Abstract

A common technique for creating composite coatings with superior performance involves altering the surface of fillers to improve their ability to bond with the resin matrix. This enhances the overall mechanical strength and corrosion resistance of the coatings, addressing inherent weaknesses in the materials. It is essential to investigate how interfacial bonding affects composite coatings in order to maximize their mechanical and anticorrosive qualities. This study investigates the impact of activating and grafting various silane coupling agents (SCAs) on mechanical and anti-corrosion properties of chopped basalt fibers (CBFs) reinforced waterborne epoxy (WEP) coatings. SEM and FT-IR analyses confirm successful SCA grafting onto CBFs. Mechanical tests, electrochemical impedance spectroscopy (EIS), salt spray aging, and UV accelerated aging demonstrate significant enhancements in mechanical properties and corrosion resistance of CBF/WEP coatings. Finite element analysis (FEA) simulates stress distribution in single fiber models to assess deformation damage resistance. Results highlight the effectiveness of KH560 modification and a 5 wt% CBFs content in enhancing corrosion resistance and mechanical properties of the CBF/WEP composite coating.