In-situ encapsulation of flaky aluminum pigment with poly(methylhydrosiloxane) anti-corrosion film for high-performance waterborne coatings

[Display omitted] •We developed an anti-corrosive flaky aluminum pigment for waterborne coatings.•The aluminum flakes was encapsulated with a PMHS-based organosilicon film.•The aluminum flakes exhibit a high corrosion resistance and good chemical stability.•The aluminum flakes can serve as a high corrosion-resistant and high glossy pigment. To improve the corrosion resistance and glossiness of flaky aluminum pigments in waterborne coatings, a flaky aluminum pigment was encapsulated with poly(methylhydrosiloxane) (PMHS) as an anti-corrosion film by in-situ polymerization, and its chemical composition was characterized by Fourier-transform infrared and X-ray photoelectron spectroscopy, and its morphology and microstructure was identified by scanning and transmission electron microcopy. Furthermore, its anticorrosive performance was confirmed by Zeta potential measurement and electrochemical impedance spectroscopy. The encapsulated flaky aluminum pigment not only exhibits excellent corrosion resistance but also shows an improved thermal stability due to the fabrication of a PMHS-based organosilicon film on the surface of aluminum flakes. Most of all, the original glossiness and brightness could be maintained for the waterborne coating film after the encapsulated flaky aluminum pigment was incorporated, indicating a great application potential in waterborne coatings, water-based paints, printing inks, spray-free materials and any more. This work provides a new strategy for design and fabrication of high corrosion-resistant and high glossy aluminum pigments.