The effect of copolymerisation on the performance of acrylate-based hybrid sol-gel coating for corrosion protection of AA2024-T3

[Display omitted] •The copolymerisation between methyl methacrylate and 3-methacryloxypropyl trimethoxysilane was more extensive under nitrogen atmosphere.•The optimum conditions were deduced from a kinetic study of copolymerisation of acrylates.•The enhanced protective performance of the hybrid coating was due to a higher degree of copolymerisation, forming Si–(alkyl chain)–Si–O–Si network.•Coatings exhibit barrier impedance properties in 0.1 M NaCl.•The coating synthesised under nitrogen atmosphere showed extremely high and long-lasting corrosion performance. The study was focused on the optimisation of the copolymerisation process of acrylate-based hybrid sol-gel coating to obtain long-lasting corrosion protection of AA2024-T3. The coating was synthesised using the radical copolymerisation process of methyl methacrylate (MMA) and 3-methacryloxypropyl trimethoxysilane (MAPTMS) performed under air and nitrogen (oxygen-free) atmospheres, followed by acidic hydrolysis and polycondensation in the presence of silica prepared from tetraethyl orthosilicate (TEOS). The sol synthesis was evaluated at various stages using real-time infrared spectroscopy, multinuclear liquid- and solid-state magnetic resonance spectroscopy and gel permeation chromatography. After deposition on AA2024-T3 substrate and curing, the coating properties were further evaluated by contact profilometer and focused ion beam/scanning electron microscopy coupled with energy-dispersive X-ray spectrometry. The corrosion performance was evaluated in 0.1 M NaCl solution using electrochemical impedance spectroscopy and salt spray chamber testing. The results indicated that the reaction performed in the nitrogen atmosphere increases the degree of the copolymerisation of acrylates groups, resulting in a larger molecular weight of the formed copolymer. After curing, both sol-gels formed continuous, smooth, ∼4 μm thick coatings that provided excellent barrier properties. However, when coating synthesised under nitrogen atmosphere, the coating provided better long-term corrosion resistance reaching almost 1 GΩ cm2 after 6 months immersion in 0.1 M NaCl solution. Superior corrosion resistance was also confirmed in the salt spray chamber where the coating prepared under N2 atmosphere remained unchanged more than 500 hours.