A highly structured composite material, which can be applied and cured as a protective layer on corroding metal substrates, particularly on steel is provided. Due to its highly structured composition it is a particularly effective barrier to protect metals against attack by corrosive substances such as hydrogen sulfide, carbon dioxide and sea water, if necessary under hydrothermal conditions. At the same time it is also abrasion stable, for example against a grinding effect by sand, as well as resistant to the impact of mechanical load e.g. by tools. This is achieved by a coating composition comprising a binder comprising at least one cross-linkable resin, wherein the resin comprises at least one of polar group; at least one type of hydrophilic flakes with an aspect ratio of more than 10, wherein the surface of the flakes at least partially comprises a metal oxide; and an organic solvent.

A corrosion inhibition composition is disclosed comprising a zinc oxide, a zinc phosphate, a calcium silicate, an aluminum phosphate, a zinc calcium strontium aluminum orthophosphate silicate hydrate, a molybdate compound, a silicate compound, and a zinc phthalate compound.

A process for preparing an anticorrosive coating includes providing a substrate, providing a sacrificial metal particle, chemically binding a graphitic material to a first molecule comprising a first group, a first spacer, and a second group, chemically binding said graphitic material to a second molecule comprising a third group, a second spacer, and a fourth group, wherein said third group is a different group from said first group, binding said sacrificial metal particle to either said first or said third group, binding either said first or said third group with said substrate, wherein said group bound to said substrate is different from said group bound to said sacrificial metal particle, chemically binding said second group and said fourth group to said graphitic material, growing thermoset resin side chains on said graphitic material, and growing siloxane side chains on said graphitic material.

Coating compositions are disclosed that include corrosion resisting particles such that the coating composition can exhibit corrosion resistance properties. Also disclosed are substrates at least partially coated with a coating deposited from such a composition and multi-component composite coatings, wherein at least one coating later is deposited from such a coating composition. Methods and apparatus for making ultrafine solid particles are also disclosed.

The invention relates to a method for producing a pre-treatment coating composition for a metal substrate, the method comprising the steps of: i. mining graphite ore from a graphite ore body; ii. subjecting the graphite ore to an electrolytic treatment to obtain an expanded graphitic material; iii. subjecting the expanded graphitic material to an exfoliation treatment to obtain single-layer graphene and few-layer graphene, and iv. functionalising the graphene with a coupling agent for coupling graphene to the metal substrate.

This coated steel sheet comprises: a steel sheet; a primer coating film that is arranged on the steel sheet and contains a chromic acid-based rust preventive pigment and aggregate that serves as primary particles, while not containing porous particles; and a top coating film that is arranged on the primer coating film. The aggregate satisfies the following formula (1) and formula (2).

D.sub.10≧0.6T (1)

D.sub.90<2.0T (2)

(In the formulae, D.sub.10 represents the 10% particle diameter (μm) of the aggregate in the number-based cumulative particle size distribution; D.sub.90 represents the 90% particle diameter (μm) of the aggregate in the number-based cumulative particle size distribution; and T represents the film thickness (μm) of a portion of the primer coating film, in which the aggregate is not present.)

A system for applying a coating composition is provided herein. The system includes a first high transfer efficiency applicator defining a first nozzle orifice and a second high transfer efficiency applicator defining a second nozzle orifice. The system further includes a reservoir. The system further includes a substrate defining a first target area and a second target area. The first high transfer efficiency applicator and the second high transfer efficiency applicator are configured to receive the coating composition from the reservoir and configured to expel the coating composition through the first nozzle orifice to the first target area of the substrate and to expel the coating composition through the second nozzle orifice to the second target area of the substrate.

The present invention relates to platelet-shaped zinc-magnesium pigments, wherein the platelet-shaped zinc-magnesium pigments comprise the 40.8 to 67.8 mol % of zinc, 32.2 to 59.2 mol % of magnesium and 0 to 7 mol % of Mn, Li, Be, Y, Sn, Al, Ti, Fe, Cu and mixtures thereof, based in each case on the total molar amount of the elements Zn, Mg, Mn, Be, Y, Li, Sn, Al, Ti, Fe and Cu, where the molar percentages add up to 100 mol %, and the median thickness h.sub.50 of the pigments is less than 1 μm. The invention further relates to the use and production of these pigments.

A coating system may be configured to be applied to an aluminum-magnesium substrate of an object. The coating system may include a primer configured to reduce the corrosion rate of the aluminum-magnesium substrate and a topcoat configured to resist water and improve solar reflectance of the coating system. The primer may include a silicate and a first additive configured to increase corrosion resistance of the coating system The topcoat may include a siloxane and a second additive configured to reduce solar absorptance of the coating system.

The present invention provides a nano phosphatic hybrid geopolymeric corrosion resistant coating material. The tailored precursor of corrosion resistant coating material is obtained by a process involving, together dry grinding of raw materials fly ash, sodium hydroxide, rice husk, tri calcium phosphate and cetyl trimethyl ammonium bromide optionally with sodium silicate, in solid powder form. The developed coating material obtained by adding water to tailored precursor contains nano sized phosphatic compounds of Cancrisilite (sodium aluminium carbonate silicate hydrate), quartz, mullite, heamatite, sodium aluminium silicate, Herschelite (sodium aluminium silicate hydrate), Sucrose, α D-Glucose, Native cellulose, and phenol, responsible for providing improved corrosion resistant properties and adhesion to the mild steel substrates. The geo-polymeric coating material is used as an anti-corrosive, heat resistant coating material on various materials e.g. mild steel substrates.