Journal of the Chinese Ceramic Society, Volume. 53, Issue 4, 1018(2025)

Research Progress on Multi-Scale Modification of Silicate Anti-Corrosion Coatings

LI Weihua1...2,3, LI Shuting1, FU Bo4, WANG Xiaojun4, ZHAO Li4, and ZHENG Haibing23,* |Show fewer author(s)
Author Affiliations
  • 1School of Civil Engineering and Communication, North China University of Water Resources and Electric Power, Zhengzhou 450045, China
  • 2Henan Academy of Sciences Institute of Chemistry, Zhengzhou 450046, China
  • 3Henan Academy of Sciences, Zhengzhou 450046, China
  • 4Shandong Longquan Pipe Industry Co. , Ltd, Zibo 255200, Shandong, China
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    Inorganic silicate coatings, as a type of inorganic paint, exhibit the superior long-term anti-corrosion performance, heat resistance, and weather resistance. Compared to the conventional organic coatings, inorganic silicate coatings are more environmentally friendly, aligning with the development of eco-friendly coatings. However, pure inorganic silicate coatings face some issues such as high brittleness, susceptibility to cracking, and poor water resistance, thus restricting their practical application. Extensive research has been conducted on the modification of these coatings to enhance the mechanical properties and anti-corrosion performance of inorganic silicate coatings. It is essential to review the current research on the modification of inorganic silicate coatings to accelerate progress in both research and practical applications in engineering. This review represents the modification of inorganic silicate coatings with various materials affecting the overall performance of the coatings in varying degrees. Based on a spatial multi-scale approach, the relevant modifying materials are categorized into three scales, i.e., macro-scale, meso-scale, and micro-scale.In the macro-scale, the modifying materials include inorganic substances such as silica sol, aluminum phosphate (AlPO4), and calcium hydrogen phosphate (CHP), while organic materials consist of organo-silicon emulsions, silane coupling agents, acrylic resins, and epoxy resins. Silica sol significantly enhances the corrosion resistance of coatings via increasing their degree of crosslinking. Phosphate compounds promote the polymerization of silanol groups by providing H⁺ ions, thereby accelerating the curing of the coatings and improving their water resistance. Organic modifiers increase the internal crosslinking density and flexibility of the coatings, while also imparting hydrophobic and self-cleaning properties, by introducing functional groups such as hydroxyl and carboxyl groups into the silicate curing process.In the meso-scale, the modifications primarily utilize micron-sized fillers, i.e., zinc-type fillers, layered structure fillers, and other metallic and metal oxide fillers. Zinc-type fillers encompass zinc powder, zinc oxide, and zinc silicate. Layered structure fillers include mica powder, two-dimensional transition metal carbides (Ti3C2Tx), and layered double hydroxides (LDHs), and other metallic and metal oxide fillers comprise aluminum powder, zinc-aluminum alloy powder, mica iron oxide, titanium (Ti), and titanium oxide (TiO2). Metal and metal oxide modified fillers enhance the anti-corrosion performance of inorganic silicate coatings through a threefold mechanism of filling, physical shielding, and electrochemical protection, which delays and prevents the penetration of corrosive media into the substrate surface. In addition, these fillers can also chemically bond with silicate matrix, thereby enhancing the adhesion and chemical stability of the coating. Layered fillers, such as mica powder, Ti3C2Tx, and layered double hydroxides (LDHs), provide the superior physical shielding and create a "maze effect" within the coating, which extends and convolutes the diffusion pathways of corrosive media like chloride ions and water molecules. This ultimately slows down the corrosion reactions of the substrate and improves the anti-corrosion performance of the coating.In the micro-scale, the materials for the modification are mainly nano-scale fillers, such as nano-silica (SiO2) and graphene-based nano-scale fillers. This review discusses the impact of modification materials in different scales on the performance of inorganic silicate coatings and elucidates their modification mechanisms. This review addresses the existing shortcomings of modification materials in various scales in current research and outlines the future development trends. Nano-SiO₂ enhances the bonding strength and anti-corrosion performance of inorganic silicate coatings via participating in the construction of the silicate network, thereby increasing the internal connectivity of the coating. Meanwhile, nano graphene-based fillers can improve the weather resistance and anti-corrosion performance of the inorganic silicate coatings due to their exceptional chemical stability, conductivity, and barrier properties.Summary and ProspectsIn the macro-scale modification, constructing an environmentally friendly coating system to reduce the use of organic solvents is a future development direction. However, inorganic modifiers have some limitations in enhancing the coating performance. The use of organic modifiers can lead to the emission of volatile organic compounds (VOCs), which negatively impacts the environment. It is thus important for the dual goals of optimizing coating performance and environmental protection to develop eco-friendly inorganic silicate coatings that balance the use of inorganic and organic modifiers. The performance of the prepared inorganic silicate anti-corrosion coatings is relatively singular. A future research can explore multifunctional composite anti-corrosion coatings that can be used under various environmental conditions, such as super-hydrophobicity, self-cleaning, self-healing, oxidation resistance, and wear resistance. In the micro-scale, the modification of inorganic silicate coatings with nanoparticles may reduce economic viability due to the high cost of nano-materials. A future research should focus on the development of more cost-effective methods for synthesizing nanoparticles, such as microwave-assisted synthesis, solvothermal methods, and sol-gel techniques. In addition, introducing specific functional groups on the surface of nanoparticles or combining them with other materials to impart the coatings with multifunctional properties like self-healing, super-hydrophobicity, antibacterial activity, and flame retardancy can be an important development direction. In the molecular/atomic scale, studies on the modification of inorganic silicate coatings primarily focus on experimental approaches, failing to delve into the molecular or atomic mechanisms. This results in an incomplete understanding of the coatings performance. A future research should focus on molecular design and optimization, as well as molecular dynamics simulations, to clarify the modification mechanisms for inorganic silicate coatings.

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    LI Weihua, LI Shuting, FU Bo, WANG Xiaojun, ZHAO Li, ZHENG Haibing. Research Progress on Multi-Scale Modification of Silicate Anti-Corrosion Coatings[J]. Journal of the Chinese Ceramic Society, 2025, 53(4): 1018

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    Paper Information

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    Received: Oct. 22, 2024

    Accepted: May. 29, 2025

    Published Online: May. 29, 2025

    The Author Email: ZHENG Haibing (zhenghaibing.ln@163.com)

    DOI:10.14062/j.issn.0454-5648.20240656

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