Studying the effect of organo-modified nanoclay loading on the thermal stability, flame retardant, anti-corrosive and mechanical properties of polyurethane nanocomposite for surface coating

Clay polyurethane nanocomposite (CPN) coating films were fabricated by uniformly dispersing nanoclay, organically modified with 25-30 wt.% octadecylamine in varying concentrations up to 5 wt.%, in a commercial two component, glossy, acrylic aliphatic polyurethane using ultrasonication. Organo-modified nanoclay was characterized by X-ray diffraction (XRD). The dispersion of the nanoclay into the matrix was investigated by scanning electron microscopy (SEM). CPN coating films were characterized by thermogravimetric analysis (TGA), and flame retardant, corrosion resistance and mechanical properties were also investigated. The XRD measurement indicated that, the organo-modified nanoclay particles were mainly constituted of montmorillonite with traces of quartz and calcite also found to be present. The SEM analysis showed that the nanoclay layers were dispersed and intercalated into the polyurethane coating. Thermogravimetric analysis showed that incorporating 5 wt.% organo-nanoclay into polyurethane considerably enhanced the thermal stability and increased the char residue to 14.11 wt.% relative to 4.58 for the sample without organo-nanoclay (blank polyurethane). The limiting oxygen index (LOI) test revealed that incorporation of organo-nanoclay led to a further increase in LOI values, which indicate an improvement in flame retardancy properties. The corrosion resistance also improved and this improvement increases with increase nanoclay wt.%. The mechanical resistance measurements demonstrated that the gloss of the CPN coating films slightly decreased, although hardness, adhesion and impact resistance of the CPN coating films improved with the incorporation of the organo-nanoclay.