Anti-corrosion performance of waterborne Zn-rich coating with modified silicon-based vehicle and lamellar Zn (Al) pigments

In order to develop the eco-friendly Zn-rich coatings with higher corrosion resistance and lower pigment contents, several series of coatings were designed and manufactured employing lamellar Zn (Al) pigments mixed with silicone-acrylate emulsion modified inorganic silicate vehicle, and then were evaluated by conventional methods and the electrochemical method. The results indicated that the pigment contents reduced to approximate 25 mass% with lamellar Zn or (Zn and Al) pigments as substitute for spherical Zn pigments, and pigment mixtures were homogeneously dispersed due to silicone-acrylate emulsion moistening modification. Furthermore, the optimal coating had good coating properties (adhesion grade: one), acid resistance (lower mass losses) and anti-corrosive performance (improved corrosion potential and anodic passivation). The experimental results indicated that the modified lamellar Zn (Al) coating was suitable for large-scale spread and application on protecting steel structures in the hostile environment.