Development of Hydrophobic Coating and Spraying System for Corrosion Resistant Coatings

Andrius Patapas; Aziz Fihri; Yassine Malajati; Remi Mahfouz; Waleed Al-Nasser; Paul Luckham

doi:10.63095/NBSEH.26.853566

Authors

Andrius Patapas Department of Chemical Engineering, Imperial College London (https://ror.org/041kmwe10), London, United Kingdom
Aziz Fihri Advanced Materials Division, Research & Innovation Complex, Saudi Aramco (https://ror.org/03ypap427), Dhahran 31311, Saudi Arabia
Yassine Malajati Advanced Materials Division, Research & Innovation Complex, Saudi Aramco (https://ror.org/03ypap427), Dhahran 31311, Saudi Arabia
Remi Mahfouz Advanced Materials Division, Research & Innovation Complex, Saudi Aramco (https://ror.org/03ypap427), Dhahran 31311, Saudi Arabia
Waleed Al-Nasser Advanced Materials Division, Research & Innovation Complex, Saudi Aramco (https://ror.org/03ypap427), Dhahran 31311, Saudi Arabia
Paul Luckham Department of Chemical Engineering, Imperial College London (https://ror.org/041kmwe10), London, United Kingdom

DOI:

https://doi.org/10.63095/NBSEH.26.853566

Keywords:

Hydrophobicity, Steel structures, Spray coating, Contact angle

Abstract

In this paper, hydrophilic silica particles (250 nm and 800 nm) were synthesized using the well-established Stöber method. The particles and their mixtures were chemically treated to achieve hydrophobic properties, confirmed using the sessile drop technique. Mild steel sheets were prepared, sand blasted and cleaned to the required surface roughness and cleanliness, verified by established quantitative methods. Two resins, Jotamastic 80 and Penguard FC, were applied as primer and topcoat to the required thickness. The resulting films were evaluated qualitatively and by optical interferometry and micrograph analysis. Samples were then coated with selected combinations of hydrophobic particles to form homogeneous coatings, and their hydrophobicity was assessed. The highest contact angle was obtained for a mixture of 75% 250 nm and 25% 800 nm particles, with other combinations showing contact angles between 130° and 140°. Optimal adhesion and hydrophobic performance were achieved when particle/ethanol suspensions were sprayed 2.5 h after topcoat application. The hydrophobic structure was best developed after 24–48 h of drying. Surface morphology was examined using Scanning Electron Microscopy, and the results are discussed.

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