Maximizing the functional properties of epoxy coatings using milled Al for enhanced mechanical strength and corrosion resistance

Herein, epoxy coatings modified with milled aluminum (Al) were tested for their mechanical strength and corrosion resistance. First, milling was performed on the as-received Al powder for 70 h. The obtained powder postmilling was added to DGEBA-type epoxy resin and cured with an amine-based D450 hardener. The milled Al powder was added in varying weight percentages (1, 2, and 3%). Different types of panels were coated using an automatic film applicator to obtain controlled film thickness and left for curing. Morphological characterization was done using field emission scanning electron microscopy and X-ray diffraction. Thermal stability of the coatings was evaluated using thermogravimetric analysis. Mechanical properties were measured using conventional testing techniques as well as nanoindentation. The analysis results suggest that milling of Al alters the structure of powder postmilling. The milling operations also have an effect on the mechanical and anticorrosion properties of the materials. The results obtained for the prepared modified coating suggest that addition of 2 wt% in the epoxy resulted in balanced mechanical and anticorrosion properties.