Synthesis, Characterization, and Application of Polyurethane-Acrylic Hybrids as Anticorrosion Coatings

In the current study, the synthesis, and properties of polyurethane (PU) and acrylic copolymer (AK), as well as polyurethane/acrylic polymer hybrid (PU/AK), were examined. Polyurethane (PU) was synthesized by the polyaddition polymerization of isocyanates [Isophorone diisocyanate (IPDI) and hexamethylene diisocyanate (HDI)] and polyols (GP 2000 and GP 4000) at an NCO/OH ratio of 0.85 and a temperature of 100 degrees C. The acrylic copolymer (AK) based on methyl methacrylate (MMA) and butyl methacrylate (BuMA) was synthesized using a bulk polymerization process using benzoyl peroxide as a catalyst. Polyurethane/acrylic hybrids (PU/AK) were created by combining PU with varying amounts of AK (5, 10, 20, 30, 40 wt.%). Several formulations were created to examine the impact of AK content on the physical and mechanical characteristics of PU/AK hybrid polymers, as well as the anticorrosion resistance of hybrid coatings (PU/AKC). To verify that the PU polymerization reaction had finished and to characterize AK, IR spectroscopy was used. The physical and mechanical properties of PU, AK, and PU/AK including viscosity, thixotropic index (TI), tensile, elongation, hardness, adhesion, contact angle, impact test, crosshatch, and anticorrosion properties were significantly affected by the concentration of AK. The viscosity, TI, tensile strength, hardness, contact angle, and adhesion increased with increasing concentration in the PU/AK hybrid. The cross-linking of PU and AK in the hybrids increases the mechanical characteristics. However, the hybrid coating containing 10% AK had the highest chemical and corrosion resistance compared to the other contents of AK and PU.