Characterization of corrosion behavior and mechanical properties of reinforced composite materials (epoxy-nano-SiO2) used in lining oil pipelines

• A.H. Jasim¹, N. Radhi², Z. Al-Khafaji^3,4, M. Falah⁵, S.A. Musheer⁶, S.Y.H. Al-Khazaali⁷ and Y.Y. Kutaif⁸

¹ College of Engineering, Al-Qasim Green University, Babylon, 51013, Iraq
² Metallurigical Engineering Department, College of Materials Engineering, University of Babylon, Babylon, 51002, Iraq
³ Scientific Research Center, Al-Ayen University, Thi-Qar, 64001, Iraq
⁴ Department of Civil Engineering, Faculty of Engineering and Built Environment, Universiti Kebangsaan Malaysia, UKM, Selangor, Bangi, 43600, Malaysia
⁵ Building and Construction Techniques Engineering Department, College of Engineering and Engineering Techniques, Al-Mustaqbal University, 51001, Babylon, Iraq
⁶ Mechanical Engineering Department, University of Al- Qadisiyah, Qadisiyah, 58002, Iraq
⁷ Management and Economics Business Administration University of Al- Qadisiyah, Qadisiyah, 58002, Iraq
⁸ College of Agriculture, Department of Horticulture and Landscape Architecture, College of Arts, University of Al-Qadisiyah, Al-Qadisiyah, 58002, Iraq

Abstract: In this work, a novel high-performance nano-silica reinforced epoxy coating has been prepared to improve the mechanical properties and corrosive resistance of oil/gas pipeline coatings. Epoxy resins are commonly used in polymeric matrices for petroleum application owing to their excellent chemical resistance and high adhesion. However, they are far from satisfactory in mechanical and/or electrochemical performance at extreme operating conditions, which demands functional nanomaterial to support them. In this study, five epoxy-based nano-composite coatings with different loadings of SiO₂ nanoparticles (ranging from 0% to 4% in weight) were synthesized by high-shear mechanical mixing and carefully controlled thermally curing. Mechanical behaviour was extensively characterised through tensile strength, impact resistance and fracture toughness testing. Simultaneously, electrochemical studies were carried out by potentiodynamic polarization method in 3.5% NaCl aqueous media to test corrosion inhibition performance. The results showed a significant improvement in tensile strength, from 42.5 MPa of unmodified control sample to 88.4 MPa of 4 wt.% SiO₂ addition. The impact and fracture toughness were gradually improved with an increased content of nanoparticles. Electrochemical studies showed a marked decrease in corrosion rate and up to 85% mitigation was obtained with respect to the reference coating. These enhancements are ascribed to the enhanced reinforcing effect of SiO₂ nanoparticles on polymer matrix and the effective physicochemical barrier created against penetration of oxidative species by the dispersed SiO₂ nanoparticles.

Keywords: oil pipelines, corrosion behavior, epoxy resin, nano-SiO2

Int. J. Corros. Scale Inhib., 2025, 14, no. 4, 2461-2477
doi: 10.17675/2305-6894-2025-14-4-40

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