功地用于喷墨印刷的帆布涂层,这项工作将为喷墨印刷行业新型阳离子乳液的开发做出贡献。有机硅改性的阳离子丙烯酸乳液和环氧树脂对碳钢板耐腐蚀性能都有很大的提升[22~24]。本研究使用半连续乳液聚合法成功制备了绿色无污染的SMCWA乳液,其乳胶粒子表面的多胺基赋予了乳液优异的兼容性和稳定性。根据SMCWA乳液乳胶粒表面胺基能够固化环氧的原理,向其中加入少量环氧树脂,与乳胶粒表面的胺基反应,进一步增强了涂层的耐腐蚀性能。将SMCWA乳液与环氧树脂复配后,在碳钢板上制备了复合防腐涂层,同时兼具两者优点,其耐CuSO4点滴能力、附着力和耐腐蚀性能都得到提高。在此基础上,乳液成功进行了中试,并在卷钢基材上获得了实际应用。

1 实验方法

本实验首先通过计算确定实验药品的用量,然后将20% (质量分数,全文同) 的打底水,40%的自制的可聚合氨基硅烷功能单体 (DGO-M),3.3%乳化剂十六烷基三甲基氯化铵 (CTAC) 水溶液和30%甲甲酯 (MMA) 与丙烯酸丁酯 (BA) 混合溶液 (质量比2∶1) 加入到四口烧瓶中。75 ℃搅拌5 min,加入3.3%引发剂偶氮二异丁脒盐酸盐 (V50) 总量的30%的用量,将剩余的所有单体混合加入到带有机械搅拌的滴定漏斗中混合,再加入之前乳化剂用量的二分之一的用量,高速搅拌,同样把剩余的V50倒入到另一个恒压漏斗中。从看到出现蓝光开始,10 min后,开始滴加漏斗中的单体和引发剂,使他们同时在3.5 h滴加完成。75 ℃继续反应90 min,然后自然冷却降温、过滤,制得SMCWA乳液。

碳钢板防腐涂层用7 μm线棒涂覆之前,碳钢板基底表面预处理过程为:擦去碳钢板表面多余的油脂,再将碳钢板的裁剪处打磨光滑,以免损伤线棒和涂覆不均匀。用无水乙醇再擦拭一遍碳钢板表面,放入到配置好的20 g/L的脱脂剂中,45 ℃,超声5 min。取出用清水荡洗多次,再用乙醇冲洗去除表面的水分,放入80 ℃的烘箱中烘干备用。

用滴管取上述适量的用水稀释相同固含的SMCWA乳液/环氧树脂复合乳液,配比分别为10/0、9/1、9.25/0.75、9.5/0.5和9.75/0.25,分别滴加到固定在涂布器预先处理好的碳钢板上。用7 μm的线棒双手压住匀速进行辊涂,迅速放入到230 ℃的烘箱中80 s,用镊子取出,即获得碳钢板复合乳液涂层,供后续测试使用。

使用ZS90型激光纳米粒度仪对用去离子水将SMCWA乳液稀释成固含量100倍的溶液进行Zeta电位和粒径及其分布的测定,温度为25 ℃。使用IRAffinity-1S型Fourier红外光谱仪 (FT-IR) 对上述制备好的涂层的结构进行表征和分析。使用JSM6490型扫描电子显微镜 (SEM) 观察碳钢板表面乳液膜层和复合防腐乳液膜层的成膜结果。

将接触角仪器里的水滴到所需测试的膜层上,再利用计算机软件分析计算出接触角的数据。据GB/T9286-1998进行实验所需碳钢板表面树脂膜层材料的附着力测试。配置CuSO4点滴所需的溶液 (100 g) :50 g CuSO4,45.2 g H2O,3.5 g NaCl,1.3 mL的0.1 mol/L HCl。用滴管吸取配置好的测试溶液滴到涂有膜层的碳钢板上,观察碳钢板表面出现红点时的时间,每个碳钢板上不同位置测试4组,取平均时间作为最终点滴数据。一般碳钢板表面从滴下液滴到出现红点的时间越长,表示碳钢板表面膜层的防腐性能越好。

利用CHI660E型电化学工作站,以碳钢板为工作电极,甘汞电极作为参比电极,铂丝电极作为辅助电极进行电化学测试分析。采用YWX/Q型盐雾箱进行中性盐雾实验,温度 (35±2) ºC,NaCl浓度 (50±5) g/L,pH 6.5~7.2之间。

2 结果与讨论

2.1 SMCWA乳液的粒径和Zeta电位

图1是制备的SMCWA乳液的粒径和粒径分布图,图2是其Zeta电位图。可以看到,所制备的乳液粒径 (dz) 87.08 nm,粒径分布 (Pdl) 较小为0.184,Zeta电位为49.8 mV。这些数据表明成功制备了一种纳米粒径且乳液含有大量相互排斥的正电荷的稳定的SMCWA乳液。在碳钢板上成膜时,由于阳离子的存在能更好地与基底上的自由电子结合,提高涂层与金属基底的附着力,具有遮蔽铁锈的作用,同时有机硅氧烷也能更好地将有机无机的物质结合起来,与金属基底形成Si-O-Me键,提高与金属基底的结合力。硅羟基自身也可以交联,能够提高膜层的致密性,增强耐腐蚀能力。

图1

图1   SMCWA 乳液中乳胶粒子的粒径大小和分布

Fig.1   Size and distribution of latex particles in SMCWA emulsion


图2

图2   SMCWA乳液中乳胶粒子的Zeta电位

Fig.2   Zeta potential of latex particles in SMCWA emulsion


2.2 SMCWA乳液与环氧树脂复合涂层的防腐性能

利用上述成功制备的SMCWA乳液作为主要成膜物质,再根据乳液中乳胶粒子表面的胺基能够固化环氧树脂的原理,使乳液与环氧树脂进行复配,在低碳钢板表面制备耐腐蚀性能优异的复合涂层。对制备的涂层进行表征分析,以此来检验复合涂层的耐腐蚀性能。

2.2.1 FT-IR分析

制备的SMCWA乳液中含有许多胺基,可以与环氧树脂发生反应,固化环氧,使SMCWA乳液与环氧树脂在金属防腐方面的优点结合起来,达到增强碳钢板上防腐复合涂层耐腐蚀能力的目的。固化前的SMCWA乳液、环氧树脂和固化后的复合涂层的红外光谱如图3所示。可以观察SMCWA乳液a的红外图谱在3340 cm-1处有一个-OH和N-H共存的一个特征峰,这是SMCWA乳液能够固化环氧树脂的关键。从红外谱图c可以看到,固化后在3340 cm-1只剩下了-OH特征吸收峰,并且在916 cm-1处b图中的环氧基消失了,说明乳液中的胺基与环氧树脂反应,起到了环氧树脂固化剂的作用。

图3

图3   SMCWA乳液与环氧树脂固化前后的红外光谱图

Fig.3   FT-IR spectra of SMCWA emulsion and epoxy resin before and after curing


2.2.2 SEM结果

将不同比例的乳液/环氧树脂涂覆在碳钢板上制备复合涂层,利用SEM观察膜层的成膜情况,结果见图4。可以观察到,不同比例的乳液/环氧树脂制得的复合涂层成膜都是完整没有缺陷的,都均匀的涂覆在碳钢板表面。这说明乳液/环氧树脂复合后能够很好地相互作用,形成致密的复合涂层,对碳钢板的耐腐蚀性能防护发挥着关键的作用。

图4

图4   不同比例SMCWA乳液/环氧树脂复合涂层的SEM图

Fig.4   SEM images of composite coatings with SMCWA emulsion/epoxy ratios of 10/0 (a), 9/1 (b), 9.25/0.75 (c) and 9.5/0.5 (d)


2.2.3 水接触角测试

对不同比例的乳液/环氧树脂复合涂层进行水接触角测试,并与空白乳液涂层进行对比,结果如图5。从图中的水接触角数据对比分析可以得到,与环氧树脂作用后所制备的复合涂层均比空白乳液涂层的水接触角的数值有所提高,说明环氧树脂的加入使复合涂层的疏水性能获得了增强。乳液中乳胶粒子表面的胺基与环氧树脂反应,使环氧树脂固化,变得更加耐水的侵蚀,使水更难通过复合涂层侵蚀碳钢板基底,达到提高其耐腐蚀性能的目的。

图5

图5   不同比例SMCWA乳液/环氧树脂复合涂层的水接触角图

Fig.5   Water contact angle diagrams of composite coatings with SMCWA emulsion/epoxy ratios of 10/0 (a), 9/1 (b), 9.25/0.75 (c), 9.5/0.5 (d) and 9.75/0.25 (e)


2.2.4 CuSO4点滴测试

SMCWA乳液/环氧树脂配比分别为10/0、9/1、9.25/0.75、9.5/0.5和9.75/0.25时,制备的复合涂层耐CuSO4点滴的时间分别为180、230、248、296和226 s。加入环氧树脂后,制备的复合涂层耐CuSO4点滴的时间都要优于空白乳液涂层,这是因为环氧树脂和SMCWA乳液共同作用以后,复合涂层兼具了SMCWA乳液和环氧树脂两者的优点,使得腐蚀介质更难到达碳钢板基底,对其造成腐蚀,使复合涂层耐腐蚀能力得到增强。

2.2.5 附着力测试

图6是不同比例SMCWA乳液/环氧树脂复合涂层的附着力测试结果图。所制备的涂层均没有脱落,并且切割边缘光滑清晰均匀,表明环氧树脂的加入没有对涂层产生破坏。所制备的涂层与碳钢板金属基底的结合均表现良好,涂层附着力测试结果都达到了最高的0级。

图6

图6   不同比例SMCWA乳液/环氧树脂复合涂层的附着力图

Fig.6   Adhesion charts of composite coatings with SMCWA emulsion/epoxy ratios of 10/0 (a), 9/1 (b), 9.25/0.75 (c), 9.5/0.5 (d) and 9.75/0.25 (e)


2.2.6 电化学测试分析

图7为不同比例SMCWA乳液/环氧树脂复合涂层的电化学阻抗谱 (EIS) 测试结果。由图7a可以看出,高频区的数值越大,说明涂层越致密,更加耐腐蚀,可以看到所有复合涂层都要高于空白乳液涂层。图7b中复合涂层的电阻值均比空白样高出一个数量级,电荷转移更加困难,腐蚀更不容易发生。图7c中,电容阻抗半径越大,即圆弧半径越大,腐蚀介质对碳钢板基底的腐蚀效率就越弱。综合分析可以得到,制备的复合涂层防腐性能要优于空白乳液涂层,且乳液/环氧树脂为9.5/0.5时,复合涂层耐腐蚀性能最优。

图7

图7   不同比例SMCWA乳液/环氧树脂复合涂层的EIS图

Fig.7   Bode (a, b) and Nyquist (c) diagrams of composite coatings with different SMCWA emulsion/epoxy ratios


使用图8等效电路进行拟合,研究复合涂层在3.5%NaCl溶液中的腐蚀行为 (浸泡1 h,腐蚀电压稳定后进行EIS测试),得到的数据如表1。其中,Rc为膜层电阻,Rct为电荷转移电阻,阻值越大,电荷转移越困难,腐蚀行为越不易进行。n为弥散系数,CPEc是与膜层相关的常相位角元件,通常来讲n值越接近于1,膜层越接近理性模型,CPEc越小,膜层越致密,防腐性能越好。通过比较表中的数据可以得到,SMCWA乳液/环氧树脂复合涂层相比于空白乳液涂层阻抗值都获得了增强。当SMCWA乳液与环氧树脂的配比为9.5/0.5时,此时碳钢板上的复合涂层Rct最大,为42008 Ω·cm2,比空白乳液涂层提高了4倍多。CPEc的值为3.5246×10-8 Ω·cm-2·s-n,也是几个配比中最小的,证明膜层更加致密疏水。弥散系数n1值为0.92514,相比于其他比例复合涂层的数值,更接近于1,碳钢板基底上的涂层更加致密光滑,更接近于理性涂层。综合以上的数据,都表明涂层的耐腐蚀性能变得更加优异。

图8

图8   SMCWA乳液/环氧树脂复合涂层EIS拟合等效电路图

Fig.8   Equivalent circuit diagram for fitting of EIS of SMCWA emulsion/epoxy composite coating


表1   不同比例SMCWA乳液/环氧树脂复合涂层的EIS拟合结果

Table 1  Fitting parameters of EIS of composite coatings with different SMCWA emulsion/epoxy ratios

SMCWA emulsion / Epoxy ratioRs / Ω·cm2Rc / Ω·cm2CPEc / Ω·cm-2·s-nn1Rct / Ω·cm2CPEdl / Ω·cm-2·s-nn2
10/026.187001.098×10-60.6948092217.667×10-50.62230
9/122.4124347.0823×10-80.83892212841.1987×10-50.70538
9.25/0.7524.7159006.7149×10-80.86988348761.1078×10-50.80804
9.5/0.522.6396803.5246×10-80.92514420081.6133×10-60.90489
9.75/0.2526.1222792.603×10-70.81547192613.8761×10-50.65058

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图9是不同复合涂层极化曲线测试的结果图,相关参数数据如表2。可以看出,加入环氧树脂以后,复合涂层的腐蚀电压与空白样相比都更加偏正,腐蚀电流密度也更小;当SMCWA乳液/环氧树脂配比为9.5/0.5时,腐蚀电位最正,腐蚀电流密度最小。一般来说,腐蚀电位越正,腐蚀电流密度越小,耐腐蚀性能就越优异。综上所述,制备的复合涂层耐腐蚀性能都有提高,其中,9.5/0.5复合涂层耐腐蚀性能最优异。

图9

图9   不同比例SMCWA乳液/环氧树脂复合涂层的Tafel极化曲线

Fig.9   Tafel polarization curves of composite coatings with different SMCWA emulsion/epoxy ratios


表2   不同比例SMCWA乳液/环氧树脂复合涂层的腐蚀参数

Table 2  Corrosion parameters of composite coatings with different SMCWA emulsion/epoxy ratios

SMCWA emulsion/epoxy ratioEcorr / VIcorr / 10-7 A·cm-2
10/0-0.58819.78
9/1-0.57213.88
9.25/0.75-0.56910.38
9.5/0.5-0.5275.926
9.75/0.25-0.57314.78

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2.2.7 中性盐雾实验

图10的中性盐雾实验结果可以看出,空白乳液涂层在8 h时已经出现了腐蚀,24 h时,出现了较多的腐蚀产物。相对于空白乳液涂层,SMCWA乳液/环氧树脂为9.5/0.5的复合涂层在8 h时,没有被腐蚀,对碳钢板基底保护优异;24 h时,只是出现了很小的腐蚀点。由此可见,复合涂层对碳钢板表现出了优异的耐腐蚀性能。

图10

图10   空白以及SMCWA乳液/环氧树脂比例为9.5/0.5的涂层中性盐雾实验不同时间后的表面形貌

Fig.10   Surface morphologies of SMCWA emulsion coating (a-c) and SMCWA emulsion /epoxy composite coating with the ratio of 9.5/0.5 (d-f) after neutral salt spray test for 0 h (a, d), 8 h (b, e) and 24 h (c, f)


3 结论

(1) 通过粒径和Zeta电位数据分析可以得出,实验成功合成了纳米粒径、带有正电荷和稳定的有机硅氧烷改性的阳离子型丙烯酸乳液。SEM、附着力测试以及水接触角测试表明制备的复合涂层均匀无缺陷,与碳钢板基底结合良好,并且疏水性能获得提高。

(2) CuSO4点滴实验和电化学测试表明涂层的致密性得到增强,耐腐蚀性能获得显著提升。其中,SMCWA乳液与环氧树脂配比为9.5/0.5时,点滴时间达到296 s,阻抗值比空白乳液涂层提高4倍多,腐蚀电流密度下降一个数量级。

(3) SMCWA乳液/环氧树脂为9.5/0.5的复合涂层中性盐雾实验表现优异,对碳钢板基材耐腐蚀防护能力强,已在实际工业中获得应用。

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