Lignin, due to its availability, molecular structure,
reported
barrier properties, and chemical modification prospects, is gaining
increasing attention for its potential in biobased functional coatings.
Herein, softwood kraft lignin (KL) was surface functionalized (phosphorylated),
yielding lignin phosphate (KLP) to engineer a functional pigment for
assessing its inhibitory properties in epoxy-based anticorrosive coatings.
The aim was to emulate the conventional inhibitive mechanism of zinc
phosphate by introducing partial solubility to KLP. This solubility
facilitates the formation of a passivation layer (iron phosphate),
which is a prerequisite for the inhibition mechanism at the interface
between the metal and coating when it is exposed to corrosive conditions.
Therefore, the utilization of KLP as a biobased inhibitive pigment
signifies an innovative approach in the field of anticorrosive coatings.
KLP was synthesized by reacting KL with phosphorus pentoxide (P2O5) and was characterized using Fourier Transform
Infrared Spectroscopy (FTIR) and Nuclear Magnetic Resonance (NMR)
spectroscopy. Subsequently, KLP was incorporated into an amine-cured
Bisphenol-A (BPA) epoxy coating (KLP-EA) with a dry film thickness
of 80 μm and evaluated as per industrial salt spray testing
for coatings (ISO 9227:2017). Furthermore, the inhibitive corrosion
resistance of KLP-EA was evaluated against a commercially available
zinc phosphate-based epoxy coating (C-EA) and an unmodified kraft
lignin-based epoxy coating (KL-EA), which is recognized solely for
its barrier mechanism. The polarization test demonstrated that KLP
effectively inhibited corrosion, resulting in lower I
corr values. The EIS results of the KLP-EA coating showed
higher impedance modulus (|Z|0.01 >
108 Ω·cm2), signifying exception
barrier
properties. The results from salt spray testing after 1000 h of exposure
demonstrated that the KLP-EA exhibited on par performance compared
to C-EA and significantly superior performance to KL-EA. Based on
the analysis of a rust creep test (ISO 12944–9:2018), KLP-EA
showed a rust creep value of 1.7 ± 0.2 mm, compared to 2.3 ±
0.2 mm for the coatings solely based on barrier properties of KL-EA
and 1.8 ± 0.2 mm for C-EA. Additionally, the underfilm corrosion
products in KLP-EA were analyzed using X-ray Photoelectron Spectroscopy
(XPS), which verified the existence of iron phosphate (passivating
film), replicating the conventional inhibitive mechanism of zinc phosphate.
The current research findings thus provide a zinc-free biobased alternative
in the domain of inhibitive anticorrosive coatings.