Synergistic enhancement of corrosion and wear resistance in polyurethane composite coatings using modified molybdenum disulfide and silicon carbide nanocomposites--颗粒学报PARTICUOLOGY

Synergistic enhancement of corrosion and wear resistance in polyurethane composite coatings using modified molybdenum disulfide and silicon carbide nanocomposites

Guilin Zhou^{a b}, Hui Nan^b, Lijun Yang^a, Jingchuan Wang^a, Ruizhu Yang^a, Fengsheng Qu^a, Hongmin Wang^c *, Hong Lin^d *, Pan Yang^a *

a Institute of Materials, China Academy of Engineering Physics, Jiangyou, 621908, China
b Key Laboratory of Qinghai Province for Light Alloy, Qinghai High Performance Light Metal Alloy and Deep Processing Engineering Technology Research Center, Qinghai University, Xi'ning, 810000, China
c Qinghai Second Geological Exploration Institute, Xi'ning, 810016, China
d State Key Laboratory of New Ceramics Materials, Tsinghua University, Beijing, 100084, China

10.1016/j.partic.2026.03.035

Volume 114, July 2026, Pages 25-35

Received 25 December 2025, Revised 17 March 2026, Accepted 27 March 2026, Available online 4 April 2026, Version of Record 11 April 2026.

E-mail: 472689346@qq.com; hong-lin@tsinghua.edu.cn; yangpan@caep.cn

Highlights

• A cross-linked network formed by KH560-PDA modified MoS₂ effectively blocks corrosive agents.

• Dispersed SiC nanoparticles optimize stress distribution and reduce surface friction.

• KPM-10S/PU coating exhibits optimal performance with 342 times higher impedance and 79% lower wear loss than pure PU.

• KPM-10S/PU coating shows outstanding resistance in HNO₃ and salt spray tests, with minimal degradation after 14 days.

• Elucidates MoS₂-SiC synergistic corrosion-wear mechanism and identifies 10 wt% SiC for optimal performance.

Abstract

Polyurethane (PU) coatings, extensively used for metal surface protection, face limitations in harsh environments due to their insufficient wear resistance. A novel PU composite coating system, synergistically reinforced with modified molybdenum disulfide (MoS₂) and silicon carbide (SiC) nanoparticles, was developed to enhance both corrosion and wear resistance. By modifying MoS₂ via the silane coupling agent (KH560)-polydopamine (PDA) cross-linking, a dense network was formed to block corrosive agents, while dispersed SiC nanoparticles optimized stress distribution and reduced surface friction. The composite coating containing 10 wt% SiC (KPM-10S/PU) demonstrates comprehensive performance, exhibiting 342 times higher impedance compared to the pure PU, 79% reduction in the wear loss volume against 316L steel, and outstanding resistance in HNO₃ and salt spray tests. Although 15 wt% SiC (KPM-15S/PU) achieved the highest initial impedance and the lowest friction coefficient, excessive SiC compromised matrix compatibility, increasing corrosion vulnerability. This work elucidates the corrosion blocking and wear inhibition reinforcement mechanism of MoS₂-SiC composite, and provides a scalable strategy for designing multifunctional coatings in demanding environments of marine infrastructure.

Graphical abstract

Keywords

Polyurethane composite coatings; Synergistic enhancement; Molybdenum disulfide; Silicon carbide; Corrosion-wear resistance

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