Dual-layer smart coating system with a hybrid corrosion inhibitor for improved durability of carbon steel pipeline

Authors

  • Kirsheela Jayabalan Department of Mechanical Engineering, Universiti Teknologi PETRONAS, Bandar Seri Iskandar, Perak, Malaysia
  • Fathin Hani Azizul Rahim Department of Mechanical Engineering, Universiti Teknologi PETRONAS, Bandar Seri Iskandar, Perak, Malaysia
  • Puteri Sri Melor Megat Yusoff Department of Mechanical Engineering, Universiti Teknologi PETRONAS, Bandar Seri Iskandar, Perak, Malaysia
  • Nuur Fahanis Che Lah Department of Mechanical Engineering, Universiti Teknologi PETRONAS, Bandar Seri Iskandar, Perak, Malaysia
  • Rohah Abdul Majid Faculty of Chemical and Energy Engineering, Universiti Teknologi Malaysia (UTM), Johor, Malaysia
  • Shahrulzaman Shaharuddin Plant Engineering Technology, Universiti Kuala Lumpur (UniKL) MITEC, Kuala Lumpur, Malaysia
  • Siti Haslina Ramli Materials, Corrosion & Inspection (MCI), Group Technology Solution, PETRONAS, Malaysia

DOI:

https://doi.org/10.15282/jmes.20.1.2026.8.0868

Keywords:

Corrosion inhibitor, Electrochemical impedance, Hydrophobic, BTA-HNT

Abstract

This study aims to develop a hybrid dual-layer smart coating system incorporating multiple corrosion inhibitors to enhance the durability and corrosion resistance of carbon steel substrates. The proposed system consists of a hydrophobic zinc oxide–stearic acid (ZnO-STA) top layer and a self-healing epoxy bottom layer containing benzotriazole-loaded halloysite nanotubes (BTA-HNT) and boiled linseed oil microcapsules (BLO-MC). Five coating systems were fabricated, including pure epoxy, conventional dual-layer coating, and hybrid dual-layer coatings with ZnO-to-epoxy ratios of 2:1, 4:1, and 6:1. Structural and chemical characteristics were verified using Fourier Transform Infrared Spectroscopy (FTIR) and Scanning Electron Microscopy with Energy Dispersive X-ray Spectroscopy. At the same time, corrosion performance was evaluated using Electrochemical Impedance Spectroscopy and scratch tests over 2 weeks of immersion in 3.5 wt.% NaCl solution. The results indicate that the hybrid coating with a ZnO: epoxy ratio of 4:1 exhibited the best corrosion resistance, maintaining impedance values between 4.45 Ω and 4.16 Ω at low frequency and showing the lowest corrosion area of 4.4% after 2 weeks of exposure. However, the hybrid coatings demonstrated reduced adhesion strength, approximately 77.30% lower than the conventional dual-layer coating. Overall, the integration of ZnO-STA, BTA-HNT, and BLO-MC in a hybrid dual-layer system enhances corrosion protection through synergistic hydrophobic barrier and self-healing mechanisms. However, further optimisation is required to improve coating adhesion for long-term application.

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Published

2026-03-31

Issue

Volume 20 No. 1, (March 2026)

Section

Article

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Copyright (c) 2026 The Author(s)

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This work is licensed under a Creative Commons Attribution-NonCommercial 4.0 International License.

How to Cite

[1]
K. Jayabalan, “Dual-layer smart coating system with a hybrid corrosion inhibitor for improved durability of carbon steel pipeline”, J. Mech. Eng. Sci., vol. 20, no. 1, pp. 11126–11135, Mar. 2026, doi: 10.15282/jmes.20.1.2026.8.0868.

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