Nanoclays have evoked a great deal of attention lately for the preparation of novel nanocomposite materials for several applications. This is attributed to their lamellar structures, which are distinguished by having high in-plane strength and stiffness, as well as a high aspect ratio. Nanocomposites have exhibited an advanced gas and water barrier properties compared to the pristine polymers. Such advancement plays a major role in enhancing the coating industry, specifically for corrosion protection. One main factor attributing to coating failure is its inability to maintain low water and oxygen permeability thought its service life. The penetration of these elements through the coating leads to corrosion initiation under the coating. The addition of clay to polymeric coatings has great potential to improve the corrosion protection performance of the coatings. This chapter will present the recent advancement in the preparation and utilization of clay nanocomposites as enhanced coatings for corrosion protection.

In this paper, hydrophilic silica particles (250 nm and 800 nm) were synthesized using the well-established Stöber method. The particles and their mixtures were chemically treated to achieve hydrophobic properties, confirmed using the sessile drop technique. Mild steel sheets were prepared, sand blasted and cleaned to the required surface roughness and cleanliness, verified by established quantitative methods. Two resins, Jotamastic 80 and Penguard FC, were applied as primer and topcoat to the required thickness. The resulting films were evaluated qualitatively and by optical interferometry and micrograph analysis. Samples were then coated with selected combinations of hydrophobic particles to form homogeneous coatings, and their hydrophobicity was assessed. The highest contact angle was obtained for a mixture of 75% 250 nm and 25% 800 nm particles, with other combinations showing contact angles between 130° and 140°. Optimal adhesion and hydrophobic performance were achieved when particle/ethanol suspensions were sprayed 2.5 h after topcoat application. The hydrophobic structure was best developed after 24–48 h of drying. Surface morphology was examined using Scanning Electron Microscopy, and the results are discussed.