Fabrication of EPYR/GNP/MWCNT carbon-based composite materials for promoted epoxy coating performance

The present study is aimed to fabricate composite materials containing epoxy resin (EPYR) reinforced by mixed carbon-based nano-fillers in the form of graphene nano-platelet (GNP) and multi-walled carbon nanotube (MWCNT) using the dissolution casting technique with the help of ultrasonic assistance. The pure epoxy resin was reinforced by variable loading of mixed GNP/MWCNT in situ, and the epoxy resin is denoted as EPYR/GNP/MWCNT(2–30). The numbers 2–30 corresponded to the final mass ratio of the nano-fillers. The designed products were reinforced by variable percentages of GNP/MWCNTs. XRD, FT-IR, thermal analyses, FE-SEM, TEM and electrical conductivity were utilized as identification techniques to confirm the structures of these composite materials. An excellent evidence for the composite formation was given by XRD diffraction patterns and FT-IR spectroscopy. The introduced amounts of mixed nano-fillers showed significant effects on the thermal, conducting and coating behaviors of pure EPYR. Pure EPYR and EPYR/GNP/MWCNT(20,30) showed higher thermal stabilities than other materials in the range of 400–410 °C. EPYR/GNP/MWCNT(20) also showed remarkable increase in the thermal stability compared to other materials. T(10) represents the temperatures at which 10% weight losses are examined. Pure EPYR and its related EPYR/GNP/MWCNT(2–30) displayed similar thermal stabilities at T(10) temperature (330 ± 4 °C). The morphological features were examined by SEM and TEM; these features showed that the nanocomposite components were extremely compatible. The in situ electrical conductivity values showed noticeable enhancement for the formulations of EPYR/GNP/MWCNT(2–10). Moreover, the coating performance of EPYR was tested by water uptake experiments and electrochemical impedance; both tests proved that the mixed GNP/MWCNT nano-fillers remarkably improved the pure EPYR coating due to the ionic charge transfer resistance and elevated barrier behaviour. The coating resistance variations values (CRv) of EPYR/GNP/MWCNT(10) were the highest among the measured composition values, closely followed by those of EPYR/GNP/MWCNT(20) and EPYR/GNP/MWCNT(30).