Enhanced corrosion resistance of mild steel in simulated concrete pore solution via composite coatings modified with binary and hybrid nanofillers: ZnO–Ni, Ni–NiO, ZnO–Zn, and ZnO–NiO

This study investigates the corrosion protection performance of polyvinylidene fluoride (PVDF) composite coatings modified with various binary and hybrid nanofillers—ZnO–Ni, ZnO–NiO, ZnO–Zn, and Ni–NiO—on mild steel substrates in chlorinated simulated concrete pore solution (SCPS). The coatings were synthesised via solution casting and evaluated using electrochemical impedance spectroscopy (EIS), Tafel polarisation (TP), and long-term weight loss analysis over 90 days. While previous studies have explored nanofiller-modified coatings, the novelty of this work lies in its comprehensive and systematic comparison of multiple binary and hybrid nanofiller systems under identical and highly aggressive conditions, combined with prolonged electrochemical and gravimetric evaluations. This approach elucidates the synergistic mechanisms at the nanofiller interfaces, providing new insights into long-term durability. The results demonstrate that all nanocomposite coatings significantly enhance corrosion resistance compared to bare steel. ZnO–Ni/PVDF exhibits the most positive open-circuit potential (OCP), the highest charge transfer resistance (Rct), the lowest corrosion current density (Icorr), and minimal mass loss. The superior performance of ZnO–Ni/PVDF was attributed to the synergistic effects at the nanofiller interface, resulting in robust barrier properties and durable passivation. These findings highlight the potential of hybrid nanofiller-modified PVDF coatings as advanced multifunctional barriers to prolong the service life of steel in chlorinated concrete environments.

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