Enhanced performance of waterborne coatings via Titanium dioxide–mineral powder coupling

Abstract

This study fabricated two composite anticorrosion coatings based on a waterborne epoxy resin matrix, incorporating TC4 alloy powder and TiO₂ nanoparticles, respectively, with mineral powder hybridization to enhance performance and reduce material costs. Salt spray testing demonstrated that both systems maintained stability in corrosive environments for over 30 days. However, the TC4-based coating exhibited local edge warping on day 10, indicative of insufficient interfacial adhesion and structural instability. In contrast, the TiO₂ composite coating retained structural integrity throughout the test period, demonstrating superior corrosion resistance. Characterization analyses (SEM, TEM, EDS, FTIR, UV–Vis) revealed that TiO₂ particles achieved better dispersion and interfacial binding capacity, effectively minimizing pore formation and structural defects. The dense oxide layer on TiO₂ surfaces amplified the “maze effect,” significantly inhibiting corrosive medium penetration. Cross-cut adhesion testing and impact resistance evaluation further confirmed the TiO₂ system's advantages in interfacial bonding strength and mechanical robustness over the TC4 counterpart. Collectively, the TiO₂–mineral hybrid coating demonstrates superior comprehensive protection properties and greater engineering application potential, offering a novel strategy for designing cost-effective, high-performance waterborne epoxy anticorrosion materials.