Engineered Hybrid Nanoclay-Infused Nano-Polymers for Multifunctional Anti-Corrosive Coatings

Year : 2026 | Volume : 14 | Issue : 01 | Page : 40 53
    By

    V. Velmurugan,

  • Dhivakar Poosapadi,

  • K. P. S. Parmar,

  • S Arun Kumar,

  • S.Parameswari,

  • L Ranganathan,

  • Kirubakaran D,

  • Akash Deep Kushwaha,

  • S.Dhivya,

  1. Associate Professor, Department of Mechanical and Automation Engineering, Sri Sairam Engineering College, West Tambaram, Chennai, Tamil Nadu, India
  2. Lead Engineer, Quest Global North America, Windsor Connecticut, , United States
  3. Associate Professor, Department of Physics, Applied Science Cluster, UPES, Dehradun, Uttarakhand, India
  4. Assistant Professor, Department of Mechatronics Engineering, Kongu Engineering College, Erode, Tamil Nadu, India
  5. Associate Professor, Department of Chemistry, Velammal Institute of Technology, Panchetti, Tamil Nadu, India
  6. Professor, Department of Mechanical Engineering, Cambridge Institute of Technology, Ranchi, Jharkhand, India
  7. Professor, Department of Electrical and Electronics Engineering, St. Joseph’s Institute of Technology, Chennai, Tamil Nadu,
  8. Assistant Professor, Department of Mechanical Engineering, School of Engineering & I.T., MATS University, Arang, Chhattisgarh, India
  9. Professor, Department of Research and Innovation, Saveetha School of Engineering, SIMATS, Chennai, Tamil Nadu, India

Abstract

Polymer nanocomposites reinforced with layered nanofillers have emerged as an effective route to enhance structural stability in protective coating applications. Polymer–clay nanocomposites also provide a promising route to enhance mechanical robustness and environmental durability in coating systems. In this study, a hybrid epoxy–polyurethane (EPU) coating was reinforced using organo-modified montmorillonite (o-MMT) and layered double hydroxide intercalated with 2-mercaptobenzothiazole (LDH–MBT). Uniform dispersion and interfacial anchoring between the nanoclays and polymer chains were achieved using GPTMS, as confirmed by XRD and FTIR analyses. The incorporation of 1.0 wt% o-MMT and 0.7 wt% LDH–MBT resulted in a significant shift in coating performance. The water contact angle increased from 77° (neat EPU) to 95°, indicating reduced surface wettability and enhanced hydrophobicity. Water absorption over 30 days decreased from 2.8 wt% to 0.9 wt%, attributed to the tortuous diffusion pathway imposed by exfoliated silicate platelets and the chloride-trapping capability of LDH layers. Mechanical testing demonstrated improved surface hardness (HB → 2H) and reduced abrasion loss (35 mg → 24 mg) while retaining full flexibility and adhesion (5B). Electrochemical impedance spectroscopy showed an increase in |Z|₀.₀₁ Hz from ~1 × 10⁷ to >2 × 10⁸ Ω·cm², and potentiodynamic polarization revealed a reduction in corrosion current density from 2.3 µA·cm⁻² to 0.6 µA·cm⁻². These results confirm the synergistic reinforcement and active–passive protection mechanisms, establishing the hybrid nanocomposite coating as a durable, high-performance polymer-based protective material.

Keywords: Anti-corrosive, nanoclays, nanofillers, protective coatings, water absorption

[This article belongs to Journal of Polymer & Composites ]

How to cite this article:
V. Velmurugan, Dhivakar Poosapadi, K. P. S. Parmar, S Arun Kumar, S.Parameswari, L Ranganathan, Kirubakaran D, Akash Deep Kushwaha, S.Dhivya. Engineered Hybrid Nanoclay-Infused Nano-Polymers for Multifunctional Anti-Corrosive Coatings. Journal of Polymer & Composites. 2026; 14(01):40-53.
How to cite this URL:
V. Velmurugan, Dhivakar Poosapadi, K. P. S. Parmar, S Arun Kumar, S.Parameswari, L Ranganathan, Kirubakaran D, Akash Deep Kushwaha, S.Dhivya. Engineered Hybrid Nanoclay-Infused Nano-Polymers for Multifunctional Anti-Corrosive Coatings. Journal of Polymer & Composites. 2026; 14(01):40-53. Available from: https://journals.stmjournals.com/jopc/article=2026/view=236212


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Regular Issue Subscription Review Article
Volume 14
Issue 01
Received 04/11/2025
Accepted 13/11/2025
Published 03/01/2026
Publication Time 60 Days
23

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