Advances in High Performance Polymer Nano Composite Coatings for Better Resistance to Corrosion and Ultraviolet Rays

Shambhu Sharan Kumar

In this industrial extensive research work in the fields of corrosion protection and surface coatings, conventional micron sized rutile TiO₂ pigment based automobile grade polyester-amino (butylated melamine formaldehyde resin-BMF) stoving paint was formulated. In subsequent approach, nano TiO₂ and nano ZnO alongwith nano SiO₂ particles modified super white stoving industrial paints were formulated for the purpose of comparative study and to improve overall performances of surface coatings with respect to the best possible protection of automobile grade steel surfaces. With reference to the improvement of erosion and corrosion resistance, weathering and ultraviolet (UV-rays) resistance, water repellence and chemical resistance, dispersion stability and aging resistance, surface covering and adhesion property, film smoothness and gloss retention alongwith other mechanical properties; nano materials adapted paints have shown great potential in several industrial applications. The nano pigment particles were characterized by SEM and XRD. Performance evaluation of surface coatings was done as per ASTM/BIS test procedures. After rigorous test observations, excellent performance results have been found i.e. 100% adhesion, 100% gloss, appreciable results in aging test, 4000 hours passed in salt spray test and 3600 hours passed in quick ultraviolet weathering resistance test due to surprising synergistic effects of dispersed different  nano materials in crosslinked polyester-amino resins  media. It has experimentally been proven that the proper application and dispersion of suitable nano materials in paint formulations, improved overall performances of surface coatings for the purpose of better surface-protection.