Preparation method and application of wear-resistant and corrosion-resistant glass flake coating

Abstract

The application provides a preparation method and application of a wear-resistant and corrosion-resistant glass flake coating, and belongs to the technical field of coatings. The coating comprises components A and B. Component A comprises an epoxy resin matrix, reinforcing fillers, self-repairing microcapsules and additives. The epoxy resin matrix is prepared by compounding at least two different types of epoxy resin components. The first epoxy resin component is a main body resin, and the second epoxy resin component is a toughening and modifying resin. The reinforcing fillers comprise glass flake with surface modification, functionalized graphene and nano zirconium dioxide particles. The self-repairing microcapsules comprise a microcapsule wall and a self-repairing agent coated inside. The additives comprise rheological additives, defoaming agents and wetting dispersants. Component B comprises a curing agent and a curing accelerator. The application can significantly improve the comprehensive wear resistance and corrosion resistance of the coating, and improve the construction adaptability of the coating.

Description

Technical Field

[0001] This invention relates to the field of coating technology, specifically to a method for preparing and applying a wear-resistant and corrosion-resistant glass flake coating. Background Technology

[0002] With the increasing demand for industrial corrosion protection, glass flake coatings have been widely used in heavy-duty corrosion protection due to their excellent shielding performance and corrosion resistance. However, existing glass flake coatings still have shortcomings in terms of the overall performance of wear resistance and corrosion resistance. Under complex working conditions, the coating is prone to wear and accelerated corrosion, affecting its service life and protective effect.

[0003] Invention patent CN103288365B discloses a surface treatment method for glass flakes used in flake resin coatings and the flake resin coating itself. By employing two silane coupling agents to perform dual modification treatment on the glass flakes, their surface simultaneously possesses hydrophilic and hydrophobic groups, thereby improving the adhesion between the glass flakes and the resin matrix, and enhancing the coating's density and impermeability. However, this technical solution primarily focuses on the surface functionalization of the glass flakes, without fully considering the coating's wear resistance under high-wear environments. Furthermore, the modification process is complex and may increase production costs. In addition, the coating may experience localized peeling due to mechanical stress during long-term use, affecting its corrosion resistance.

[0004] Invention patent CN102260451B discloses a solvent-free epoxy glass flake coating and its manufacturing method. By employing a solvent-free formulation, it reduces volatile organic compound (VOC) emissions during the coating curing process. Simultaneously, the addition of reactive diluents and rheology modifiers improves the coating's application performance and impermeability. However, this technical solution is relatively weak in terms of abrasion resistance, especially under high-impact or high-friction environments, where the coating's mechanical strength and durability may be insufficient. Furthermore, the curing conditions of this coating are highly demanding in terms of the application environment, potentially limiting its application in low-temperature or humid environments.

[0005] Existing glass flake coatings still have certain shortcomings in terms of wear resistance, corrosion resistance, and application adaptability. Summary of the Invention

[0006] The purpose of this invention is to provide a method for preparing and applying a wear-resistant and corrosion-resistant glass flake coating. By optimizing the modification process of glass flakes and the coating formulation, the overall performance of the coating is improved to meet the needs for efficient and long-lasting protection under complex working conditions.

[0007] To solve the above-mentioned technical problems, the technical solution adopted by the present invention is as follows:

[0008] A method for preparing a wear-resistant and corrosion-resistant glass flake coating, wherein the coating comprises component A and component B. Component A includes an epoxy resin matrix, reinforcing fillers, self-healing microcapsules, and additives. The epoxy resin matrix is ​​composed of at least two different types of epoxy resin components, wherein the first epoxy resin component is the main resin and the second epoxy resin component is a toughening modified resin. The reinforcing fillers include surface-modified glass flakes, functionalized graphene, and nano-zirconia particles. The self-healing microcapsules include a microcapsule wall and a self-healing agent encapsulated inside. The additives include a rheology modifier, a defoamer, and a wetting and dispersing agent. Component B includes a curing agent and a curing accelerator.

[0009] The specific preparation method is as follows:

[0010] Step 1, Functional treatment of glass flake surface: Immerse or spray the glass flakes in an aqueous solution of 0.5%–2.0% silane coupling agent for 10–30 min, and then dry at 100°C–120°C for 2–4 h;

[0011] Step 2, Dispersion of functionalized nanofillers: Functionalized graphene and nano-zirconia particles are added to a portion of the first epoxy resin component and dispersed under high shear at 1000 rpm–3000 rpm for 1–3 hours using a planetary mixer or sand mill.

[0012] Step 3, Mixing of Component A: Add the remaining first epoxy resin component, second epoxy resin component, wetting and dispersing agent and defoamer to the mixing container, stir at 500 rpm–1000 rpm for 30–60 min, and degas under a vacuum of -0.08 MPa to -0.09 MPa.

[0013] Step 4, Mixing the reinforcing phase: Add the surface-functionalized glass flakes and self-healing microcapsules from Step 1 to the mixture obtained in Step 3, stir at a low speed of 100 rpm–300 rpm for 30–60 min, then add the rheology modifier and continue stirring at 500 rpm–800 rpm for 30–60 min.

[0014] Step 5, Preparation of Component B: Mix the curing agent and curing accelerator at 300 rpm–600 rpm for 10–20 min;

[0015] Step 6, On-site mixing: Mix component A and component B according to the preset ratio, and stir at 500rpm–800rpm for 3–5min.

[0016] Furthermore, the silane coupling agent is a mixture of (3-epoxypropoxypropyl)trimethoxysilane and (3-aminopropyl)triethoxysilane; the glass flakes are of type C or ECR, with a thickness of 3μm–5μm, an average particle size D50 of 80μm–120μm, and an aspect ratio of 20–100.

[0017] Furthermore, the epoxy equivalent (EEW) of the first epoxy resin component is 180 g / eq–200 g / eq, and the viscosity at 25°C is 10 Pa·s–15 Pa·s.

[0018] The epoxy equivalent (EEW) of the second epoxy resin component is 250 g / eq–350 g / eq, and the viscosity at 25°C is 30 Pa·s–50 Pa·s.

[0019] The mass ratio of the first epoxy resin component to the second epoxy resin component is 100:10-100:30.

[0020] Furthermore, the functionalized graphene is graphene oxide (GO) or reduced graphene oxide (rGO), with a lateral dimension of 1μm–5μm, a thickness of <5nm, and surface grafted with epoxy groups, hydroxyl groups, or amino functional groups.

[0021] The nano-zirconia particles are spherical or near-spherical with an average particle size of 20nm–50nm, and their surfaces are treated with silane coupling agents.

[0022] Functionalized graphene accounts for 0.1%–0.5% of the total mass of the coating, and nano-zirconia accounts for 0.5%–2.0%.

[0023] Furthermore, the wall material of the self-healing microcapsules is polyurea-formaldehyde or poly(melamine-formaldehyde) resin, with an average diameter of 50μm–200μm and a wall thickness of 1μm–5μm; the internal self-healing agent contains bisphenol F type epoxy resin (EEW ​​160g / eq–170g / eq, viscosity <5Pa·s at 25°C) and latent curing agent imidazole derivatives or polythiol; the self-healing microcapsules account for 1%–5% of the total mass of the coating.

[0024] This invention also discloses a method for applying a wear-resistant and corrosion-resistant glass flake coating, comprising:

[0025] Step 101, Substrate pretreatment: Sandblasting or shot blasting the metal substrate to Sa2.5 grade, with a roughness Rz of 40μm–70μm;

[0026] Step 102, Coating application: Apply the coating prepared by the above method to the substrate with a single layer thickness of 200μm–500μm. When applying multiple layers, the recoating interval is 6h–24h.

[0027] Step 103, coating curing: Curing at 5°C–40°C and relative humidity 30%–85% for surface drying in 6h–8h, hard drying in 24h–48h, and complete curing in 7 days.

[0028] Furthermore, in step 101, the metal substrate is carbon steel, stainless steel or alloy steel, and the concrete substrate needs to be cleaned of floating dust and subjected to pH neutralization treatment so that the pH value of the concrete substrate surface reaches 7-10.

[0029] Furthermore, in step 102, the coating method is air-assisted spraying, airless spraying, roller coating or brush coating. When the total coating thickness is ≥800μm, it is coated in at least two layers. The coating method can be the same or different, and the recoating interval between adjacent layers is 6h–24h.

[0030] Furthermore, in step 103, when the ambient temperature is below 10°C during curing, a low-temperature curing accelerator is used to accelerate the reaction.

[0031] Compared with the prior art, the present invention has the following beneficial effects:

[0032] This invention achieves multi-scale reinforcement of the coating by introducing nano-zirconia particles and functionalized graphene into an epoxy resin matrix. The nano-zirconia particles, with their high hardness and uniform dispersion, endow the coating with excellent surface hardness and scratch resistance, effectively resisting abrasive and impact wear. Functionalized graphene, through its two-dimensional structure and high strength properties, plays a toughening role at the nanoscale. Through stress dispersion and crack deflection mechanisms, it significantly improves the coating's fracture toughness, impact strength, and fatigue life, enabling the coating to maintain structural integrity under dynamic mechanical stress and reducing surface defects caused by wear. Furthermore, the self-healing microcapsules can automatically release a repair agent when the coating suffers micro-damage, effectively healing micro-cracks and fundamentally preventing further damage propagation, thus maintaining the long-term mechanical integrity of the coating.

[0033] Meanwhile, this invention, through surface treatment of glass flakes with a multifunctional silane coupling agent, constructs a stronger and more reactive chemical bond interface between the glass flakes and the epoxy resin matrix, effectively inhibiting the penetration and diffusion of corrosive media along the interface and improving the coating's anti-permeation capability. The highly tortuous nanoscale penetration pathways formed by functionalized graphene in the coating greatly extend the time required for corrosive media to reach the substrate, further enhancing the coating's physical shielding effect. More importantly, the self-healing microcapsules, after repairing microcracks and defects caused by wear, can restore the coating's density and integrity, thereby eliminating potential weak points for corrosive media penetration and ensuring that the coating continuously provides efficient anti-corrosion protection under wear conditions. The optimized epoxy resin compound system and curing agent system ensure high cross-linking density and low free volume after coating curing, further enhancing the coating's density and resistance to various chemical corrosive media.

[0034] This invention effectively solves the performance limitations of existing glass flake coatings in dealing with the coupled effects of dynamic wear and corrosion. Attached Figure Description

[0035] To more clearly illustrate the technical solutions of the embodiments of the present invention, the accompanying drawings used in the embodiments will be briefly introduced below. It should be understood that the following drawings only show some embodiments of the present invention and should not be regarded as a limitation of the scope. For those skilled in the art, other related drawings can be obtained from these drawings without creative effort.

[0036] Figure 1 This is an overall flowchart of the preparation method described in this invention. Detailed Implementation

[0037] In the following description, only certain exemplary embodiments are briefly described. As those skilled in the art will recognize, the described embodiments can be modified in various ways without departing from the spirit or scope of the embodiments of the invention. Therefore, the drawings and description are considered to be exemplary in nature and not restrictive.

[0038] The following is in conjunction with the appendix Figure 1 The embodiments of the present invention will be described in detail below.

[0039] This invention discloses a wear-resistant and corrosion-resistant glass flake coating, mainly composed of component A and component B. Component A mainly includes an epoxy resin matrix, reinforcing fillers, self-healing microcapsules, and additives, while component B mainly consists of a curing agent and a curing accelerator.

[0040] The epoxy resin matrix forms the core framework of the coating. The epoxy resin matrix used in this invention is composed of at least two different types of epoxy resins blended in a specific mass ratio. The first epoxy resin component serves as the main resin, with its epoxy equivalent controlled within the range of 180 g / eq to 200 g / eq, and its viscosity at 25°C between 10 Pa·s and 15 Pa·s. One suitable main resin is a bisphenol A type epoxy resin, which possesses good versatility and basic mechanical properties.

[0041] The second epoxy resin component is introduced as a toughening and modifying resin, with an epoxy equivalent range of 250 g / eq to 350 g / eq and a viscosity range of 30 Pa·s to 50 Pa·s at 25°C.

[0042] Toughening modified resins can be obtained in various ways, such as through modification with carboxyl-terminated nitrile butadiene rubber (CTBN) or through modification with hyperbranched polymers. Both modification techniques aim to impart higher toughness to the epoxy resin matrix, thereby effectively absorbing and dispersing external impact energy, reducing stress concentration, and thus improving the impact resistance and crack resistance of the coating, enabling it to maintain structural integrity under abrasive conditions.

[0043] Regarding the formulation, the preferred mass ratio of the first epoxy resin component to the second epoxy resin component is 100:10-100:30. This ensures that the cured coating has both a high cross-linking density to resist the penetration of corrosive media and excellent toughness to cope with external mechanical stress, thereby effectively reducing stress concentration and significantly improving the coating's impact resistance and crack resistance.

[0044] The reinforcing filler system is a multi-scale composite reinforcement structure comprising surface-modified glass flakes, functionalized graphene, and nano-zirconia particles. Each component plays a unique role and, through a synergistic effect, enhances the overall performance of the coating.

[0045] The first type of reinforcing filler is glass flakes. C-type or ECR-type glass flakes are preferred, with a thickness ranging from 3μm to 5μm, an average particle size D50 ranging from 80μm to 120μm, and an aspect ratio (the ratio of average diameter to average thickness) of 20-100.

[0046] The mass content of glass flakes in the coating is controlled between 15% and 30%.

[0047] Before the glass flakes are added to the epoxy resin matrix, they need to undergo a rigorous surface treatment, which is carried out by using one or more silane coupling agents.

[0048] In a preferred embodiment of the present invention, the silane coupling agent is a mixture of (3-epoxypropoxypropyl)trimethoxysilane and (3-aminopropyl)triethoxysilane.

[0049] Among them, (3-epoxypropoxypropyl)trimethoxysilane mainly functions to form stable covalent bonds with the epoxy resin matrix, thereby constructing a strong interfacial bond; while (3-aminopropyl)triethoxysilane is used to enhance the interfacial bonding between glass flakes and polar functional groups, further optimizing the overall stability of the composite system.

[0050] The silane coupling agent is prepared as an aqueous solution at a mass concentration of 0.5%-2.0% for impregnation or spraying of glass flakes.

[0051] The treated glass flakes need to be dried at a specific temperature of 100°C-120°C to promote the hydrolysis and condensation reaction of the silane coupling agent and form a dense organosilicon-modified layer on the glass flake surface. This improves the interfacial bonding strength and stability between the glass flakes and the epoxy resin matrix, helps to effectively transfer stress when the coating is subjected to external stress, and inhibits interfacial debonding, thereby enhancing the overall impermeability and mechanical properties of the coating.

[0052] The second type of reinforcing filler is functionalized graphene, which can be graphene oxide (GO) or reduced graphene oxide (rGO). Reactive functional groups such as epoxy groups, hydroxyl groups, or amino groups are introduced onto the surface through chemical grafting or physical adsorption to ensure good compatibility and reactivity with the epoxy resin matrix or curing agent molecular chains.

[0053] The functionalized graphene preferably has a lateral dimension of 1 μm-5 μm and a thickness of less than 5 nm. The functionalized graphene has a mass content of 0.1%-0.5% in the coating.

[0054] The introduction of functionalized graphene, leveraging its enormous specific surface area, superior mechanical strength, and excellent barrier properties, forms a nanoscale two-dimensional network structure within an epoxy resin matrix. This network structure significantly increases the tortuous path through which corrosive media penetrate the coating, thereby greatly extending the time required for the corrosive media to reach the substrate. Simultaneously, through its nanoscale reinforcement mechanism, functionalized graphene significantly improves the overall mechanical properties of the coating, particularly tensile strength, flexural strength, and fracture toughness, thus achieving a synergistic enhancement of the coating's wear resistance and corrosion resistance.

[0055] The third type of reinforcing filler is nano-zirconia (ZrO2) particles.

[0056] The nano-zirconia particles typically exhibit a spherical or near-spherical morphology, with an average particle size controlled between 20 nm and 50 nm. To improve their dispersion uniformity in epoxy resin and the interfacial bonding strength with the resin matrix, the surface of the nano-zirconia particles also needs to be treated with a silane coupling agent, such as (3-aminopropyl)triethoxysilane or vinyltrimethoxysilane.

[0057] The nano-zirconia particles constitute 0.5%-2.0% of the coating by mass. The introduction of nano-zirconia particles aims to significantly improve the surface hardness, scratch resistance, and wear resistance of the coating by utilizing their inherent high hardness and high modulus. Their nano-size effect allows these particles to be uniformly dispersed in the resin matrix, forming a uniformly distributed hard phase, thereby effectively resisting external mechanical wear.

[0058] Self-healing microcapsules consist of a microcapsule wall and a self-healing agent encapsulated within it. The microcapsule wall is preferably made of polyurea-formaldehyde or poly(melamine-formaldehyde) resin, which possesses good mechanical properties and chemical stability, effectively encapsulating the internal repair agent.

[0059] The average diameter of the microcapsules ranges from 50μm to 200μm, and the wall thickness is controlled between 1μm and 5μm to ensure that they can rupture and release the repair agent in a timely manner when the coating suffers local mechanical damage (such as microcracks), while maintaining sufficient stability during coating preparation and application.

[0060] The self-healing agent comprises at least two components: a low-viscosity epoxy prepolymer and a latent curing agent or catalyst. The low-viscosity epoxy prepolymer is, for example, a bisphenol F type epoxy resin with an epoxy equivalent (EEW) ranging from 160 g / eq to 170 g / eq and a viscosity of less than 5 Pa·s at 25°C. This low-viscosity characteristic facilitates the rapid penetration and filling of microcracks by the repair agent after the microcapsules rupture. The latent curing agent or catalyst is, for example, a blocked polyamine curing agent that does not react with the epoxy prepolymer under normal storage conditions, thereby ensuring the storage stability of the microcapsules. Once the microcapsules rupture and release, the latent curing agent or catalyst can rapidly react with and cure the epoxy groups in the epoxy prepolymer or the coating matrix, thereby achieving rapid repair of damage. Imidazole derivatives or polythiols encapsulated in the microcapsule wall are preferred examples of latent curing agents or catalysts.

[0061] The self-healing microcapsules are controlled to have a mass content of 1%-5% in the coating. The introduction of these microcapsules enables the coating to automatically release its internal self-healing agent when subjected to localized mechanical damage (such as microcracks or scratches). This agent reacts with the coating matrix or the coating itself, filling and repairing the micro-damage, inhibiting crack propagation, and maintaining the integrity of the coating. This mechanism fundamentally extends the service life and corrosion resistance of the coating under dynamic wear environments.

[0062] The additives used in this invention mainly include rheology modifiers, defoamers, and wetting and dispersing agents. Specifically, the rheology modifier is, for example, surface-treated (hydrophobic) fumed silica with a specific surface area ranging from 150 m² / g to 300 m² / g. The mass content of the rheology modifier in the coating is 0.5%-2.0%. The core function of the rheology modifier is to impart good thixotropy to the coating, enabling it to exhibit high viscosity under static conditions, thereby effectively preventing sagging and ensuring uniform coating thickness. Simultaneously, under shear force (e.g., during spraying or roller coating), its viscosity can rapidly decrease for ease of application, and it quickly recovers its viscosity after application, ensuring excellent leveling properties of the coating and resulting in a smooth and aesthetically pleasing coating surface.

[0063] The defoamer is a silicone-free defoamer based on polyether-modified polysiloxane. Its mass content in the coating is controlled between 0.1% and 0.5%. The introduction of this defoamer aims to effectively suppress and eliminate air bubbles generated within the system during coating preparation, mixing, and application. Effective bubble removal is crucial for ensuring the density, smoothness, and defect-free nature of the final coating film, directly affecting its corrosion resistance and mechanical properties.

[0064] The wetting and dispersing agent is a polyurethane or block copolymer type. Its mass content in the coating is 0.2%-1.0%. This wetting and dispersing agent promotes the uniform dispersion of solid reinforcing fillers such as glass flakes, functionalized graphene, and nano-zirconia particles in the epoxy resin matrix, effectively preventing particle agglomeration. Uniformly dispersed fillers not only fully exert their reinforcing effect but also significantly reduce the viscosity of the system, thereby improving the coating's workability and ultimately enhancing the mechanical properties and appearance quality of the cured coating.

[0065] The curing agent used in this invention is a modified cycloaliphatic polyamine or polyamide amine with an active hydrogen equivalent weight (AHEW) ranging from 60 g / eq to 80 g / eq. The epoxy group equivalent ratio of the curing agent to the epoxy resin in component A is preferably controlled between 0.9:1 and 1.1:1 to ensure sufficient crosslinking reaction and achieve optimal curing effect and performance.

[0066] Curing accelerators are used to further optimize the rate and efficiency of the curing reaction. This invention preferably uses tris(dimethylaminomethyl)phenol or urea derivatives as curing accelerators. The mass content of the curing agent component is 0.5%-2.0%. The introduction of the curing accelerator aims to further accelerate the curing reaction rate, especially significantly improving the curing efficiency under low temperature or high humidity environments, thereby ensuring that the coating can reach optimal performance in a shorter time, shortening the construction cycle, and guaranteeing the reliability of the coating performance.

[0067] This invention provides a method for preparing wear-resistant and corrosion-resistant glass flake coatings. By precisely controlling the process parameters of each step, the optimal dispersion, stability, and synergistic effect of each component are ensured.

[0068] Step 1: Functionalization treatment of glass flake surface.

[0069] First, prepare the required amount of glass flakes. Next, immerse or spray the glass flakes in an aqueous solution containing 0.5%-2.0% (mass concentration) of a silane coupling agent (e.g., a mixture of (3-epoxypropoxypropyl)trimethoxysilane and (3-aminopropyl)triethoxysilane). The immersion time is preferably controlled between 10 and 30 minutes to ensure that the silane coupling agent is fully wetted and adsorbed onto the glass flake surface. Subsequently, the treated glass flakes are dried at 100°C-120°C for 2-4 hours. This promotes the hydrolysis and condensation reaction of the silane coupling agent, forming a stable and reactive siloxane layer on the glass flake surface. This enhances the interfacial bonding strength between the glass flakes and the subsequently added epoxy resin matrix, thereby improving the overall impermeability and mechanical properties of the coating, effectively resisting the penetration of corrosive media along the interface and the debonding of the interface under external stress.

[0070] Step 2: Dispersion preparation of functionalized nanofillers.

[0071] To ensure uniform and stable dispersion of the nano-scale reinforcing fillers (functionalized graphene and nano-zirconia particles) in the epoxy resin, thereby fully leveraging their nano-reinforcing effect, a portion of the first epoxy resin component is first added to a high-shear mixing device, such as a planetary mixer or a sand mill, to provide sufficient dispersion shear force. Subsequently, the functionalized graphene and the nano-zirconia particles are slowly and uniformly added to this portion of the epoxy resin. Dispersion is then performed using the high-shear mixing device, preferably for 1-3 hours, with the dispersion speed controlled at 1000-3000 rpm.

[0072] During this process, it is necessary to closely monitor the dispersion effect to ensure that the functionalized graphene and nano-zirconia particles form a uniform and stable nano-dispersion in the epoxy resin, effectively avoiding particle agglomeration. This lays the foundation for the subsequent preparation of component A and fully leverages its enhancing effect in the final coating, including improving the mechanical and barrier properties of the coating.

[0073] Step 3: Preparation of the main component A by mixing.

[0074] The remaining portion of the first epoxy resin component, the second epoxy resin component, the wetting and dispersing agent, and the defoamer are sequentially added to a clean mixing container. Thorough mixing is performed using a stirring device for 30-60 minutes at a speed of 500-1000 rpm. During mixing, to remove air bubbles introduced by stirring and any trace gases that may be present in the epoxy resin itself, a vacuum is preferably applied, for example, -0.08 MPa to -0.09 MPa. Vacuum degassing is crucial for ensuring the final coating's density and eliminating porosity defects. This ensures the formation of a uniform, bubble-free epoxy resin premix system, preparing the material for subsequent addition of solid fillers.

[0075] Step 4: Addition and mixing of glass flakes, self-healing microcapsules and rheology modifiers.

[0076] In the homogeneous, bubble-free mixture obtained in step three, the surface-functionalized glass flakes and the self-healing microcapsules obtained in step one are slowly and uniformly added. During the addition process, the stirring speed must be strictly controlled within a low range, for example, 100 rpm-300 rpm, and stirring should be continued for 30-60 minutes. The purpose of low-speed stirring is to prevent the glass flakes from breaking, especially to avoid damage to the integrity of their lamellar structure, while maximizing the protection of the integrity of the self-healing microcapsules and preventing premature rupture. The integrity of the glass flakes is crucial for the formation of an effective barrier layer in the coating, while the integrity of the self-healing microcapsules directly determines the effectiveness of their self-healing function. Subsequently, while maintaining low-speed stirring, the rheology modifier is added. After adding the rheology modifier, the stirring speed can be moderately increased to 500 rpm-800 rpm, and stirring should continue for 30-60 minutes to ensure that the rheology modifier is uniformly dispersed in the system and exerts its thixotropic effect. The final product is component A, which has good thixotropic properties. It has high viscosity under static conditions to prevent sagging, while it can reduce viscosity under shear force to facilitate construction.

[0077] Step 5: Preparation of component B.

[0078] This mainly involves the uniform mixing of the curing agent and the curing accelerator. The curing agent and the curing accelerator are added to another clean mixing container. The mixture is thoroughly stirred using a stirring device for 10-20 minutes at a speed of 300-600 rpm. This step ensures that the curing agent and accelerator achieve a highly uniform mixture within component B, thereby guaranteeing that the curing reaction proceeds uniformly and rapidly after the final mixing of components A and B, ultimately forming a cured coating with the desired properties.

[0079] Step Six: On-site mixing and application.

[0080] Before actual construction, component A and component B are thoroughly mixed on-site according to the preset mixing ratio. The mixing ratio is precisely determined based on the epoxy equivalent of the epoxy resin in component A and the active hydrogen equivalent of the curing agent in component B, typically controlled between 0.9:1 and 1.1:1. The preferred on-site mixing time is 3-5 minutes, and the mixing speed is controlled between 500 rpm and 800 rpm.

[0081] Ensure that components A and B react fully to initiate the curing process. After mixing, the coating should be applied within the specified workable time (often referred to as the "activation period" or "potential period"). This time window depends on the ambient temperature and coating formulation and is crucial to ensuring the coating has sufficient fluidity for application before curing.

[0082] The application method of the wear-resistant and corrosion-resistant glass flake coating disclosed in this invention aims to ensure that the coating can fully exert its excellent performance in actual engineering and provide long-lasting protection.

[0083] Step 1: Pretreatment of substrate surface.

[0084] For the metal or concrete substrate to be coated, thorough surface cleaning and roughening are required. For metal substrates, sandblasting (Sa2.5 grade) or shot blasting is preferred. The Sa2.5 grade standard requires the removal of all visible grease, dirt, scale, rust, coatings, and any other foreign matter. The treated surface should exhibit a uniform metallic sheen and achieve a specified roughness, such as Rz 40μm-70μm. Surface roughness significantly enhances the adhesion between the coating and the substrate by providing mechanical interlocking points. Furthermore, it is essential to ensure that the surface is completely free of all oil, rust, and scale. For concrete substrates, grinding is typically required to remove surface laitance, loose layers, and contaminants, followed by thorough vacuuming to ensure the surface is dry, free of loose material, and free of oil. The pH value of the concrete substrate should also be within an acceptable range (e.g., pH 7-10) to avoid adverse effects on coating curing and long-term performance. Provide a clean, rough surface with sufficient surface energy for the coating to maximize the chemical bonding and mechanical interlocking between the coating and the substrate, thereby ensuring excellent adhesion of the coating and effectively preventing the coating from falling off due to interface failure during service.

[0085] When performing pH neutralization treatment, a pH adjuster is used, such as a 1%-3% hydrochloric acid solution or a 2%-5% sodium bicarbonate solution.

[0086] Step 2: Coating application.

[0087] After the substrate surface pretreatment is completed, component A and component B, prepared according to the method described in this invention, are thoroughly mixed at the construction site according to a precise ratio. After mixing, the coating can be uniformly applied to the pretreated substrate surface using various application methods. Preferred application methods include air-assisted spraying, airless spraying, roller coating, or brush coating. The choice of application method typically depends on the specific conditions of the construction site, the required coating thickness, the required construction efficiency, and the complexity of the substrate shape.

[0088] During application, the thickness of a single coating layer is typically controlled between 200μm and 500μm. To achieve the desired total coating thickness or superior protective effect, multiple layers can be applied. When applying multiple layers, the interval between each layer must strictly adhere to the recoating interval requirements of the coating system, which usually depends on ambient temperature and humidity; for example, it may require 6 to 24 hours under specific conditions. Strictly controlling the recoating interval is crucial for ensuring interlayer adhesion and preventing coating defects such as delamination and cracking.

[0089] Step 3: Coating curing.

[0090] The coating, once applied, needs to be cured under specific environmental conditions to achieve the desired mechanical and anti-corrosion properties. The coating prepared by this invention can be cured under a wide range of conditions, including ambient temperatures of 5°C-40°C and relative humidity of 30%-85%.

[0091] To facilitate a better understanding of the present invention by those skilled in the art, the present invention will be further described below with reference to specific embodiments and comparative experiments.

[0092] Example 1: Preparation and Performance Testing of Wear-Resistant and Corrosion-Resistant Glass Flake Coatings

[0093] 1. Coating component composition: The specific proportions (mass percentage) of components A and B in the coating prepared in this embodiment are as follows:

[0094] Component A:

[0095] Epoxy resin matrix: First epoxy resin component (bisphenol A type epoxy resin, EEW: 190 g / eq, viscosity at 25°C: 12 Pa·s): 65.0%; Second epoxy resin component (CTBN modified epoxy resin, EEW: 300 g / eq, viscosity at 25°C: 40 Pa·s): 15.0%.

[0096] Reinforcing filler: Surface functionalized glass flakes (ECR type, thickness 4μm, D50 100μm, aspect ratio 50): 20.0%.

[0097] Surface treatment agent: 0.75% (3-epoxypropoxypropyl)trimethoxysilane and 0.75% (3-aminopropyl)triethoxysilane aqueous solution (mass concentration 1.5%).

[0098] Functionalized graphene (graphene oxide, with epoxy groups introduced on the surface, lateral dimension 2μm, thickness <2nm): 0.2%.

[0099] Zirconia nanoparticles (spherical, average particle size 30 nm, surface treated with (3-aminopropyl)triethoxysilane): 1.0%.

[0100] Self-healing microcapsules: polyurea-formaldehyde wall material, average diameter 100μm, wall thickness 3μm, encapsulated with bisphenol F type epoxy prepolymer (EEW ​​165g / eq, viscosity 3Pa·s) and imidazole derivative latent curing agent: 3.0%.

[0101] Additives: Rheology modifier (hydrophobic fumed silica, specific surface area 200 m² / g): 1.0%; Defoamer (polyether modified polysiloxane silicone-free defoamer): 0.2%; Wetting and dispersing agent (block copolymer): 0.6%.

[0102] Component B:

[0103] Curing agent (modified cycloaliphatic polyamine, AHEW: 70g / eq): 97.5%; curing accelerator (tris(dimethylaminomethyl)phenol): 2.5%.

[0104] Mixing ratio of component A to component B: Component A and component B are mixed at a mass ratio of 4:1. At this time, the equivalent ratio of epoxy groups to active hydrogen is approximately 1.0:1.0.

[0105] 2. Preparation method:

[0106] Step 1: Functionalization treatment of glass flake surface.

[0107] 1000g of ECR-type glass flakes were placed in an impregnation tank, and 2000g of a pre-prepared aqueous solution of silane coupling agent (containing 15g of (3-epoxypropoxypropyl)trimethoxysilane and 15g of (3-aminopropyl)triethoxysilane) was added. The impregnation time was set to 20 minutes. After impregnation, the glass flakes were removed and placed in an oven to dry at 110°C for 3 hours to ensure that the silane coupling agent formed a dense siloxane layer on the surface of the glass flakes.

[0108] Step 2: Dispersion preparation of functionalized nanofillers.

[0109] Add 200g of the first epoxy resin component (bisphenol A type epoxy resin) to a planetary mixer. Slowly add 0.2g of functionalized graphene and 1.0g of nano-zirconia particles. Start the planetary mixer, set the dispersion speed to 2000rpm, and the dispersion time to 2 hours to ensure that the functionalized nanofiller forms a uniform and stable nano-dispersion in the epoxy resin without visible agglomeration.

[0110] Step 3: Preparation of the main component A by mixing.

[0111] In another large mixing container, add the remaining 450g of the first epoxy resin component, 150g of the second epoxy resin component, 6g of wetting and dispersing agent, and 2g of defoamer. Start the stirrer and set the stirring speed to 800 rpm for 30 minutes. During stirring, gradually apply a vacuum of 0.085 MPa for 20 minutes to effectively remove air bubbles generated during mixing.

[0112] Step 4: Addition and mixing of glass flakes, self-healing microcapsules and rheology modifiers.

[0113] The nano-dispersion obtained in step two is slowly added to the mixture obtained in step three, while the stirrer is running at a low speed of 200 rpm. Then, 200 g of surface-functionalized glass flakes and 30 g of self-healing microcapsules obtained in step one are slowly and evenly added. The mixture is stirred at a low speed for 45 minutes to avoid damage to the glass flakes and microcapsules. Next, 10 g of rheology modifier is added, and the stirring speed is increased to 700 rpm. Stirring continues for 40 minutes to ensure that all components are uniformly dispersed, forming component A with good thixotropic properties.

[0114] Step 5: Preparation of component B.

[0115] In a separate mixing container, add 97.5g of curing agent and 2.5g of curing accelerator. Start the stirrer and stir at 450rpm for 15 minutes to ensure uniform mixing of the curing agent and accelerator, thus obtaining component B.

[0116] 3. Application method:

[0117] Step 1: Pretreatment of substrate surface.

[0118] Q235 carbon steel plate was selected as the substrate, and the steel plate was treated with sandblasting to Sa2.5 grade, achieving a surface roughness of Rz60μm. Before coating, the surface was wiped with acetone to remove all residual oil and dust.

[0119] Step 2: Coating application.

[0120] At the construction site, component A obtained in step four and component B obtained in step five were weighed at a mass ratio of 4:1 and poured into a mixing tank. An electric mixer was used to mix at 600 rpm for 4 minutes to ensure thorough and uniform mixing of components A and B. The mixed coating was then applied to the pre-treated steel plate surface using an airless spraying method. The thickness of each single layer was controlled at 300 μm. Two layers were applied, with a total coating thickness of 600 μm. After the first layer was applied, the coating was allowed to stand for 8 hours at 25°C and 60% relative humidity until it was surface dry before applying the second layer.

[0121] Step 3: Coating curing.

[0122] After coating, the test panels were cured at 25°C and 60% relative humidity. The surface drying time was approximately 7 hours, and the complete drying time was approximately 36 hours. Subsequent performance tests could only be conducted after the test panels were fully cured (after 7 days).

[0123] Comparative Example 1: Preparation and Performance Testing of Traditional Glass Flake Epoxy Coatings

[0124] 1. Coating component composition:

[0125] The specific formulations (mass percentage) of component A and component B of the conventional glass flake epoxy coating prepared in this comparative example are as follows:

[0126] Component A:

[0127] Epoxy resin matrix: Bisphenol A type epoxy resin (EEW: 190 g / eq, viscosity at 25°C: 12 Pa·s): 80.0%.

[0128] Reinforcing filler: Untreated glass flakes (Type C, thickness 4μm, D50 100μm, aspect ratio 50): 18.0%.

[0129] Additives: Rheology modifier (fumed silica): 1.0%, defoamer (polysiloxane): 0.2%, wetting and dispersing agent: 0.8%.

[0130] Component B: Curing agent (general aliphatic polyamine, AHEW: 80g / eq): 97.5%, curing accelerator (none): 2.5%.

[0131] Mixing ratio of component A to component B: Component A and component B are mixed at a mass ratio of 4.5:1, at which point the equivalent ratio of epoxy groups to active hydrogen is approximately 1.0:1.0.

[0132] 2. Preparation and application methods:

[0133] The preparation and application methods are similar to those in Example 1, but the steps of treating the glass flakes with silane coupling agent, dispersing and preparing the nanofiller, adding the self-healing microcapsules, and adding the relevant additives and the second epoxy resin component are omitted. No curing accelerator is also added. During application, the thickness of each coating layer is controlled at 300 μm, with two layers totaling 600 μm. The curing conditions are the same as in Example 1.

[0134] Performance testing and data comparison:

[0135] Several key performance tests were conducted on the coatings prepared in Example 1 and Comparative Example 1, including abrasion resistance, corrosion resistance, adhesion, pencil hardness, impact strength, flexibility, and water absorption.

[0136] Abrasion resistance test: The abrasion tester (CS-10 type abrasion wheel, 1000g load, 1000 revolutions) was used to measure the abrasion weight loss (mg).

[0137] Corrosion resistance test: Salt spray test: conducted according to ASTM B117 standard, to assess corrosion spread (mm).

[0138] Acid immersion test: Immerse the coating in a 5% sulfuric acid solution and observe the coating condition after 2000 hours (visual evaluation, grade 0-5, 5 is no change).

[0139] Alkali immersion test: Immerse the coating in a 5% sodium hydroxide solution and observe the coating condition after 2000 hours (visual evaluation, grade 0-5, 5 is no change).

[0140] Adhesion test: The adhesion is evaluated using the cross-cut test (ISO2409) to assess the adhesion level (0-5, with 0 being the best).

[0141] Pencil hardness test: conducted according to ASTM D3363 standard, expressed from softest to hardest.

[0142] Impact strength test: The normal impact test (ASTM D2794) was used to record the maximum non-cracking impact height (cm·kg).

[0143] Flexibility test: The conical shaft bending test (GB / T6742) is used to record the bending shaft diameter (mm). The smaller the degree of bending, the better the flexibility.

[0144] Water absorption rate: The coated sample was immersed in distilled water at 25°C for 7 days, and the weight gain percentage was measured.

[0145] Self-healing function verification: Scratches (approximately 50 μm deep) were made on the coating surface, and the healing process and the recovery of local corrosion protection were observed.

[0146] The results of all tests are summarized in the table below:

[0147] Performance indicators Test methods unit Comparative Example 1 (Traditional Coating) Example 1 (Coating of the Invention) Performance improvement (compared to Comparative Example 1) Taber wear and weight loss ASTM D4060 mg 85.2 32.5 61.9% Salt spray test (after 1000 hours) ASTM B117 (Corrosion Propagation) mm 3.8 0.5 86.8% Salt spray test (after 2000 hours) ASTM B117 (Corrosion Propagation) mm 5.5 0.8 85.5% <![CDATA[Soak in 5% H2SO4 (2000 h)]]> Visual assessment (0-5, 5 being optimal) grade 2 4 Significant improvement Soak in 5% NaOH for 2000 hours. Visual assessment (0-5, 5 being optimal) grade 3 5 Significant improvement Adhesion ISO 2409 (Cross-cut method) Level (0 is the best) 2 0 100% (Higher Level) Pencil hardness ASTM D3363 - 3H 6H Significantly improved Impact strength ASTM D2794 (Normal Impact) cm·kg 40 80 100% flexibility GB / T6742 (Bending of Conical Shafts) mm 16 8 50% (smaller bend diameter) Water absorption rate (7 days) ASTM D570 % 1.8 0.4 77.8% Self-repair function Scratch healing and protective recovery - none have - Construction adaptability Low temperature / high humidity curing performance - Difference excellent Significantly broadened

[0148] The test results are analyzed as follows:

[0149] The comparative data above clearly shows that the wear-resistant and corrosion-resistant glass flake coating provided by this invention is significantly superior to traditional glass flake coatings in many key performance indicators.

[0150] Firstly, regarding wear resistance: In the Taber abrasion test, the coating of Example 1 showed a wear weight loss of only 32.5 mg, far lower than the 85.2 mg of Comparative Example 1. This indicates that the present invention significantly improves the surface hardness and wear resistance of the coating by introducing nano-zirconia particles and functionalized graphene. The high hardness of nano-zirconia endows the coating with excellent scratch resistance and abrasive wear resistance, while functionalized graphene, through its two-dimensional structure and nano-reinforcing effect, effectively disperses stress and inhibits the initiation and propagation of cracks, thereby improving the overall wear resistance of the coating.

[0151] Secondly, regarding corrosion resistance: In the salt spray test, the corrosion expansion of the coating in Example 1 was only 0.5 mm and 0.8 mm after 1000 hours and 2000 hours, respectively, compared to 3.8 mm and 5.5 mm in Comparative Example 1, representing an improvement of over 85% in corrosion protection. This fully demonstrates the synergistic effect of the invention, achieved through surface modification of glass flakes using a multifunctional silane coupling agent, the nanoscale tortuous penetration path constructed with functionalized graphene, and the optimization of the epoxy resin matrix and curing agent system, which greatly enhances the coating's density and barrier ability against corrosive media. In the acid and alkali immersion test, the coating in Example 1 exhibited excellent chemical stability, with a visual assessment level significantly higher than that of Comparative Example 1, especially achieving the highest level of resistance to strong alkalis. This proves the superior protective capability of the invention in complex chemical environments.

[0152] Thirdly, regarding mechanical properties: the coating of Example 1 exhibits superior mechanical properties. Its adhesion reaches grade 0, far superior to grade 2 of Comparative Example 1. This is attributed to the stronger interfacial bonding between the glass flakes and the resin matrix after treatment with the silane coupling agent, and the optimization of filler dispersion by the wetting and dispersing agent. The pencil hardness increased from 3H in the Comparative Example to 6H in the Example, indicating a significant increase in surface hardness, making it more scratch-resistant. The impact strength increased from 40 cm·kg to 80 cm·kg, and the flexibility (bending shaft diameter) decreased from 16 mm to 8 mm. These data fully demonstrate the significant contribution of the toughened modified resin, functionalized graphene, and self-healing microcapsules in this invention to the coating's toughness, impact resistance, and crack resistance, making the coating less prone to brittle fracture under dynamic mechanical stress.

[0153] Fourthly, regarding water absorption: the coating of Example 1 has a water absorption rate of only 0.4%, far lower than the 1.8% of Comparative Example 1. This lower water absorption rate directly reflects the coating's higher density and lower free volume, which is crucial for improving the coating's hydrolysis resistance and long-term corrosion resistance. This is attributed to the optimized epoxy resin compounding system, the densifying effect of functionalized graphene, and the tight interfacial bonding between the components.

[0154] Fifth, self-healing function and construction adaptability: The coating in Example 1 clearly demonstrates self-healing function. After being subjected to micro-scratches, the internal self-healing microcapsules can rupture and release a repair agent, effectively filling and healing the scratches, thereby restoring the integrity of the coating and its anti-corrosion barrier function. This is something that traditional coatings completely lack, greatly extending the service life of the coating in abrasive environments. In addition, due to the optimized design of the curing agent system, the coating of this invention can achieve reliable curing in a wider range of temperatures (e.g., 5°C-40°C) and humidity (e.g., 30%-85%), significantly improving the construction adaptability of the coating and solving the pain point of traditional coatings being difficult to apply in low-temperature or high-humidity environments.

[0155] In summary, this invention provides a glass flake coating system that significantly improves wear resistance, corrosion resistance, mechanical properties, application adaptability, and service life through the ingenious design and synergistic effect of the epoxy resin matrix, multi-scale reinforcing fillers, self-healing microcapsules, and curing system. This invention does not simply stack various reinforcing components, but rather achieves a significant improvement in overall performance through the ingenious synergistic effect between these components, providing an innovative heavy-duty corrosion protection solution for complex and harsh industrial environments.

[0156] Example 2:

[0157] To further quantify and verify the long-term protective performance of the coating of the present invention in actual working conditions, a mathematical model for predicting coating failure was constructed based on the material composition, performance test data and construction process of Example 1, and the service life of the coating was evaluated through this model.

[0158] Based on the core technical features of multi-scale reinforcement, self-healing, and thick-coat protection in Example 1, and considering the coupling effect of mechanical stress, environmental erosion, coating structure, and self-healing compensation, the following service life prediction model is established:

[0159] parameter definition Relationship with Example 1 L Expected service life of coating (in years) The core evaluation objective needs to be derived based on the performance data from Example 1. K Enhanced synergy factor (values ​​5-15) The synergistic effect of the multi-scale reinforcing fillers in Example 1 is directly related to the dispersion and reinforcing effects of functionalized graphene (0.2%), nano-zirconia (1.0%), and surface-modified glass flakes (20%). In Example 1, due to the significant synergistic effect of the reinforcing phases, K=10. t Total coating thickness (unit: μm) In Example 1, the coating was applied in multiple layers with a total thickness of 600 μm. Increasing the coating thickness can extend the penetration path of the corrosive medium, therefore a thickness correction was introduced. σc Critical stress of coating (unit: MPa) Based on the mechanical property test derivation of Example 1: In Example 1, the coating impact strength is 80 cm·kg and the pencil hardness is 6H, corresponding to a critical stress σc = 50 MPa (the critical load characterizing the coating's resistance to cracking). σa Actual working stress (unit: MPa) The application scenario corresponding to Example 1 (chemical equipment): the combined stress generated by media erosion and equipment vibration. In Example 1, the typical working condition σa = 30 MPa. η Environmental erosion factor (values ​​range from 0.3 to 1.0) Based on the corrosion resistance test results of Example 1, it was determined that: immersion in 5% sulfuric acid for 2000 hours resulted in a corrosion level of 4, and the salt spray corrosion extension after 1000 hours was only 0.5 mm, corresponding to a moderately corrosive environment, with η = 0.5. ε Wear strain rate (unit: % / year) Based on the wear resistance test in Example 1, the Taber wear weight loss in Example 1 was 32.5 mg / 1000 rpm, corresponding to a wear-induced strain accumulation rate of ε˙ = 0.2% / year. C Self-healing compensation coefficient (value range: 0.1-0.3) The value is directly related to the content of self-healing microcapsules in Example 1: In Example 1, the proportion of self-healing microcapsules was 3%, and the self-healing function was verified; therefore, C=0.1.

[0160] Substitute the data from Example 1 into the formula:

[0161] The enhancement synergy factor K=10, based on the synergistic enhancement of graphene, nano-zirconia, and glass flakes in Example 1;

[0162] The total coating thickness t = 600 μm, which is the actual total thickness during construction in Example 1;

[0163] The critical stress σc = 50 MPa, derived from the impact strength of 80 cm·kg in Example 1;

[0164] Actual working stress σa = 30 MPa, typical operating condition for chemical equipment;

[0165] The environmental corrosion factor η = 0.5, based on the salt spray / acid-alkali corrosion test results in Example 1;

[0166] The wear strain rate ε = 0.2% / year, derived based on the Taber wear data in Example 1;

[0167] The self-healing compensation coefficient C=0.1 is based on the 3% self-healing microcapsule content in Example 1;

[0168] The calculation process is as follows:

[0169] ;

[0170] This embodiment demonstrates the protective gain effect of the coating through molecular terms, including the multi-scale enhanced phase synergy K, the thick coating process t, and the stress safety margin. The denominator reflects performance degradation factors, such as environmental erosion η and wear accumulation ε, and introduces a self-healing compensation coefficient C to quantify the crack repair effect of microcapsules, thereby achieving dynamic evaluation of the coating's entire life cycle.

[0171] Model calculations show that the coating prepared in Example 1 has an expected service life of 91.3 years under typical operating conditions of chemical equipment, which is significantly better than the traditional glass flake coating, with a calculated service life of 22.8 years.

[0172] When the multi-scale reinforcing phase was removed (K=5), the lifetime decreased to 45.6 years; when the self-healing microcapsules were removed (C=0), the lifetime decreased to 74.1 years; and when the coating thickness was halved (t=300μm), the lifetime decreased to 45.6 years. The results confirm the synergistic effect of various technical features on extending lifetime.

[0173] The model calculation results provide a quantitative basis for the engineering application of the coating, indicating that the coating of the present invention can meet the long-term protection requirements of chemical equipment and has significant economic and safety value.

[0174] The mathematical model constructed in this embodiment can effectively evaluate the service life of the coating. The calculation results confirm that the glass flake coating prepared in Example 1 has excellent long-term wear and corrosion resistance under complex working conditions. The synergistic effect of various technical features significantly improves the service life of the coating.

[0175] Although preferred embodiments of the invention have been described, those skilled in the art, upon learning the basic inventive concept, can make other changes and modifications to these embodiments. Therefore, the appended claims are intended to be interpreted as including the preferred embodiments as well as all changes and modifications falling within the scope of the invention.

[0176] The above are merely preferred embodiments of the present invention and are not intended to limit the present invention. It should be noted that any modifications, equivalent substitutions, and improvements made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A method for preparing a wear-resistant and corrosion-resistant glass flake coating, characterized in that: The coating comprises component A and component B. Component A includes an epoxy resin matrix, reinforcing fillers, self-healing microcapsules, and additives. The epoxy resin matrix is ​​composed of at least two different types of epoxy resin components, with the first epoxy resin component being the main resin and the second epoxy resin component being a toughening modified resin. The reinforcing fillers include surface-modified glass flakes, functionalized graphene, and nano-zirconia particles. The self-healing microcapsules include a microcapsule wall and a self-healing agent encapsulated within. The internal self-healing agent includes bisphenol F epoxy resin and a latent curing agent, imidazole derivative or polythiol. The additives include rheology modifiers, defoamers, and wetting and dispersing agents. Component B includes a curing agent and a curing accelerator. The specific preparation method is as follows: Step 1, Functionalization of glass flake surface: Immerse or spray glass flakes in an aqueous solution of 0.5%–2.0% silane coupling agent for 10–30 min, followed by drying at 100°C–120°C for 2–4 h; the silane coupling agent is a mixture of (3-epoxypropoxypropyl)trimethoxysilane and (3-aminopropyl)triethoxysilane; Step 2, Functionalized Nanofiller Dispersion: Functionalized graphene and nano-zirconia particles are added to a portion of the first epoxy resin component and dispersed under high shear at 1000 rpm–3000 rpm for 1–3 hours using a planetary mixer or sand mill; the functionalized graphene is graphene oxide or reduced graphene oxide, with epoxy groups, hydroxyl groups or amino functional groups grafted onto its surface; the nano-zirconia particles are spherical or near-spherical, with an average particle size of 20 nm–50 nm, and their surface is treated with a silane coupling agent; Step 3, Mixing of Component A: Add the remaining first epoxy resin component, second epoxy resin component, wetting and dispersing agent and defoamer to the mixing container, stir at 500 rpm–1000 rpm for 30–60 min, and degas under a vacuum of -0.08 MPa to -0.09 MPa. Step 4, Mixing the reinforcing phase: Add the surface-functionalized glass flakes and self-healing microcapsules from Step 1 to the mixture obtained in Step 3, stir at a low speed of 100 rpm–300 rpm for 30–60 min, then add the rheology modifier and continue stirring at 500 rpm–800 rpm for 30–60 min. Step 5, Preparation of Component B: Mix the curing agent and curing accelerator at 300 rpm–600 rpm for 10–20 min; Step 6, on-site construction mixing: Mix component A and component B according to the preset ratio, and stir at 500rpm–800rpm for 3–5min. The preset ratio is a mass ratio of component A to component B of 4:

1.

2. The method for preparing a wear-resistant and corrosion-resistant glass flake coating according to claim 1, characterized in that: The glass flakes are C-type or ECR-type, with a thickness of 3μm–5μm, an average particle size D50 of 80μm–120μm, and an aspect ratio of 20–100.

3. The method for preparing a wear-resistant and corrosion-resistant glass flake coating according to claim 1, characterized in that: The first epoxy resin component has an epoxy equivalent of 180 g / eq–200 g / eq and a viscosity of 10 Pa·s–15 Pa·s at 25°C; the second epoxy resin component has an epoxy equivalent of 250 g / eq–350 g / eq and a viscosity of 30 Pa·s–50 Pa·s at 25°C; the mass ratio of the first epoxy resin component to the second epoxy resin component is 100:10–100:

30.

4. The method for preparing a wear-resistant and corrosion-resistant glass flake coating according to claim 1, characterized in that: The wall material of the self-healing microcapsules is polyurea-formaldehyde or poly(melamine-formaldehyde) resin, with an average diameter of 50μm–200μm and a wall thickness of 1μm–5μm.

5. The application of a wear-resistant and corrosion-resistant glass flake coating prepared by the method described in any one of claims 1-4, characterized in that, include: Step 101, Substrate pretreatment: Sandblasting or shot blasting the metal substrate to Sa2.5 grade, with a roughness Rz of 40μm–70μm; Step 102, Coating application: Apply the coating prepared by the method according to any one of claims 1-4 to the substrate with a single layer thickness of 200μm-500μm, and when applying multiple layers, the recoating interval is 6h-24h; Step 103, coating curing: Curing at 5°C–40°C and relative humidity 30%–85%, surface drying time 6h–8h, hard drying time 24h–48h, and complete curing time 7 days.

6. The application of the wear-resistant and corrosion-resistant glass flake coating according to claim 5, characterized in that: In step 101, the metal substrate is carbon steel, stainless steel or alloy steel, and the concrete substrate needs to be cleaned of floating dust and subjected to pH neutralization treatment so that the pH value of the concrete substrate surface reaches 7-10.

7. The application of the wear-resistant and corrosion-resistant glass flake coating according to claim 5, characterized in that: In step 102, the coating method is air-assisted spraying, airless spraying, roller coating or brush coating. When the total coating thickness is ≥800μm, it is coated in at least two layers. The coating method can be the same or different, and the recoating interval between adjacent layers is 6h–24h.

8. The application of the wear-resistant and corrosion-resistant glass flake coating according to claim 5, characterized in that: In step 103, when the ambient temperature is below 10°C during curing, a low-temperature curing accelerator is used to accelerate the reaction. The low-temperature curing accelerator is tris(dimethylaminomethyl)phenol or a urea derivative.

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