Scratch, wear and corrosion resistant organic inorganic hybrid materials for metals protection and barrier

• Polysiloxane coatings as protective barriers to delay erosion/corrosion of Fe 430 B metal substrates.
• Methyl groups feature a very small steric hindrance and confer ductility to the Si–O–Si backbone.
• Phenyl groups feature a larger steric hindrance, but they ensure stability and high chemical inertness.
• Remarkable adhesion to the substrate, good scratch resistance and high wear endurance.
• Innovative ways to design of long lasting protective barriers against corrosion and aggressive chemicals.

Polysiloxanes are widely used as protective barriers to delay erosion/corrosion and increase chemical inertness of metal substrates. In the present work, a high molecular weight methyl phenyl polysiloxane resin was designed to manufacture a protective coating for Fe 430 B structural steel. Methyl groups feature very small steric hindrance and confer ductility to the Si–O–Si backbone of the organic inorganic hybrid resin, thus allowing the achievement of high thickness. Phenyl groups feature larger steric hindrance, but they ensure stability and high chemical inertness. Visual appearance and morphology of the coatings were studied by field emission scanning electron microscopy and contact gauge surface profilometry. Micro-mechanical response of the coatings was analyzed by instrumented progressive load scratch, while wear resistance by dry sliding linear reciprocating tribological tests. Lastly, chemical inertness and corrosion endurance of the coatings were evaluated by linear sweep voltammetry and chronoamperometry in aggressive acid environment. The resulting resins yielded protective materials, which feature remarkable adhesion to the substrate, good scratch resistance and high wear endurance, thus laying the foundations to manufacture long lasting protective barriers against corrosion and, more in general, against aggressive chemicals.

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