Enhancement of the Corrosion and Wear Resistance of an Epoxy Coating Using a Combination of Mullite Powder and PVB

Currently, with the gradual development of corrosion-resistant materials, coatings often exhibit ultra-high hydrophobic properties while possessing corrosion resistance, complicating the preparation of corrosion-resistant coatings. To explore a novel coating that combines high corrosion resistance with simplified preparation methods, mullite/kaolin powder was stirred using ball milling, and polyvinyl butyral was added to serve as a binder, thereby preparing a hydrophilic and highly corrosion-resistant coating. The coating was characterized using SEM, IR, XRD, and other testing methods. The results revealed that the components of the coating are connected through physical crosslinking, avoiding chemical reactions. Regarding the coating’s performance, electrochemical and salt spray tests were conducted to characterize the prepared coating. According to electrochemical impedance spectroscopy tests, after immersion for 7 days, the electrochemical impedance spectroscopy impedance value of the A4C6EP coating reached 1.13 × 108 Ω·cm2, several times higher than that of other coatings, demonstrating its superior corrosion resistance. After a salt spray test for 2000 h, the coating surface showed neither bubbles, further validating the excellent corrosion resistance of the A4C6EP coating. The A4C6EP coating underwent an abrasion test using sandpaper and, after 100 cycles, the contact angle decreased by only 2.3°, with only slight scratches appearing on the surface, indicating very high mechanical abrasion resistance. This research demonstrates the successful preparation of a hydrophilic coating with excellent corrosion resistance and ultra-high mechanical abrasion resistance through a simple method, providing new insights for the development of hydrophilic corrosion-resistant coatings and reducing the cost of such coatings.