Synergistic Effects of Zn-Rich Layered Double Hydroxides on the Corrosion Resistance of PVDF-Based Coatings in Marine Environments

In this study, zinc–aluminum layered double hydroxide (ZLDH) and its calcined counterpart (CZLDH) were synthesized and incorporated into a poly(vinylidene fluoride) (PVDF) matrix to develop high-performance anti-corrosion coatings for mild steel substrates. The structural integrity, morphology, and dispersion of the LDH fillers were analyzed using FTIR, XRD, Raman spectroscopy, and SEM/EDS, while coating performance was evaluated through water contact angle (WCA), adhesion tests, and electrochemical techniques. Comparative electrochemical impedance spectroscopy (EIS) and potentiodynamic polarization tests in a 3.5% NaCl solution revealed that the ZLDH/PVDF coating exhibited superior corrosion resistance and long-term stability compared to CZLDH/PVDF and pristine PVDF coatings. The intact lamellar structure of ZLDH promoted excellent dispersion within the polymer matrix, enhancing interfacial adhesion, reducing porosity, and effectively blocking chloride ion penetration. Conversely, calcination disrupted the lamellar structure of ZLDH, reducing its compatibility and adhesion performance within the PVDF matrix. This study demonstrates the critical role of ZLDH’s structural integrity in achieving enhanced adhesion, barrier properties, and corrosion protection, offering an effective anti-corrosion coating for marine applications.