The ultimate goal
of this research was to produce a cold galvanizing
compound (CGC) at reduced pigment volume concentration (PVC) to protect
metallic structures from corrosion attacks. The influence of partial
replacement of Zn by nanolayered graphene (NGr) and red iron oxide
(Fe
2
O
3
) nanoparticles on the electrochemical,
morphological, rheological, and mechanical properties of CGCs was
investigated. Electrochemical impedance spectroscopy (EIS) was used
to investigate the electrochemical nature of coatings. The EIS results
revealed that the partial replacement of Zn by NGr and Fe
2
O
3
nanoparticles enhanced the cathodic protection at reduced
PVC (4:1) by improving the electrical contact between the Zn particles
and the metal substrate. The Tafel scan was conducted to support the
cathodic behavior of the coatings. It was found that the sample formulated
solely with Zn at PVC 4:1 was dominated in physical barrier characteristics
over cathodic protection. By increasing the concentration of NGr in
the formulation, the corrosion potential shifted toward a more negative
side, and the coating with 1.5% NGr showed the highest galvanic action
at reduced PVC. Field-emission scanning electron microscopy confirmed
the interconnected network of conducting particles. The coating without
NGr and Fe
2
O
3
at PVC 4:1 showed significant
gaps between the Zn particles. The novelty was evidenced when micrographs
showed the consistent distribution of NGr and Fe
2
O
3
nanoparticles all over the surface, which acted as a bridge
between spherical Zn particles and provided cathodic protection at
a reduced PVC. The layered structure of graphene also improved the
physical shielding effect of the coatings, which limited the diffusion
of electrolytes and corrosion products (oxides/hydroxides) into the
coatings, which was reflected by the salt spray test. The rheological
properties of coatings were studied in continuous ramp, peak hold
step, temperature ramp, and frequency sweep oscillation experiments.
All the coatings showed good liquid/fluid properties. The coatings
having less PVC displayed better flow behavior during the application
due to the less frictional forces in the internal structure. All the
coatings showed excellent adhesion but had different strength values.
In NGr/Fe
2
O
3
-modified coatings, the strength
increased from 7.14 to 14.12 Mpa at reduced PVC. The addition of NGr
provided an additional chemical bonding (galvanic action) to steel,
which supported the physical adhesion and increased the overall adhesion
strength. A real-time scratch resistance assessment showed that all
the coatings had good scratch resistance due to the solid interconnection
between Zn, NGr, and Fe
2
O
3
particles.