Synergistic effect of ultrasonically assisted exfoliated MWCNTs by ZrO ₂ nanoparticles on thermo-mechanical and anti-corrosive properties of epoxy nanocomposites

Exploiting the boundless potential of multi-walled carbon nanotubes (MWCNTs) is the critical issue in developing multifunctional nanocomposites. In this study, the MWCNTs are exfoliated by ZrO ₂ nanoparticles using the ultrasonication technique. The obtained MWCNT/ZrO ₂ hybrid nanofiller is infused in the epoxy matrix to produce multifunctional nanocomposites with superior thermo-mechanical and anti-corrosive properties. The physical, morphological, and structural properties of MWCNT/ZrO ₂ hybrid nanofiller are successfully studied by using XRD crystallography, Raman spectroscopy, and transmission electron microscopy analysis. The chemical interaction between the MWCNT/ZrO ₂ hybrid nanofiller with the epoxy (EP) matrix is evaluated using FTIR spectroscopy. Results indicated that the corrosion protection performance of mild steel coated with MWCNT/ZrO ₂ hybrid epoxy nanocomposite (MNC) is considerably increased at 1.0 wt.% of MWCNT/ZrO ₂ hybrid nanofiller by reducing the corrosion rate from 8.82 MPY to 56 × 10 ⁻³ MPY. Furthermore, the tensile strength and lap shear strength of MNC with the same loading content is improved by 67.8% and 58.04%, respectively, compared to neat EP. The field emission scanning electron microscopy images of tensile fracture surfaces of MNC (1.0 wt.%) confirm the cluster-free uniform dispersion of MWCNTs in the EP matrix.