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Progress in Organic Coatings 179 (2023) 107517

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Progress in Organic Coatings


journal homepage: www.elsevier.com/locate/porgcoat

Corrosion, electrical and thermal behaviour of graphene modified polyester


powder coatings
Francesco Andreatta a, *, Alfredo Rondinella a, Matteo Zanocco a, Giovanni Capurso a,
Roberto Vendramin b, Alessandro Guarino b, Lorenzo Fedrizzi a
a
University of Udine, Polytechnic department of engineering and architecture, Via del Cotonificio 108, 33100 Udine, Italy
b
PLT GmbH, A-9065 Ebenthal in Kärnten, Miegererstrasse 40, Austria

A R T I C L E I N F O A B S T R A C T

Keywords: This work investigates polyester powder coatings containing graphene on aluminium alloy AA6060. The coatings
Powder coatings were developed with a multifunctional approach in order to combine efficient barrier properties and high
Polyester resin electrical and thermal conductivity. Graphene contents up to 10 wt% were introduced in the composite powder
Graphene
coatings. The barrier properties were investigated by means of electrochemical impedance spectroscopy (EIS) in
Barrier properties
0.1 M NaCl solution. This technique was also employed to obtain information about the electrical parameters of
Electrical conductivity
Thermal conductivity the coatings. Although barrier properties remain high over immersion times up to 35 days, a strong increase of
coating capacitance and a decrease of coating resistance were observed by EIS for the coatings with graphene
content above 1 wt%. Impedance data were interpreted on the base of the electrical percolation theory in order
to correlate the increase of capacitance and the decrease of the resistance to the existence of graphene-rich
agglomerates in the composites coatings. Moreover, the thermal behaviour of the composite powder coatings
was preliminarily evaluated indicating that the introduction of graphene can improve heat dissipation.

1. Introduction efficient barrier [10]. Indeed, this can reduce the tortuosity of the path
for diffusion of species with a negative effect on the barrier properties of
Graphene and its derivatives are well-established anti-corrosion ad­ the nanocomposite [7].
ditives for organic coatings [1–6]. This is due to the peculiar two The properties of graphene and its derivatives have been exploited to
dimensional structure of graphene with high aspect ratio and flexibility improve the barrier effect of different organic coatings. Li et al. [2]
that enables its use as an efficient barrier for liquids and gases [7–9]. investigated the anti-corrosive behaviour of graphene oxide, reduced
Indeed, defect-free graphene has the ability to impede diffusion of gases graphene oxide and functionalized graphene in a waterborne poly­
and liquids through its ultrathin two dimensional structure. One of the urethane matrix. It was shown that 0.2 wt% of graphene oxide could be
strategies to develop an efficient physical barrier is the preparation of a uniformly dispersed in the polyurethane matrix strongly increasing the
graphene/polymer nanocomposite by physical or chemical mixing the barrier properties of the coatings applied on electrogalvanized steel. EIS
graphene with a polymer (matrix). Different graphene derivatives can be results reported in this work show that the impedance modulus at 0.1 Hz
employed including graphene oxide, reduced graphene oxide and remained stable at values in the order of 109 Ω cm2 after 235 h im­
functionalized graphene oxide [1]. The graphene and its derivatives can mersion in 3.5 wt% NaCl solution [2]. In addition, it was shown that an
function as a filler in order to block diffusion of liquids and gasses trough increase of the content of the graphene additive from 0.2 to 0.4 wt% led
the polymeric matrix. This is based on the formation of a highly tortuous to a further improvement of the corrosion barrier properties that was
path for the diffusion through the polymer nanocomposite [5,7]. The attributed to a marked self-alignment of the additive parallel to the
efficiency of the barrier mainly depends on the size of the graphene substrate [11]. In the work of Li et al. [2], the barrier properties of
additive, its degree of dispersion and orientation in the polymeric ma­ graphene loaded polyurethane coatings were associated to a percolation
trix. On the other hand, the marked tendency for self-agglomeration of phenomenon controlled by the aspect ratio of the graphene additive and
graphene and its derivatives is a critical factor for the formation of an its dispersion in the coating. According to the percolation model, the

* Corresponding author.
E-mail address: francesco.andreatta@uniud.it (F. Andreatta).

https://doi.org/10.1016/j.porgcoat.2023.107517
Received 3 November 2022; Received in revised form 1 February 2023; Accepted 24 February 2023
Available online 6 March 2023
0300-9440/© 2023 Elsevier B.V. All rights reserved.
F. Andreatta et al. Progress in Organic Coatings 179 (2023) 107517

graphene additive can form a continuous network hindering the and its derivatives can induce a significant increase of thermal con­
permeation of the electrolyte to the substrate [12]. A percolating ductivity already for volume fractions of about 2 % in a polymer matrix
behaviour could be obtained with a 0.2 wt% content of the additive [39]. The thermal properties of graphene and its derivatives are
since the high aspect ratio of graphene and its derivatives strongly re­ important for applications where efficient heat removal are critical such
duces the percolation threshold as compared to other nanofillers like as thermal dissipation in electronic devices or in renewable energy
clays or graphite platelets [2,6,12,13]. Due to tendency to agglomera­ generation by photovoltaic solar cells [39]. In contrast to electrical
tion of graphene and its derivatives, a percolation network is not always percolation, thermal percolation in graphene loaded polymer matrix
formed since agglomerated graphene could result in isolated islands. In composites can be less pronounced because the polymeric matrix can
this case, corrosion barrier properties would be mainly controlled by the contribute to the thermal conductivity. Nevertheless, different works in
tortuous path for the electrolyte to reach the metal substrate through the literature prove the existence of thermal percolation in graphene loaded
graphene islands [2]. A lot of research has been carried out in order to composites [40–43]. Accordingly, the thermal conductivity can be
improve the dispersion and compatibility of graphene and its derivatives strongly enhanced when the content of graphene reaches the percolation
with waterborne epoxy coatings [1,3,14–20] and acrylic coatings threshold [40].
[21–24]. Teijido et al. [6] recently reviewed the state of the art and The literature discussed above clearly evidences that graphene
current trends on layered inorganic-polymer coatings for corrosion composite organic coatings can provide efficient corrosion protection.
protection highlighting that most of the research has been dedicated to Due to their strong potential, several commercial formulations con­
study the compatibility of graphene with some of the most employed taining graphene has become available [6]. However, commercial
polymeric matrixes in the coatings industry, as epoxy resins or poly­ available paints containing graphene can provide only a limited increase
urethanes. Loading of graphene in polyester resins found only limited of corrosion protection (factor 2) [6]. Moreover, another critical issue is
applications, mainly devoted to controlling mechanical, electrical and related to the use of solvents or other environmentally dangerous sub­
thermal properties of composite materials [25–29]. stances to functionalize graphene and to control its dispersion in the
Graphene and its derivatives are conductive fillers in polymer coat­ organic matrix and even during paint application. Different application
ings and composites [30–33]. The electrical conductivity of graphene is methods were employed for application of graphene loaded organic
extremely high, 6 105 S m− 1 due to the combination of high charge coatings including dip coating, application by means of a bar or wire
carrier mobility and high charge carrier concentration [34]. The high coater, high pressure spraying, spin coating and air brushing [6]. To the
conductivity of graphene can induce galvanic corrosion with the best of our knowledge, there are no applications of graphene containing
metallic substrate in corrosion protective coatings containing graphene. powder coatings applied by electrostatic deposition, which is considered
As an example, Wu et al. [35] reported the formation of a galvanic in this work. This application method presents several advantages
couple in defected graphene films on copper, which displayed anodic including low or no volatile organic content, high utilization rates, 100
behaviour relative to the graphene film. The risk of galvanic corrosion % solid content and elimination of hazardous waste [44–46].
issues can be mitigated by graphene functionalization, which is reported This work investigates polyester powder coatings containing gra­
to reduce the conductivity of graphene [1]. Nevertheless, the electrical phene deposited on AA6060. The coatings were developed with a
conductivity of graphene and its derivatives can be important for multifunctional approach in order to combine corrosion protection and
obtaining multifunctional coatings and composite materials with high electrical and thermal conductivity. In particular, efficient thermal
different applications including anti-static components, electromagnetic dissipation was the main target in the development of the multifunc­
shielding, lightning strike protection, conductive adhesives and strain tional composite coatings. The corrosion protection was investigated by
sensors [31]. The electrical conductivity of graphene loaded polymer EIS in order to evaluate the efficiency of the barrier protection over long
composites is described by the percolation theory. For a random distri­ immersion time (35 days). Moreover, EIS data were used to obtain in­
bution of an electrically conductive filler in a polymer matrix, a con­ formation about the electrical parameters of the composite coatings. An
ducting network can be formed when the filler concentration is above interpretation of impedance data is proposed based on the electrical
the percolation threshold. This is associated to a marked increase of percolation theory in order to demonstrate that graphene-rich regions in
electrical conductivity. This behaviour identifies three characteristic the composite coatings can promote percolation strongly decreasing the
regimes: insulating, percolating and conductive [31]. The insulating electrical resistance of the coating and increasing its capacitance. The
regime is established when there is no conductive path through the percolating behaviour of the coating is also observed on the thermal
filler, while the conductive regime is associated to the formation of a dissipation, which was also qualitatively evaluated in this work.
directly connected network. The percolating regime is a quantum phe­
nomenon associated to electron tunneling trough an interface formed 2. Materials and methods
between the filler and the polymeric matrix. This is well documented for
graphene and its derivatives [30,31]. The percolation properties can be 2.1. Substrate and coating production
affected also by agglomeration of graphene. This leads to the phenom­
enon of selective localization, which results in conductive behaviour at AA6060 was the substrate for the deposition of polyester powder
low graphene loadings [30,36]. Due to the high aspect ratio of graphene, coatings loaded with graphene additive. AA6060 panels with size 10 cm
the percolation threshold of graphene loaded coatings is very low, in the × 5 cm were ultrasonically cleaned in ethanol and rinsed in deionized
order of 0.5 vol% [31,37]. Percolation thresholds below 1 wt% are often water prior to coating deposition. The polyester powder coatings were
reported in literature [32]. applied by electrostatic deposition at PLT GmbH. The graphene additive
As for electrical conductivity, the incorporation of different graphene was introduced in a polyester powder by melt compounding. This led to
fillers in a polymeric matrix improves the thermal conductivity of the the production of different masters with fixed graphene/resin ratio,
composite [37,38]. Two-dimensional graphene is regarded as an ideal which were employed for the production of all graphene loaded powder
thermal conductive filler due to its high specific surface area. The coatings investigated in this work. In particular, three masters were
thermal conductivity of graphene can be higher than 3000 W/mK at used: master 1 with 1 wt% graphene, master 2 with 7 wt% graphene and
room temperature [39]. This is higher than the conductivity of carbon master 3 with 10 wt% graphene. The final graphene content of the
nanotubes and bulk graphite. Moreover, it is almost one order of coatings was controlled by mixing in proper ratios the master with fixed
magnitude higher than the thermal conductivity of aluminium oxide, graphene/resin ratio and virgin polyester powder. By this approach,
aluminium nitride, boron nitride and silver nanoparticles, which are polyester powder coatings with the following graphene contents were
alternative fillers employed to control thermal properties of polymer produced: 0.5, 1, 3.5 and 10.0 wt%. Polyester powder coatings without
matrix composites [39,40]. Another important aspect is that graphene graphene were also used in this work as a reference. Additives typically

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F. Andreatta et al. Progress in Organic Coatings 179 (2023) 107517

Fig. 1. Polyester powder coatings without graphene and with 0.5, 1, 3.5 and 10.0 wt% graphene (the coating thickness is also reported in the figure).

employed for the production of polyester powder coatings such as tita­ electrode configuration. The area of the coated sample exposed to the
nium dioxide and barium sulphate were also included in all coating electrolyte (working electrode) was 3.14 cm2. A silver/silver chloride
formulations in order to evaluate the effect of the graphene additive in a electrode (Ag/AgCl 3 M KCl) was employed as reference electrode. A Pt
formulation similar to those commercially available. Coatings formu­ wire was used as counter electrode.
lations investigated in this work are proprietary and cannot be disclosed.
The polyester powder containing the graphene additive was applied
on the AA6060 panels using a conventional electrostatic spraying 2.4. Characterization of the electrical and thermal properties of the
equipment (PG 1 Powder Gunfrom Gema with 60 kV output voltage). coatings
Successively, the coated panels underwent thermal treatment at 190 ◦ C
for 20 min in order to enable the curing of the sprayed polyester powder. In this work, impedance measurements were also employed for
The AA6060 panels with the polyester powder coatings with and evaluating the electrical properties of the polyester powder coatings
without graphene are shown in Fig. 1. The dry coating thickness was containing graphene. Electrical parameters of the coatings without
ranging between 85 and 100 μm for the coated panels (standard devi­ graphene and with different contents of the graphene additive were
ation below 5 μm). extracted by fitting with an equivalent circuit. A single time-constant
equivalent circuit was used for fitting impedance data of the panels
with polyester powder coatings without graphene. The circuit consists of
2.2. Characterization of the graphene-loaded master and coatings
the electrolyte resistance in series with the parallel combination of a
resistance and constant phase element (CPE) describing the electro­
The graphene-loaded master and the AA6060 panels coated with the
chemical behaviour of the coating. The CPE was employed to take into
polyester powder coating containing graphene were investigated by FE-
account that the coated panels did not display pure capacitive behav­
SEM in order to evaluate the presence of the graphene additive. Sec­
iour. Nevertheless, this is qualitatively treated as a capacitor in the
ondary electron images were acquired with a JSM-7610FPlus FE-SEM
discussion of impedance data presented in this work. The impedance
for the master and on polished sections of the graphene-loaded coatings.
data of the graphene loaded polyester powder coatings were fitted with
In addition, Raman spectroscopy was employed to obtain further
a two time-constant equivalent circuit. This approach was followed in
confirmation of the presence of graphene in the master. Raman spectra
order to discuss impedance data considering electrical percolation,
were obtained by means of a through an XploRA Plus confocal Raman
which is a well-documented phenomenon in graphene-polymer com­
spectrometer (Horiba Jobin Yvon Srl). The sample was analysed through
posites [30,31]. The two time-constants equivalent circuit consists of
a green laser (532 nm) with a power of 10 mW. The diffraction grating
two parallel resistance/constant phase element combinations, which are
had a density of 1200 lines per mm. Spectra were acquired from 500 to
in series with each other. The electrolyte resistance was also included in
3600 cm− 1, with 5 accumulations per spectrum and 60 s as the acqui­
the circuit. The first resistance/constant phase element combination
sition time for each spectrum. The spectra were acquired on the gra­
describes the behaviour of percolating regions of the coating (graphene
phene additive, on the unloaded polyester powder and on two different
rich), while the second one accounts for non-percolating regions
masters with different graphene/resin ratio (master 1 and master 2).
(polyester matrix or regions with low graphene content). This approach
for fitting the behaviour of graphene loaded coatings is based on the
2.3. Characterization of the electrochemical behaviour of the coatings high tendency for agglomeration of graphene additives in organic
coatings and it is typically employed for the interpretation of electrical
The electrochemical behaviour of coated AA6060 panels was conductivity measurements in graphene-polymer composites. The same
initially investigated by electrochemical impedance spectroscopy in equivalent circuit was recently employed by Mollik et al. [47] to
order to evaluate their protective properties. Three panels for each type describe the behaviour of starch/reduced graphene oxide (PS/rGO)
of coating were investigated in this work. Impedance spectra were ac­ nanocomposites and by Li et [2] al for the interpretation of EIS data of
quired in 0.1 M NaCl solution as a function of the immersion time waterborne polyurethane coatings containing graphene. In the discus­
employing an Autolab PGSTAT30 potentiostat. The spectra were sion of results obtained by fitting EIS data, the constant phase element
recorded at the open circuit potential with an applied AC amplitude of was arbitrarily treated considering Q0 as a pure capacitance. Although
10 mV in the frequency range from 105 Hz to 10− 2 Hz (7 points/decade). this is not correct and different equations are proposed for the conver­
A second set of impedance measurements was preliminarily performed sion of Q0 to an equivalent capacitance [48,49], this is not considered in
with 50 mV AC amplitude showing the same trend than those obtained our work that aims to highlight qualitative differences between coatings
with 10 mV amplitude. In this work, only EIS data obtained with 10 mV with different graphene content.
amplitude are presented because they were reproducible and adequate A detailed investigation of thermal conductivity of the graphene
to assess the electrical properties of the coatings. The EIS measurements loaded polyester coatings is beyond the scope of this work. Nevertheless,
were performed with an electrochemical cell with standard three- thermal properties of the coatings were qualitatively investigated with

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F. Andreatta et al. Progress in Organic Coatings 179 (2023) 107517

Fig. 2. FE-SEM images of the polyester powder containing graphene (master).

an internal test developed at PLT GmbH. Two coated panels (a reference variable since rather large particles could be observed in the micro­
coating without graphene and a coating containing 1 wt% graphene) graph. At higher magnification (Fig. 2B), structures associated to the
were placed in an oven at 90 ◦ C until the sample surface reached a stable typical morphology of graphene additives can be recognized: graphene
temperature, which was read with thermocouples positioned on the agglomerates and plate-like structures. Details of such structures are
coating surfaces. The temperature of the coating surface was recorded shown in Fig. 2C and D. The layered structure of the graphene additive is
versus time during the heating cycle and during cooling to room tem­ clearly visible in the agglomerate in Fig. 2C. Its size is in the order of 100
perature. The trend of the coating temperature during the heating and μm. Similar agglomerates are often observed in the master suggesting a
cooling cycles provides information about the thermal behaviour of the marked tendency of the graphene additive to agglomerate in the poly­
coated panels investigated in this work. ester matrix during melt compounding. This tendency was probably
enhanced by the high graphene amounts (above the percolation
3. Results and discussion threshold) that were deliberatively added to the coatings in order to
modify their electrical and thermal properties. It is likely that a better
3.1. Polyester powder containing graphene (master) exfoliation of the graphene additive could limit their tendency to
aggregate during melt compounding and coating deposition. In addition
Fig. 2 shows representative FE-SEM images of the polyester powder to graphene agglomerates, several regions showing plate-like structures
containing the graphene additive (master), which was employed for could be observed in the coatings (Fig. 2B). An example is given in
application by electrostatic spraying on AA6060 panels after mixing Fig. 2D. These regions are most likely regions of the polyester matrix
with virgin polyester powder. The particle size visible in Fig. 2A is rather enriched with the graphene additive.

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F. Andreatta et al. Progress in Organic Coatings 179 (2023) 107517

regions correspond to the polyester resin with no or low graphene


content in the coating with 3.5 wt% graphene. Moreover, it can be seen
that both the neat polyester resin and the coating containing graphene
are characterized by the presence of particles with size in the micro­
meter range, which are associated to the additives introduced in the
coating formulation such as titanium dioxide and barium sulphate. The
micrographs in the panels E and F of Fig. 4 further highlight the different
morphology of the coating with graphene as compared to the reference
coating. The high tendency to agglomerate of graphene platelets is
confirmed also in the deposited coatings. As commented above, a better
exfoliation of the graphene additive could limit this tendency during the
production of the master and the coating deposition. The neat polyester
resin (panel E of Fig. 4) displays a rather smooth morphology with some
porosity, which should be considered typical of polyester powder coat­
ings. In contrast, panel F of Fig. 4 shows the interfacial region between a
graphene-rich region and the surrounding polyester matrix. The layered
plate-like structure of the graphene is clearly visible in this micrograph.

3.3. Electrochemical behaviour of polyester powder coatings without


Fig. 3. Raman spectra of graphene, polyester resin and two different masters graphene
with different graphene content (master 1 with 1 wt% graphene and master 2
with 7 wt% graphene).
The Bode and Nyquist plots of electrochemical impedance of AA6060
coated with a polyester coating without graphene in 0.1 M NaCl solution
The presence of the graphene additive in the master was further are shown in Fig. 5A and B, respectively. The impedance modulus at low
investigated by Raman spectroscopy. Fig. 3 shows the characteristic frequency (10− 2 Hz) is 2.0 1011 Ω cm2 indicating that the polyester
Raman spectra for the graphene additive, the polyester resin and for two coating is providing a highly efficient barrier effect (panel A of Fig. 5).
different masters with different graphene/resin ratio. The spectrum of Moreover, the Bode plot shows that the impedance does not change as a
the graphene additive displays four characteristic peaks: at 1322 cm− 1 function of the immersion time (up to 840 h immersion). This means that
(D band) associated to carbon atoms with sp3 hybridization or defects in the barrier properties of the coating are retained for a relatively long
the carbon structure; at 1583 cm-1 (G band) due to carbon atoms with immersion time without any significant decrease of the barrier effect.
sp2 hybridization; at 1615 cm-1 (D′ band) due to structural defects and The Nyquist plot of the impedance clearly show that the behaviour of the
overlapping with the G band; at 2635 cm-1 (2D band) associated to the AA6060 with the polyester coating without graphene is almost purely
layered structure of the graphene additive [50–52]. The spectrum of the capacitive for all immersion times. In order to evaluate the coating
polyester resin exhibits two strong peaks: the band at 1630 cm− 1 that is capacitance, impedance data were fitted with the equivalent circuit
produced by the double carbon‑carbon bonds in the styrene and the shown in Fig. 5C, where Rs is the electrolyte resistance, Rc is the coating
band at 1730 cm− 1 related to the carbonyl group. Moreover, two resistance and CPEc is the constant phase element. The parameters of
superimposed peaks due to the carbon‑hydrogen bond are visible at CPEc are reported in Table 1. As indicated in Section 2.4, the constant
about 1400 cm− 1 [53]. The spectrum of master 1, employed for the phase element was arbitrarily treated considering Q0 as a pure capaci­
production of coatings with low graphene content (0.5 and 1 wt%), tance since n values were closed to 1. Fig. 5D displays the coating
shows a Raman spectrum very similar to that of the polyester resin. In capacitance (Cc) as a function of the immersion time (up to 240 h im­
particular, the characteristic peaks observed for the graphene additive mersion).The coating capacitance is 4.6 10− 10 F cm− 2 immediately after
are not visible in the spectrum. In contrast, the spectrum of master 2 immersion. The capacitance increases during the first 24 h of immersion
with higher graphene/resin ratio exhibits the characteristic peaks of due to water uptake of the coating and remains stable at a value of about
graphene, while the peaks related to the polyester resin become no 5.7 10− 10 F cm− 2 for longer immersion times.
longer visible. This clearly indicates that the Raman response of the
masters is determined by the graphene additive, when the graphene/ 3.4. Electrochemical behaviour of polyester powder coatings containing
resin ratio is sufficiently high. graphene

3.2. Cross sectional characterization of the coatings Fig. 6 displays the Bode (panels A, C and E) and Nyquist plots (panels
B, D and F) of the impedance of AA6060 with coatings containing
Fig. 4 displays FE-SEM images of the cross section of AA6060 with a different graphene content (1, 3.5 and 10 wt%). Impedance data about
polyester coating without graphene (panels A, C and E) and with a the coating containing 0.5 wt% graphene are not included in the figure
coating containing 3.5 wt% graphene (panels B, D and F). Micrographs because the behaviour of this sample was very similar to that observed in
at low magnification (panels A and B of Fig. 4) show that the coatings Fig. 5 for the polyester coating without graphene. The coating con­
with and without graphene are well adherent to the substrate. Pull-off taining 1 wt% of graphene additive displays stable impedance as a
tests performed on the coated panels exhibited similar adhesion values function of the immersion time (panels A and B of Fig. 6). The imped­
for all coatings (about 5 MPa) without being affected by their graphene ance modulus at low frequency (10− 2 Hz) is 3.2 108 Ω cm2 immediately
content. Moreover, it can be seen that the coating containing graphene is after immersion in the testing electrolyte (panel A of Fig. 6). This is
thicker than the reference coating, in accordance with thickness values remarkably lower than the value measured for the reference coating
reported in Fig. 1. At higher magnification, the polyester coating with without graphene (panel A of Fig. 5). Moreover, the Bode and Nyquist
3.5 wt% graphene exhibits graphene-rich regions embedded in a matrix plots clearly demonstrate the existence of two time constants for the
of polyester resin (panel D of Fig. 4). The graphene-rich regions are coating containing 1 wt% of graphene additive. The first time constant is
highlighted by dotted lines. These regions are agglomerates consisting of at about 102 Hz, while the second time constant is visible at the lowest
plate-like exfoliated structures similar to those observed in Fig. 2 (panels frequencies. The coating with 3.5 wt% graphene (panels C and D of
C and D). Other regions present a morphology similar to that of the Fig. 6) displays similar behaviour to that observed for the coating with 1
coating without graphene (panel C of Fig. 4). It is likely that these wt% of graphene. The impedance of the coating is stable during the

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F. Andreatta et al. Progress in Organic Coatings 179 (2023) 107517

Fig. 4. FE-SEM images of the cross section of the polyester coating without graphene (A, C and E) and of the coating containing 3.5 wt% of graphene (B, D and F).
Regions enriched of graphene are highlighted by dotted lines.

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F. Andreatta et al. Progress in Organic Coatings 179 (2023) 107517

Fig. 5. Electrochemical impedance of the sample coated with the polyester powder coating without graphene in 0.1 M NaCl solution: Bode plot (A), Nyquist plot (B),
equivalent circuit (C) and coating capacitance vs immersion time (D).

immersion time and the impedance modulus at low frequency (10− 2 Hz)
Table 1
is 1.6 108 Ω cm2 immediately after immersion in the electrolyte. The
Parameters for CPEc in Fig. 5C.
Nyquist plot (panel D of Fig. 6) shows that the semicircle associated to
2
Immersion time / h Q0 / F cm− n the time constant at higher frequencies becomes smaller increasing the
0 4.57 10− 10
0.993 graphene content from 1 wt% to 3.5 wt%. A similar trend is observed for
10
4 5.42 10− 0.987 the coating containing 10 wt% of graphene additive. Indeed, the
10
8 5.55 10− 0.985 impedance of the coated AA6060 remains stable during the test with an
10
24 5.72 10− 0.984
48 5.70 10− 10
0.985
impedance modulus at low frequency (10− 2 Hz) of 6.4 108 Ω cm2
96 5.77 10− 10
0.983 immediately after immersion in the testing electrolyte. Moreover, the
168 5.67 10− 10
0.984 semicircle observed at higher frequencies becomes even smaller than
10
240 5.79 10− 0.982 that for the coating with 3.5 wt% graphene additive. Data in Fig. 6
10
840 5.67 10− 0.982
indicate that polyester coatings containing graphene can adequately
protect the substrate against corrosion providing a barrier effect that is
not affected by the immersion time in the testing electrolyte. All samples
investigated in this work, with and without graphene, displayed stable

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F. Andreatta et al. Progress in Organic Coatings 179 (2023) 107517

Fig. 6. Electrochemical impedance measured in 0.1 M NaCl solution for samples coated with the polyester powder coating with 1 wt%, 3.5 wt% and 10 wt%
graphene: Bode plots (A,C and E) and Nyquist plots (B, D and F).

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F. Andreatta et al. Progress in Organic Coatings 179 (2023) 107517

Fig. 7. Equivalent circuit employed to fit electrochemical impedance data for the samples coated with the polyester powder coating with 1 wt%, 3.5 wt% and 10 wt
% graphene (A) and schematic representation of electrically conductive paths for the coatings with graphene content above the percolation threshold (B).

barrier properties for 840 h in 0.1 M NaCl solution. No signs of corrosion coatings.
of the substrate, including possible galvanic effects related to the
introduction of graphene in the coatings were observed for the immer­
sion times considered in this work. The appearance of a second time 3.5. Electrical properties of the coatings containing graphene
constant at high frequencies in the coatings with graphene content
above 1 wt% show that the electrical properties of the coatings are In order to evaluate the electrical properties of the coatings,
modified by the addition of graphene indicating an electrical percolation impedance data were fitted with an equivalent circuit to obtain resis­
effect due to the introduction of graphene in the polyester powder tance and capacitance values for the coatings containing different
amounts of graphene. In the case of the coatings with graphene content

Fig. 8. Coating capacitance (A) and coating resistance (B) of the samples coated with the polyester powder coating without graphene and with 1 wt%, 3.5 wt% and
10 wt% graphene.

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F. Andreatta et al. Progress in Organic Coatings 179 (2023) 107517

Table 2 composite. Since the cross sectional analysis by FE-SEM clearly shows
Parameters for the equivalent circuit in Fig. 7A for samples coated with the that the polyester powder coatings loaded with graphene consist of
polyester powder coating containing 1 wt%, 3.5 wt% and 10 wt% graphene. graphene-rich regions embedded in a polyester matrix, it was decided to
Graphene-poor regions Graphene-rich regions interpret our impedance data on the base of the electrical percolation
Graphene Immersion R1 / CPE1 R2 / CPE2
theory [30]. It is likely, that the graphene-rich regions are in contact
content time / h ohm ohm with each other due to the high amount of graphene in the coatings
cm2 cm2 investigated in our work. In particular, perhaps with the exception of the
Q01 / n1 Q02 / n2 coating with 0.5 wt% graphene, the additive contents considered in our
F F work are well above the percolation threshold that is reported to be
cm− 2 cm− 2 about 0.5 wt% [31]. Therefore, it can be expected that the network of
1 wt% 0 9.14 2.34 0.676 1.18 1.48 0.942 graphene rich-regions could provide a continuous path for electrons as
108 10− 8 108 10− 9 schematically represented in Fig. 7B.
4 1.15 3.32 0.658 1.53 1.96 0.938 Fig. 8A displays the coating capacitance obtained for polyester
109 10− 8 108 10− 9
powder coatings with and without graphene in order to assess the effect
8 9.79 3.36 0.657 1.53 2.06 0.931
108 10− 8 108 10− 9 of graphene on the electrical properties of the coatings. The coating
24 1.00 3.39 0.662 1.46 2.19 0.930 capacitance was obtained with the equivalent circuit in Fig. 5C for the
109 10− 8 108 10− 9 coating without graphene and with 0.5 wt% graphene, while they were
48 4.89 3.11 0.671 1.36 2.31 0.926 calculated with the equivalent circuit in Fig. 7A for coatings with higher
108 10− 8 108 10− 9
96 3.06 2.95 0.675 1.37 2.41 0.920
graphene content taking into account the contributions of the constant
108 10− 8 108 10− 9 phase elements CPE1 and CPE2. Table 2 displays the parameters for the
168 2.44 3.30 0.671 1.42 2.67 0.910 equivalent circuit in Fig. 7A for samples coated with the polyester
108 10− 8 108 10− 9 powder coating containing 1 wt%, 3.5 wt% and 10 wt% graphene.
240 3.43 3.46 0.665 1.57 2.59 0.914
Again, the constant phase elements were arbitrarily treated considering
108 10− 8 108 10− 9
840 2.39 3.38 0.671 1.46 2.81 0.909 Q0 as a pure capacitance (1/Cc = 1/C1 + 1/C2) since n values in Table 2
108 10− 8 108 10− 9 are close to 0.9 or higher (with the exception of the n value of CPE1 in
3.5 wt% 0 5.79 7.34 0.931 2.17 4.74 0.892 the sample with 1 wt% graphene for which there were few points at low
108 10− 8 106 10− 9 frequency for a precise fitting of the data). The capacitance Cc displays a
4 1.18 7.19 0.946 2.25 4.88 0.890
109 10− 8 106 10− 9
similar trend for all samples with an initial increase due to water uptake
8 1.54 7.08 0.950 2.30 4.98 0.888 and stationary behaviour for immersion times longer than 24 h.
109 10− 8 106 10− 9 Nevertheless, the coating capacitance is strongly affected by the gra­
24 1.18 7.41 0.947 2.22 5.27 0.887 phene content in the polyester coating. The coating without graphene
109 10− 8 106 10− 9
and that with 0.5 wt% graphene exhibit a capacitance of about 5.0
48 2.29 7.34 0.953 2.25 5.44 0.885
109 10− 8 106 10− 9 10− 10 F cm− 2 after 24 h immersion. This is about 2.0 10− 9 F cm− 2 for the
96 1.54 7.62 0.945 2.29 5.60 0.882 coating with 1 wt% graphene, 5.0 10− 9 F cm− 2 for the coating with 3.5
109 10− 8 106 10− 9 wt% graphene and 1.0 10− 8 F cm− 2 for the coating with 10 wt% gra­
168 3.21 7.48 0.950 2.28 5.64 0.882 phene. Fig. 8B displays the coating resistance measured immediately
109 10− 8 106 10− 9
240 2.68 7.70 0.944 2.34 6.02 0.877
after immersion in 0.1 M NaCl solution. The coating resistance was
109 10− 8 106 10− 9 obtained from the equivalent circuit in Fig. 5C for the coatings without
840 4.88 7.98 0.948 2.25 6.10 0.880 graphene and with 0.5 wt% graphene. In this case, a relatively high error
109 10− 8 106 10− 9 was observed for resistances calculated for these coatings due to the
10 wt% 0 4.54 2.09 0.962 4.27 1.29 0.909
highly capacitive behaviour displayed in Fig. 5. The resistance was
109 10− 8 105 10− 8
4 3.14 2.23 0.946 5.38 1.72 0.899 calculated with the equivalent circuit in Fig. 7A for coatings with 1 wt%,
109 10− 8 105 10− 8 3.5 wt% and 10 wt% graphene. In this case the coating resistance was
8 5.84 2.16 0.948 5.62 1.74 0.896 obtained considering the contribution of R1 and R2 (Rc = R1 + R2). The
109 10− 8 105 10− 8 coating resistance is strongly reduced by additions of graphene above 1
24 6.10 2.19 0.943 6.87 1.83 0.897
109 10− 8 105 10− 8
wt%, with a reduction between one or two orders of magnitude relative
48 4.34 2.27 0.948 5.74 1.85 0.896 to the coating without graphene. This trend is not affected by the high
109 10− 8 105 10− 8 error in the evaluation of the resistance of the reference coating without
96 3.30 2.16 0.942 5.99 1.75 0.897 graphene and with 0.5 wt% graphene using the equivalent circuit in
109 10− 8 105 10− 8
Fig. 5C. The increase of the coating capacitance and the decrease of the
168 3.26 2.22 0.935 6.89 1.79 0.899
109 10− 8 105 10− 8 coating resistance reflects the electrical percolating behaviour high­
240 5.59 2.27 0.948 6.89 1.95 0.894 lighted by impedance data in Fig. 6. This effect is evident already for a
109 10− 8 105 10− 8 graphene content of 1 wt%. Nevertheless, it should be considered that a
840 5.14 2.52 0.938 6.51 2.07 0.899 better exfoliation of the graphene additive during the preparation of the
109 10− 8 105 10− 8
master and coating deposition could further improve the electrical
properties of the coatings.
higher than 1 wt%, the two-time constants equivalent circuit shown in The contribution of graphene-poor and graphene-rich regions to the
Fig. 7A was employed for fitting impedance data. The circuit consists of electrical properties of the coatings can be separated according to the
two parallel resistance/constant phase element combinations (R1/CPE1 equivalent circuit in Fig. 7A (circuit parameters given in Table 2). In
and R2/CPE2), which are in series with each other and with the solution order to avoid the effect of water uptake, resistance values extracted
resistance Rs. This circuit was employed by other authors for the inter­ from impedance data are considered immediately after immersion (0 h).
pretation of electrical conductivity measurements for graphene-polymer Fig. 9 presents the resistance of graphene-poor (panel A) and graphene-
composites on the base of the theory of electrical percolation [2,47]. rich regions (panel B) for the samples coated with the polyester powder
This is based on the existence of a continuous network of graphene rich containing 1 wt%, 3.5 wt% and 10 wt% graphene. The resistance of the
regions that strongly increases the electrical conductivity of the coating without graphene and that for the coating with 0.5 wt% gra­
phene are also reported as a reference. The low-frequency parallel

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F. Andreatta et al. Progress in Organic Coatings 179 (2023) 107517

Fig. 9. Resistance of graphene-poor (A) and graphene-rich regions (B) for the samples coated with the polyester powder containing 0.5 wt%, 1 wt%, 3.5 wt% and 10
wt% graphene. The resistance of the coating without graphene is also reported in the figure.

graphene content of the coating. The value of R1 is 1.2 108 Ω cm2 for the
coating containing 1 wt% graphene, while it is 2.2 106 Ω cm2 for 3.5 wt
% graphene content and 4.3 105 Ω cm2 for 10 wt% graphene content. In
particular, there is a reduction of resistance of about two orders of
magnitude for coatings with a high graphene content (3.5 and 10 wt%).
This reflects the contribution of the agglomerated graphene additive
that is decreasing the electrical resistance of the coating in line with the
electrical percolation theory. It is worth to note that the decrease of
electrical resistance is obtained without impairing the protective prop­
erties of the polyester composite powder coating. In fact, impedance
diagrams remain almost overlapped during the whole immersion time
up to 840 h for all graphene containing coatings. This trend is also
confirmed by data reported in Table 2.

3.6. Thermal properties of the coatings containing graphene

In order to have information about the thermal properties of the


coatings, the temperature of coated panels was measured by means of a
Fig. 10. Temperature profile for a polyester powder coating with 1 wt% gra­ thermocouple positioned on the coating surface during a heating/cool­
phene and for a coating without graphene during a heating/cooling cycle. ing cycle. Fig. 10 shows the temperature of the coated AA6060 panels for
a coating without graphene and a coating with 1 wt% graphene. During
resistance/constant phase element combination (R1/CPE1) of the the test, the coated panels were heated at 90 ◦ C. The panel with the
equivalent circuit in Fig. 7 can be associated to the poor conducting coating with graphene displays a higher temperature during the heating
regions of the polyester matrix with no or very low graphene content. As cycle than the coating without graphene indicating that the addition of
can be seen in Fig. 9A, the resistance Rc of graphene-poor regions in the graphene increases the thermal conductivity of the coating. After the
coating with 0.5 wt% graphene is about 3 1011 Ω cm2, which is similar to heating cycle at 90 ◦ C, the coated panels were extracted from the oven
that of the coating without graphene (about 5 1011 Ω cm2). The resis­ and temperature of the coated panel was measured during air cooling at
tance R1 remains between 5 108 and 5 109 Ω cm2 for coatings containing room temperature. The temperature of the panel with the coating con­
1, 3.5 and 10 wt% of graphene. These high resistance values indicate taining graphene is lower than that of the coating without graphene
that the polyester matrix behaves as an insulator when the graphene is during cooling. As an example, the temperature of the coating with 1 wt
not providing a continuous path to the substrate. The resistance R2 of % graphene is 43.3 ◦ C after a measurement time of 6 min while it is
graphene-rich regions is shown in Fig. 9B for the coatings with different 51.6 ◦ C for the coating without graphene. A similar, or slightly better,
graphene content. This resistance corresponds to the high-frequency behaviour was observed for samples containing higher amounts of
parallel resistance/constant phase element combination (R2/CPE2). It graphene. The trend of the temperature of the coated panels during
can be seen that the resistance R2 strongly decreases increasing the cooling clearly indicates that thermal dissipation is strongly promoted
by addition of graphene to the coating, which is a very important

11
F. Andreatta et al. Progress in Organic Coatings 179 (2023) 107517

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