Encapsulated cerium nitrate inhibitors to provide high-performance anti-corrosion sol–gel coatings on mild steel

A rapid cure silane sol–gel coating containing encapsulated corrosion inhibitors that can be applied to a mild steel substrate to form a crack-free coating has been developed. The benefit of this system is that it appears to emulate the protection mechanism found with traditional chrome (VI) based systems, but without the environmental disadvantages, namely that it is non-toxic and non-carcinogenic. The high corrosion resistance performance of this coating is derived from the combination of the hydrophobic nature of the sol–gel coating and the presence of the encapsulated rare earth corrosion inhibitor which can be released at defects within the coating resulting in cerium hydroxide precipitation which hinders the reduction reaction at cathodic sites. The proposed mechanism for this protection is based upon an evaluation of the barrier properties of the coating using electrochemical impedance spectroscopy and long-term immersion/salt spray tests.