Influence of surface modified ilmenite/melamine formaldehyde composite on the anti-corrosion and mechanical properties of conventional polyamine cured epoxy for internal coating of gas and oil transmission pipelines

Abstract To support the corrosion protection behavior and mechanical performance properties of conventional epoxy utilized for internal coating of gas and oil transmission pipelines, the present approach was performed to prepare different high build epoxy coating formulations modified using various amounts of processed ilmenite/melamine formaldehyde composite (IMFC) cured by poly amine hardener. X-ray diffraction (XRD) analysis was implemented to assure the phase identification of the crystalline ilmenite particles. Dynamic light scattering measurements were accomplished to measure the particle size distribution of micro-sized ilmenite particles. The lamellar shape of the prepared ilmenite pigment particles (FeTiO 3 ) was illustrated by transmission electron microscope (TEM) investigation. Flaky-like nature and the arrangement in overlapping plates of ilmenite particles were confirmed by scanning electron microscope (SEM) technique. Energy dispersive analysis of X-rays (EDX) was performed to ensure the elemental composition of ilmenite pigment particles. FTIR characteristic spectra for melamine formaldehyde resin, ilmenite/melamine formaldehyde composite (IMFC), conventional polyamine cured epoxy and polyamine cured ilmenite/melamine formaldehyde epoxy composite were done. The anti-corrosion performance properties of the considered IMFC epoxy coating formulations against unmodified blank conventional epoxy were studied by accelerated corrosion experiment (salt spray chamber) after 500 h exposure in 5% NaCl solution. The obtained results revealed a significant improvement in the rust grade, blistering size, color tolerance and adhesion strength of IMFC modified epoxy coated steel films with increasing the loading level (%) by weight of the nanocomposite modifier in the coating film. To confirm the previous concept, mass loss method was performed. The mechanical performance properties of these films were investigated by adhesion pull-off, bend, impact and abrasion coating tests to confirm their application efficiency. From the recorded results, the adhesion properties, elongation character, resistance to rapid deformation and film stiffness of these coatings increased significantly with increasing the amount of IMFC modifier.