Synergistic Effect of Nanoclay and Barium Sulfate Fillers on the Corrosion Resistance of Polyester Powder Coatings

Nanoclay has proven to be an active anti-corrosive additive due the self-repairing effect from nanoclay swelling and expansion, except for its passive barrier high aspect ratio. But it is still uncertain how these effects of are intertwined with other components in a complex coating system corrosive environments. In this study, we examined combined nanoclays two particle sizes commonly used cost-reducing filler, BaSO4. By employing neutral salt spray tests, electrochemical analysis, surface characterization, identified optimal conditions achieving strong effect. Surprisingly, relatively low dosage 2% BaSO4 filler exhibited synergistic behavior. not only compensated reduction owing addition by offering effects, but also overcame delamination issues observed at higher dosages (4% above). The panel larger showed orders magnitude pore resistance than without nanoclay, remaining 107 Ω∙cm2 after 25 days immersion. As result, demonstrated significantly slower corrosion expansion reached lifetime 2500 h when creepage exceeded 2 mm tests. This study contributes full understanding proper utilization high-performance, smart coatings.