Mechanism of Long-Term Corrosion Protection for Silicone Epoxy Coatings Reinforced by BN-PDA-CeO₂ Ternary Composites in Harsh Environments

Corrosion in harsh environments causes global economic losses exceeding 3 trillion US dollars annually. Traditional silicone epoxy (SE) coatings are prone to failure due to insufficient physical barrier properties and lack of active protection. In this study, cerium dioxide (CeO₂) was in situ grown on the surface of hexagonal boron nitride (h-BN) mediated by polydopamine (PDA) to prepare BN-PDA-CeO₂ ternary nanocomposites, which were then incorporated into SE coatings to construct a multi-scale synergistic corrosion protection system. Fourier transform infrared spectroscopy (FT-IR), X-ray diffraction (XRD), and transmission electron microscopy (TEM) confirmed the successful preparation of the composites, where PDA inhibited the agglomeration of h-BN and CeO₂ was uniformly loaded. Electrochemical tests showed that the corrosion inhibition efficiency of the extract of this composite for 2024 aluminum alloy reached 99.96%. After immersing the composite coating in 3.5 wt% NaCl solution for 120 days, the coating resistance (Rc) and charge transfer resistance (Rct) reached 8.5 × 10⁹ Ω·cm² and 1.2 × 10¹⁰ Ω·cm², respectively, which were much higher than those of pure SE coatings and coatings filled with single/binary fillers. Density functional theory (DFT) calculations revealed the synergistic mechanisms: PDA enhanced interfacial dispersion (adsorption energy of −0.58 eV), CeO₂ captured Cl⁻ (adsorption energy of −4.22 eV), and Ce³⁺ formed a passive film. This study provides key technical and theoretical support for the design of long-term corrosion protection coatings in harsh environments such as marine and petrochemical industries.