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The effect of pigment volume concentration on self-stratification and physico-mechanical properties of solvent-free silicone/epoxy coating systems

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Abstract

Self-stratifying coatings facilitate segregation of two distinct and inter connected coating layers with complimentary properties in a single shot application. This novel process thus obviates the need for multiple coating steps. In the current work, we report the effect of pigmentation on self-stratification of a solvent-free coating system comprising incompatible polymer blends of epoxy and silicone resins. The resins were pigmented to impart anticorrosive properties to the epoxy layer (pigment volume concentration, PVC of 10, 20 and 30% using red iron oxide) and weathering resistance to the silicone resin using TiO2 (a fixed PVC of 10%). A series of complimentary analytical techniques were employed to probe the degree of stratification of the cured coating at different length scales, namely contact angle goniometry, attenuated total reflectance-Fourier transformed infrared spectroscopy, scanning electron microscopy and energy-dispersive X-ray spectroscopy. There were evidence of TiO2 migrating towards epoxy and iron oxide towards silicone resin, even though, the pigments were properly dispersed in their corresponding resins. This implied significant effect of PVC on stratification of epoxy and silicone resins. Rheological studies were employed to epoxy, silicone resin and their pigmented mixture to understand the curing behaviour as well as to understand its effect on stratification process. We also scrutinized the outcome of constrained stratification on thermo/mechanical and anticorrosive performance of the coatings. Contact angle values obtained for top surfaces of all PVC, i.e., 10, 20 & 30 stratified coatings were found to be > 106°and shows hydrophobicity and the bottom coat was found to be < 50° which is more hydrophilic in 20 & 30 PVCs coatings. The 20 PVC coating showed clear stratification, optimal anticorrosive and hydrophobic properties as revealed by electrochemical impedance spectroscopy and contact angle goniometry studies, respectively.

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Acknowledgements

The authors are thankful to Dr. C. P. Ramanarayanan, Vice-Chancellor of DIAT (DU) for motivation, and support. The authors would like to thank Shri. P. T. Rojatkar, Director of Naval Material Research Laboratory for providing guidance and encouragement to carry out this work. The authors are thankful to the Editor, and anonymous reviewers for improving the quality of the revised manuscript by their valuable comments, and suggestions.

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  1. Naval Materials Research Laboratory, DRDO, Shil Badlapur Road, Ambernath East, Mumbai, Maharashtra, 421506, India

    Sushil S. Pawar, R. Baloji Naik, Srikanth Billa, Sangram K. Rath & Tapan K. Mahato

  2. Department of Metallurgical and Materials Engineering, Defence Institute of Advanced Technology (DU), Ministry of Defence, Girinagar, Pune, Maharashtra, 411025, India

    Sushil S. Pawar & Balasubramanian Kandasubramanian

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Pawar, S.S., Naik, R.B., Billa, S. et al. The effect of pigment volume concentration on self-stratification and physico-mechanical properties of solvent-free silicone/epoxy coating systems. Polym. Bull. 80, 2045–2067 (2023). https://doi.org/10.1007/s00289-022-04138-w

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