Exploration of Diverse Epoxy-Based Surface Coating Methods for Enhancing Anticorrosion Characteristics

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Year : 2026 | Volume : 14 | 02 | Page :
    By

    Kundurthi Bharadwaja,

  • Srinivasa Rao Seeram,

  • Pusam Vamsikrishna,

  • Ashwini Kumar Baluguri,

  1. Associate Professor, Department of Mechanical Engineering, Malla Reddy Deemed to be University, Secunderabad, Hyderabad, Telangana, India
  2. Professor, Department of Mechanical Engineering, KL University, Vaddeswaram, Andhra Pradesh, India
  3. Research Scholar, Department of Mechanical Engineering, Malla Reddy Deemed to be University Secunderabad, Hyderabad, Telangana, India
  4. Research Scholar, Department of Mechanical Engineering, KL University, Vaddeswaram, Andhra Pradesh, India

Abstract

Epoxy-based polymers, commonly referred to as polyepoxides, constitute one of the most versatile and widely adopted categories of polymeric materials due to their exceptional structural, mechanical, and chemical characteristics. Their unique macromolecular framework enables strong interfacial bonding, high mechanical stability, and superior resistance to environmental and chemical degradation, positioning them as advanced alternatives to many traditional organic corrosion inhibitors that often fail under prolonged exposure to aggressive conditions  When polyepoxides interact with metallic surfaces, they tend to form highly ordered molecular clusters that function as active adsorption centers. This chemisorption mechanism plays a critical role in mitigating corrosion, particularly in harsh environments such as acidic solutions, alkaline media such as sodium hydroxide, and marine atmospheres. In addition to preventing uniform corrosion, epoxy-based films have shown effectiveness against more complex phenomena including crevice corrosion, interfacial degradation, and mixed-mode electrochemical corrosion.A broad spectrum of experimental investigations and computational modeling approaches—including Density Functional Theory (DFT), Molecular Dynamics (MD), and Monte Carlo simulations—have been used to study the adsorption behavior of epoxy molecules on metal substrates. These studies highlight the importance of donor–acceptor interactions, electron density distribution, and charge-transfer processes that contribute to the strong adherence of epoxy systems to metal surfaces. Althoughpolyepoxides offer outstanding protective properties, their limited solubility in many polar and nonpolar solvents restricts their direct use in liquid-phase corrosion inhibition. Consequently, they are predominantly applied as protective surface coatings. Epoxy-based coatings serve as highly effective physical and chemical barriers for both ferrous and non-ferrous alloys, especially when exposed to corrosive saline environments, industrial chemicals, and atmospheric moisture.To enhance their performance, researchers have explored the incorporation of a wide range of natural and synthetic additives such as metallic oxides, silane coupling agents, graphene derivatives, biopolymers, nanoclays, and other nanostructures. These additives improve coating adhesion, hydrophobicity, thermal stability, and resistance to electrochemical attack. Recent developments in self-healing epoxy systems, utilizing microcapsules or nanocontainers loaded with healing agents, have opened new possibilities in smart coating technology by enabling autonomous repair of surface damage and extending service life.This review compiles and critically examines the anticorrosion behavior of both uncured and fully cured epoxy formulations. It provides an integrated understanding of their physicochemical properties, adsorption mechanisms, and performance across various metallic substrates and electrolytic environments. Additionally, the review outlines future directions in epoxy coating technology, emphasizing environmentally friendly formulations, sustainable synthesis pathways, and advanced hybrid nanocomposite systems for high-performance corrosion protection in modern industrial applications.

Keywords: Nanocomposite, polyepoxides, polymers, nanocomposite, Molecular Dynamics.

How to cite this article:
Kundurthi Bharadwaja, Srinivasa Rao Seeram, Pusam Vamsikrishna, Ashwini Kumar Baluguri. Exploration of Diverse Epoxy-Based Surface Coating Methods for Enhancing Anticorrosion Characteristics. Journal of Polymer & Composites. 2026; 14(02):-.
How to cite this URL:
Kundurthi Bharadwaja, Srinivasa Rao Seeram, Pusam Vamsikrishna, Ashwini Kumar Baluguri. Exploration of Diverse Epoxy-Based Surface Coating Methods for Enhancing Anticorrosion Characteristics. Journal of Polymer & Composites. 2026; 14(02):-. Available from: https://journals.stmjournals.com/jopc/article=2026/view=239449


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Ahead of Print Subscription Review Article
Volume 14
02
Received 13/11/2025
Accepted 29/12/2025
Published 30/03/2026
Publication Time 137 Days
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