Journal of Coating Technology and Innovation

ABSTRACT

The durability of epoxy-based coatings in corrosive environments is often compromised by moisture and ion penetration. In this study, hexagonal boron nitride (h-BN) nanosheets were incorporated into an epoxy matrix to enhance corrosion protection, leveraging their two-dimensional barrier characteristics. Nanocomposite coatings were formulated with varying h-BN loadings (0,1,3 and 5 wt%) and applied to mild steel substrates. Electrochemical performance was evaluated using potentiodynamic polarization and electrochemical impedance spectroscopy (EIS), while accelerated salt spray testing was used to assess long-term durability. Results revealed that the 3 wt% h-BN
coating exhibited the lowest corrosion current density (0.5 μA/cm2) and the highest impedance (68.0 kΩ·cm2), indicating signicant enhancement in protective behavior. Visual analysis after salt spray exposure conrmed minimal rust formation (~12%) for this formulation. However, performance declined at 5 wt% due to probable nanosheet agglomeration and micro-defect formation. These ndings highlight the importance of optimal ller loading in nanocomposite coatings and suggest that 3 wt% h-BN oers a robust and scalable strategy for improving corrosion resistance in epoxy systems. This work provides valuable insights into the design of high-performance anti-corrosive coatings using 2D nanollers and lays the groundwork for future research into hybrid or functionalized systems for broader industrial applications.

KEYWORDS

1. Hexagonal boron nitride (h-BN)
2. Epoxy nanocomposite coatings
3. Marine corrosion protection
4. Anti-corrosion coating
5. SEM and XRD characterization