ISSN print edition: 0366-6352 ISSN electronic edition: 1336-9075 Registr. No.: MK SR 9/7 Published monthly

Electrochemical and structural evaluation of Poly(VTZ-co-GMA)/ZrO₂ nanocomposite coatings for corrosion protection of mild steel

O. Akbar Basha, I. Pugazhenthi, K. Mohammed Rehan, and S. Mohammed Safiullah

P.G. & Research Department of Chemistry, C. Abdul Hakeem College (Autonomous), (Affiliated to Thiruvalluvar University, Vellore), Melvisharam, India

E-mail: safiullah.che@cahc.edu.in

Received: 17 July 2025  Accepted: 10 November 2025

Abstract:

Corrosion of metallic materials remains a persistent challenge in industrial environments, resulting in substantial economic losses and safety concerns. Developing efficient and durable protective coatings is, therefore, a key scientific and engineering priority. This study hypothesizes that incorporating zirconia (ZrO₂) nanoparticles into a Poly[(4-methyl-5-vinylthiazole)-co-glycidyl methacrylate] [Poly(VTZ-co-GMA)] matrix will enhance the coating’s structural integrity and electrochemical corrosion resistance on mild steel. Accordingly, Poly(VTZ-co-GMA) and its nanocomposites containing various loadings of ZrO₂ were synthesized via in-situ solution polymerization and systematically characterized using Fourier-transform infrared spectroscopy (FT-IR), X-ray diffraction (XRD), scanning electron microscopy (SEM), and transmission electron microscopy (TEM). Electrochemical behavior was evaluated using potentiodynamic polarization and electrochemical impedance spectroscopy (EIS) in a 3.5% NaCl solution. Results revealed that bare mild steel (MS) exhibited the highest corrosion rate (0.71190 mm/yr), whereas Poly(VTZ-co-GMA) coatings substantially reduced corrosion (0.07092 mm/yr) with an increase in polarization resistant (R_p) and a positive shift in corrosion potential (E_corr). Notably, the Poly(VTZ-co-GMA)/ZrO₂ (2.0 wt%) nanocomposite achieved the lowest corrosion rate (0.00354 mm/yr), with high R_p (31.79 × 10⁴ Ω), charge transfer resistance (R_ct) (2067 Ω·cm²), low double layer capacitance (C_dl) (1.023 × 10^− 6 F·cm^− 2), and a protection efficiency exceeding 96%. The superior protection is attributed to the homogeneous dispersion of ZrO₂ nanoparticles, which improve the coating’s barrier performance and reduce ionic diffusion pathways. Overall, the study demonstrates that ZrO₂ incorporation into Poly(VTZ-co-GMA) offers a promising route for developing advanced nanocomposite coatings with enhanced structural stability and electrochemical corrosion resistance.

Keywords: Polymer; Electroactive; Optically active; Nanocomposites; Coatings

Full paper is available at www.springerlink.com.

DOI: 10.1007/s11696-025-04505-7

Chemical Papers 80 (2) 1989–2004 (2026)