Optimizing Anticorrosion Coating Performance: Synthesis of Polyurethane/Epoxy Hybrids
Bekbayeva L. Negim E.-S. Al Azzam K.M. Zhanibekov R. Yeligbayeva G. Moldabayeva G.Z. Ewies E.F.
June 2025Multidisciplinary Digital Publishing Institute (MDPI)
Polymers
2025#17Issue 11
Corrosion-resistant coatings are essential for prolonging the lifespan of metal structures, yet conventional formulations often lack sufficient mechanical strength and chemical durability. This study focuses on the development of polyurethane/epoxy hybrid coatings (PUAE) with varying epoxy resin content (5%, 10%, and 15% by weight) to enhance performance. The hybrid films demonstrated improved mechanical properties with increasing epoxy content, including a rise in tensile strength from 39.1 MPa (PUA) to 86.3 MPa (PUAE15) and adhesion from 2.5 MPa to 8.3 MPa. Hardness also increased from 69 Shore A to 98 Shore A, while elongation at break decreased from 158% to 95%, indicating a shift toward a stiffer material. The thermal stability, assessed by TGA, showed higher degradation temperatures, with PUAE15 reaching a maximum decomposition temperature of 390 °C, compared to 320 °C for pure polyurethane. Viscosity at 5 rpm increased from 12.300 mPa·s to 18.563 mPa·s, and the contact angle improved from 105° to 149°, highlighting enhanced hydrophobicity. PUAE15 also displayed superior resistance to solvents and acidic environments. These results affirm that epoxy content significantly influences the structural, mechanical, and corrosion-resistant properties of polyurethane-based coatings, making PUAE15 a promising candidate for advanced anticorrosive applications.
corrosion , epoxy , hybrid , mechanical , polyurethane , resistance
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School of Chemical Engineering, Kazakh British Technical University, 106 Walikhanov Street, Almaty, 050010, Kazakhstan
National Nanotechnology Open Laboratory, Al-Faraby Kazakh National University, Almaty, 050040, Kazakhstan
Department of Chemistry, Faculty of Science, The University of Jordan, Amman, 11942, Jordan
Institute of Organic Synthesis and Carbon Chemistry of the Republic of Kazakhstan, Alikhanov Street., Karaganda, 100000, Kazakhstan
School of Petroleum Engineering, Satbayev University, 22 Satpayev Street, Almaty, 050013, Kazakhstan
Organometallic and Organometalloid Chemistry Department, Chemical Industries Research Institute, National Research Centre, El-Bhouth Street, Giza, Dokki, 12622, Egypt
School of Chemical Engineering
National Nanotechnology Open Laboratory
Department of Chemistry
Institute of Organic Synthesis and Carbon Chemistry of the Republic of Kazakhstan
School of Petroleum Engineering
Organometallic and Organometalloid Chemistry Department
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