Research Progress on the Corrosion Resistance of Epoxy Coatings Regulated by Micro/Nano Containers

ZHANG Chong; CHEN Lingyu; ZHANG Ping; HOU Mingxin

doi:10.16490/j.cnki.issn.1001-3660.2026.16.014

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Surface Technology ›› 2026, Vol. 55 ›› Issue (16) : 190-211. DOI: 10.16490/j.cnki.issn.1001-3660.2026.16.014

Corrosion and Protection

Research Progress on the Corrosion Resistance of Epoxy Coatings Regulated by Micro/Nano Containers

ZHANG Chong^a,b,c, CHEN Lingyu^a,c,*, ZHANG Ping^a,c, HOU Mingxin^a,b,c

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Abstract

The economic losses and safety hazards caused by metal corrosion have become a significant global challenge. Although epoxy coatings are widely used, their inherent curing defects and hydrophilic nature make them susceptible to attack by corrosive media, and they are difficult to self-heal after damage. Micro/nano containers, as intelligent fillers, offer an effective pathway to achieve active protection and self-healing for epoxy coatings by loading and responsively releasing corrosion inhibitors or healing agents. The work aims to systematically review the recent research progress of micro/nano containers in the field of epoxy anticorrosive coatings. Firstly, from the perspective of material systems and their preparation, the types, structural characteristics, and main fabrication methods of inorganic, organic, and composite micro/nano containers are elucidated. Inorganic containers mostly rely on sol-gel methods (hydrolysis-condensation forming covalent bond networks), hydrothermal/solvothermal methods (coordination bond self-assembly), physical/chemical precipitation methods (ionic bond nucleation), and ball milling (mechanically induced physical bonding) to construct rigid frameworks, possessing high strength and ordered channels. Organic containers form flexible polymer shells through in-situ polymerization (covalent crosslinking at oil-water interfaces), interfacial polymerization (oriented addition polymerization), or solvent evaporation (non-covalent physical deposition), endowing the coating with favorable tailorability and self-healing triggering capability. Composite containers couple the strong chemical bonds of the inorganic phase with the non-covalent/coordination bonds of the organic phase, achieving a synergistic multi-bond combination that integrates rigidity and flexibility. In particular, the introduction of emerging systems such as metal-organic frameworks and layered double hydroxides has expanded the functional designability from a single "encapsulation-release" mode to richer implementation forms, including "structural degradation enabling functional release" and "ion exchange as a response trigger". Secondly, to address the agglomeration and polarity mismatch with the epoxy matrix caused by surface hydroxyl groups of inorganic containers, strategies for improving compatibility are emphatically analyzed. These strategies encompass covalent bridging by coupling agents, polymer encapsulation, bio-based molecular modification, covalent grafting/non-covalent doping of organic molecules, physical structure regulation (particle size optimization, point-plane structures, hollow rough surfaces), and epoxy matrix modification (crosslinking network regulation, amphiphilic blending). The essence of all strategies lies in eliminating active surface hydroxyl groups, shielding interparticle forces, and increasing interfacial adhesion work. A multiscale characterization system based on "chemical bonds (FTIR/XPS)-dispersion morphology (SEM/TEM/DLS)-interfacial energy (contact angle/DMA)" must be established to systematically evaluate the compatibility improvement. Furthermore, the core mechanisms by which micro/nano containers enhance the corrosion resistance of coatings are thoroughly discussed. This mechanism has evolved into a three-level synergistic system: mechanical property enhancement-physical barrier reinforcement-responsive release and self-healing. Mechanical enhancement maintains structural integrity through densification filling, crack deflection, and energy absorption. Physical barrier reinforcement utilizes filling effects, labyrinth effects, barrier networks, and hydrophobic effects, following Fick's law to retard the permeation of corrosive media. Multiple stimuli responsiveness (e.g., pH, ion exchange, redox, mechanical damage) triggers the release, initiating chemical healing by forming passivation/complexation films and physical healing by crack filling and solidification, thereby achieving active intervention at the early stage of corrosion. Multi-stimuli responsive containers further enhance protection under complex service conditions through "orthogonality" and "temporal matching" designs. Research requires multiscale experimental characterization ranging from macroscopic electrochemical impedance spectroscopy, polarization curves, and salt spray tests to microscopic SEM/EDS, XPS, and scanning vibrating electrode techniques to provide a complete chain of evidence for each protection level. Finally, current challenges are identified, and future directions are prospected. Regarding compatibility, systematic studies should be conducted on the correlations between parameters such as surface chemistry, geometric structure, and surface energy of containers and the curing behavior and interfacial bonding strength of epoxy, to establish predictive models based on interfacial thermodynamics and kinetics. For multi-mechanism synergy, based on the spatiotemporal evolution characteristics of corrosion electrochemistry (initiation, development, propagation), hierarchical response systems should be designed to precisely connect barrier enhancement, inhibitor release, and self-healing, and their activation thresholds, action duration, and synergistic windows should be revealed. In terms of long-term service evaluation, multi-factor coupled service performance assessment methods need to be constructed, and correlation models between laboratory accelerated tests and actual engineering service life should be established. For greenization and intelligence, efforts should be made to promote environmentally friendly technologies such as bio-based materials, aqueous-phase synthesis, and low-temperature preparation, explore the transition from single-stimulus response to multi-stimulus synergistic response and from passive release to active sensing and feedback regulation, and construct a "sensing-response-healing" closed loop, thereby providing theoretical references and technical support for the development of high-performance intelligent anticorrosive coatings.

Key words

epoxy coating / micro/nano container / compatibility / responsive release / regulatory mechanism

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ZHANG Chong, CHEN Lingyu, ZHANG Ping, HOU Mingxin. Research Progress on the Corrosion Resistance of Epoxy Coatings Regulated by Micro/Nano Containers[J]. Surface Technology. 2026, 55(16): 190-211

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Funding

Zhanjiang Science and Technology Plan Project (2025B01049, 2026B01095); Fund of Guangdong Provincial Key Laboratory of Intelligent Equipment for South China Sea Marine Ranching (2023B1212030003); Guangdong Provincial Pearl River Talents Program (2025); Youth S&T Talent Support Programme of Guangdong Provincial Association for Science and Technology (SKXRC2026530, SKXRC2026506); Project of Guangxi Zhuang Autonomous Region Key Technologies R&D Program (GK AB23026069)