Self-Healing Polymer Coatings with Microcapsule-Based Systems for Corrosion Protection of Steel Substrates

Elena Vasquez; Wei Zhou; Marc Dubois

doi:10.55001/jams.v1i2.48

Abstract

This study develops dual-capsule self-healing epoxy coatings incorporating urea-formaldehyde microcapsules loaded with linseed oil and epoxy-amine healing agents for active corrosion protection of Q235 carbon steel. The optimized coating formulation (15 wt% linseed oil capsules and 10 wt% epoxy-amine capsules) achieves a self-healing efficiency of 92.4% in artificial scratch tests, as quantified by electrochemical impedance spectroscopy (EIS). Salt spray exposure (ASTM B117, 720 h) reveals that healed scratches maintain impedance modulus above 10⁹ Ω·cm², compared to rapid degradation below 10⁶ Ω·cm² for conventional epoxy controls. Scanning electron microscopy confirms capsule rupture and polymer flow into damaged regions within 24 h at ambient temperature. The dual-capsule architecture provides both physical barrier restoration and corrosion inhibitor release, offering a scalable strategy for extending the service life of marine and infrastructure steel components.

Author Biographies

Elena Vasquez Department of Materials Science, University of Manchester, Manchester M13 9PL, UK

Elena Vasquez is a professor at Department of Materials Science, University of Manchester, Manchester M13 9PL, UK. Their research focuses on advanced materials, with over 46 publications in peer-reviewed journals.
Wei Zhou State Key Laboratory of Metal Corrosion and Protection, Institute of Metal Research, CAS, Shenyang 110016, China

Wei Zhou is an assistant professor at State Key Laboratory of Metal Corrosion and Protection, Institute of Metal Research, CAS, Shenyang 110016, China. Their research focuses on energy systems, with over 39 publications in peer-reviewed journals.
Marc Dubois Laboratoire de Chimie des Polymères, Université de Bordeaux, 33615 Pessac, France

Marc Dubois is a professor at Laboratoire de Chimie des Polymères, Université de Bordeaux, 33615 Pessac, France. Their research focuses on energy systems, with over 20 publications in peer-reviewed journals.