Direct to metal (DTM) coatings are in great demand today as it has proven to be a sustainable solution eliminating need for primer layers. DTM Coatings are monolayer coatings that fulfill the role of both primer and topcoat. In current research acrylic polyester-based hybrid polyurethane nanocomposite coating was formulated for DTM application. Concentrations of acrylic and polyester polyols along with titanium dioxide pigment were optimized using the Taguchi-based statistical model and then nano-silica was added in various loadings and tested for its properties concerning DTM application. Addition of nano-silica has been found to significantly contribute towards enhanced mechanical properties. Nano-silica dispersion in the coating matrix along with its morphology was ascertained using SEM study while structural characterization was done by FTIR. At 8% nano-silica loading, formulated coatings revealed better thermal stability, excellent weathering performance along with anti-corrosive properties and chemical resistance owing to the presence of hybrid polymer chains.
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