Experimental Design and Optimization of a Novel Hybrid Epoxy-Based Coating for Corrosion Resistance Using Response Surface Methodology
Keywords:
Hybrid epoxy coating, Carbon steel, Corrosion resistance, Coconut husk nanoparticles, Manganese oxide, Response Surface Methodology
Abstract
The problem of corrosion of carbon steel in acidic environment remains a serious problem in industrial usage, causing a shortening of service life, and higher maintenance expenses. In this paper, a novel hybrid manganese oxide (MnO2) and coconut husk nanoparticles (CHNP) have been developed and optimized to enhance corrosion resistance. The experimental runs were designed and optimized using Response Surface Methodology (RSM) where MnO2 and CHNP loadings were the key variables. The weight loss method in varied concentration of a simulated acidic media (0.5 – 2.5 M H2SO4 solution) was used to evaluate the corrosion behaviour. Findings showed the hybrid coatings to have excellent protective efficiency of over 94% and a drastic reduction in corrosion rate occurred (35.42 mm/yr in uncoated steel to 1.8424 mm/yr in optimum hybrid coating). The sufficiency of the RSM models was statistically confirmed and the coefficients of determination were high (R2 = 0.99). It is shown that agro-waste-derived CHNP, mixed with MnO2, is a cost-effective, environmentally friendly, and high-performance reinforcer of epoxy coating when used in a harsh acidic condition.
References
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Yuan, S., Zhao, X., Jin, Z., Liu, N., Zhang, B., Wang, L., . . . Hou, B. (2022). Fabrication of an environment-friendly epoxy coating with flexible superhydrophobicity and anti-corrosion performance. Colloids and Surfaces A: Physicochemical and Engineering Aspects, 633(1). doi:10.1016/j.colsurfa.2021.127545
Zehra, S., Mobin, M., & & Aslam, J. (2022). 1 - An overview of the corrosion chemistry. Environmentally Sustainable Corrosion Inhibitors, 3-23.
Zhang, D., Huang, Y., Xu, L., Tao, C., Yang, X., & Wang, X. (2023). Synergistic effects of nanoparticle geometric shape and post curing on carbon-based nanoparticle reinforced epoxy coatings: Characterization, microstructure, and adhesion properties. Progress in Organic Coatings, 185. doi:10.1016/j.porgcoat.2023.107929
Aryai, V., Baji, H., & Mahmoodian, M. (2022). Failure assessment of corrosion affected pipeline networks with limited failure data availability. Process Safety and Environmental Protection, 157, 306-319. doi:10.1016/j.psep.2021.11.024
Bratasyuk, N. A., Latyshev, A. V., & Zuev, V. V. (2023). Water in Epoxy Coatings: Basic Principles of Interaction with Polymer Matrix and the Influence on Coating Life Cycle. coatings, 14(1). doi:10.3390/coatings14010054
Chen, Q., Wang, C., Yu, S., Song, Z., Fu, H., & An, T. (2022). Low-temperature mechanical properties of polyurethane-modified waterborne epoxy resin for pavement coating. International Journal of Pavement Engineering, 24(2). doi:10.1080/10298436.2022.2099853
Chen, Z., Liu, X., Chen, H., Li, J., Wang, X., & Zhu, J. (2024). Application of epoxy resin in cultural relics protection. Chinese Chemical Letters, 35(4). doi:10.1016/j.cclet.2023.109194
Chopra, I., Ola, S. K., Dhayal, V., & Shekhawat, D. S. (2022). Recent advances in epoxy coatings for corrosion protection of steel: Experimental and modelling approach-A review. Materials Today: Proceedings, 62(3), 1658-1663. doi:10.1016/j.matpr.2022.04.659
Dubey, A., Prasad, R. S., Kumar Singh, J., & Nayyar, A. (2022). Optimization of diesel engine performance and emissions with biodiesel-diesel blends and EGR using response surface methodology (RSM). Cleaner Engineering and Technology, 8, 1-11. doi:10.1016/j.clet.2022.100509
Elkelawy, M., El Shenawy, E. A., Bastawissi, H. A., Shams, M. M., Balasubramanian, D., Anand, V., & Alwetaishi, M. (2024). Predictive modeling and optimization of a waste cooking oil biodiesel/diesel powered CI engine: An RSM approach with central composite design. Scientific Reports, 14(1), 1-13. doi:10.1038/s41598-024-77234-8
Esmailzadeh, M., Tammari, E., Safarpour, T., Razavian, S. M., & Pezzato, L. (2024). Anti-corrosion effect of chitin and chitosan nanoparticles in epoxy coatings. Materials Chemistry and Physics, 317. doi:10.1016/j.matchemphys.2024.129097
Ezzeddin, B., & Al-khalidi, M. (2024). An investigation into the effect of using different metal oxide nanoparticles on the anti-corrosion properties of coatings: a comparative study. Moroccan Journal of Chemistry, 12(2), 657-675. doi:10.48317/IMIST.PRSM/morjchem-v12i2.43008
Fu, Q., Wu, S., Li, C., Xu, J., & Wang, D. (2022). Delamination and chip breaking mechanism of orthogonal cutting CFRP/Ti6Al4V composite. Journal of Manufacturing Processes, 73, 183-196. doi:10.1016/j.jmapro.2021.11.015
Gnanavelbabu, A., Vinothkumar, E., & P. M. (2024). Investigation on corrosion behaviour of metal oxide nanoparticles reinforced magnesium composites by salt spray and immersion corrosion test methods. Advances in Materials and Processing Technologies, 1-25. doi:10.1080/2374068X.2024.2402971
Iyer, T., Nayak, S. Y., Hiremath, A., Heckadka, S. S., & Jaideep, J. P. (2023). Influence of TiO2 nanoparticle modification on the mechanical properties of basalt-reinforced epoxy composites. Cogent Engineering, 10(1). doi:10.1080/23311916.2023.2227397
Joseph, O. O., SBanjo, S., Afolalu, S. A., & Babaremu, K. O. (2022). Global and economic effects of corrosion - An overview. AIP Conf. Proc, 2437. doi:10.1063/5.0092286
Joshi, R., Bajpai, P. K., & Mukhopadhyay, S. (2023). Processing and performance evaluation of agro wastes reinforced bio-based epoxy hybrid composites. Proceedings of the Institution of Mechanical Engineers, Part L: Journal of Materials: Design and Applications, 237(2). doi:10.1177/14644207221118686
Kania, H. (2023). Corrosion and Anticorrosion of Alloys/Metals: The Important Global Issue. Coatings, 13(2). doi:10.3390/coatings13020216
Kocakulak, T., Halis, S., Ardebili, S. M., Babagiray, M., Haşimoğlu, C., Rabeti, M., & Calam, A. (2023). Predictive modelling and optimization of performance and emissions of an auto-ignited heavy naphtha/n-heptane fueled HCCI engine using RSM. Fuel, 333. doi:10.1016/j.fuel.2022.126519
Menga, A., Kanstad, T., Cantero, D., Bathen, L., Hornbostel, K., & Klausen, A. (2023). Corrosion-induced damages and failures of posttensioned bridges: A literature review. Structural Concrete, 24(1), 84-99. doi:10.1002/suco.202200297
Oisakede, M. O., & Sadjere, E. G. (2022). Analysis of the Wear Resistance of Epoxy-Agro Waste Nanoparticle Coating. NIPES Journal of Science and Technology Research, 4(2), 289 - 305.
Okon, K., Ekeke, I. C., Maduabuchi, C. A., Ayogu, I. I., Azeez, T. O., & Akalezi, C. O. (2025). Recent advances in the use of metal oxides as corrosion inhibitors: a review. KOM – Corrosion and Material Protection Journal, 69, 14-33. doi:10.2478/kom-2025-0003
Opadoyin, P. O., Fayomi, O. S., & Atiba, J. O. (2024). Agro-Waste Nanofiller as a Reinforcer for Service Life Improvement of Coated Sample. International Conference on Science, Engineering and Business for Driving Sustainable Development Goals (SEB4SDG). Omu-Aran, Nigeria: IEEE.
Rahman, M., & Akhtarul Islam, M. (2022). Application of epoxy resins in building materials: progress and prospects. Polym. Bull., 79, 1949–1975. doi:10.1007/s00289-021-03577-1
Samardžija, M., Alar, V., Špada, V., & Stojanović, I. (2022). Corrosion Behaviour of an Epoxy Resin Reinforced with Aluminium Nanoparticles. Coatings, 12(10). doi:10.3390/coatings12101500
Sesia, R., Spriano, S., Sangermano, M., & Ferraris, S. (2023). Natural Polyphenols and the Corrosion Protection of Steel: Recent Advances and Future Perspectives for Green and Promising Strategies. metals, 13(6), 1070-1097. doi:10.3390/met13061070
Sreehari, H., Sethulekshmi, A. S., & & Saritha, A. (2022). Bio Epoxy Coatings: An Emergent Green Anticorrosive Coating for the Future. Macromolecular Materials and Engineering, 307(8).
Srinivasa Perumal, K., Selvarajan, L., Mathan Kumar, P., & Shriguppikar, S. (2025). Enhancing mechanical and morphological properties of glass fiber reinforced epoxy polymer composites through rutile nanoparticle incorporation. Prog Addit Manuf, 10, 831-848. doi:10.1007/s40964-024-00675-0
Wang, J., Wu, S., Ma, L., Zhao, B., Xu, H., Ding, X., & Zhang, D. (2022). Corrosion resistant coating with passive protection and self-healing property based on Fe3O4-MBT nanoparticles. Corrosion Communications, 7, 1-11. doi:10.1016/j.corcom.2021.12.005
Yuan, S., Zhao, X., Jin, Z., Liu, N., Zhang, B., Wang, L., . . . Hou, B. (2022). Fabrication of an environment-friendly epoxy coating with flexible superhydrophobicity and anti-corrosion performance. Colloids and Surfaces A: Physicochemical and Engineering Aspects, 633(1). doi:10.1016/j.colsurfa.2021.127545
Zehra, S., Mobin, M., & & Aslam, J. (2022). 1 - An overview of the corrosion chemistry. Environmentally Sustainable Corrosion Inhibitors, 3-23.
Zhang, D., Huang, Y., Xu, L., Tao, C., Yang, X., & Wang, X. (2023). Synergistic effects of nanoparticle geometric shape and post curing on carbon-based nanoparticle reinforced epoxy coatings: Characterization, microstructure, and adhesion properties. Progress in Organic Coatings, 185. doi:10.1016/j.porgcoat.2023.107929
Published
2025-10-27
How to Cite
Oghenekowho, P. A., Oreko, B. U., & Ajuwa, C. I. (2025). Experimental Design and Optimization of a Novel Hybrid Epoxy-Based Coating for Corrosion Resistance Using Response Surface Methodology. European Journal of Science, Innovation and Technology, 5(5), 63-70. Retrieved from https://ejsit-journal.com/index.php/ejsit/article/view/716
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Copyright (c) 2025 Oghenekowho, P. A., Oreko, B. U., Ajuwa, C. I.
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