Chemical Technology and Corrosion Behavior of Industrial Primer-enamel Coating Systems on Carbon Steel
Year: 2026
Type: article
Abstract: Complex interactions among formulation chemistry, film integrity, and interfacial sta-bility determine the anticorrosion performance of industrial primer-enamel coating systems. In this study, the influence of key formulation variables on coating quality indicators and cor-rosion behavior was systematically investigated using industrial epoxy-based primers and al-kyd/acrylic enamels. Particular attention was given to the role of zinc phosphate content, or-ganic corrosion inhibitors, and silane adhesion promoters under controlled technological con-ditions. Eight primer-enamel variants were prepared based on identical binder systems and application regimes, differing only in formulation parameters. All coatings were applied to steel substrates under standardized surface preparation, curing, and film formation conditions. Coating quality indicators, including dry film thickness, adhesion to steel, film compactness, defect tendency, and functional inhibitor activity, were evaluated to characterize film integrity before corrosion assessment.Corrosion resistance trends were subsequently analyzed using a comparative frame-work that emphasizes relative performance differences among formulation variants. The results demonstrate that coating performance cannot be attributed to a single factor. Increased zinc phosphate content primarily enhanced barrier continuity and film compactness, while silane adhesion promoters significantly improved interfacial bonding and reduced susceptibil-ity to underfilm corrosion. Organic corrosion inhibitors contributed independently to corro-sion suppression by limiting electrochemical activity at the metal-coating interface without altering bulk film morphology. The highest corrosion resistance was observed for formula-tions combining enhanced barrier properties, strong adhesion, and active inhibitor functionali-ty, indicating a synergistic interaction between structural and functional protection mecha-nisms.The findings establish clear formulation-performance relationships for industrial pri-mer-enamel systems and highlight the importance of balanced chemical and technological design for achieving durable anticorrosion protection.
Language: English
Subfield: Materials Chemistry
Field: Materials Science
Domain: Physical Sciences
Open Access status: diamond
OpenAlex ID: W7163704100