Formulation and performance evaluation of hydroxyl terminated hyperbranched polyesters based poly (ester–urethane–urea) coatings on mild steel

A low molecular weight, anticorrosive hyperbranched poly (ester–urethane–urea) HB-P(EUU)] coatings were formulated using 2nd generation hydroxyl terminated hyperbranched polyesters (OH–HBPEs), isophorone di-isocyanate (IPDI) as a cross linking agent and dibutyltin dilaurate (DBTDL) as a catalyst with certain additives. First, NCO terminated prepolymers (HBPEUs) were formulated by reacting OH–HBPEs with IPDI at NCO:OH ratio of 1.1:1 for 4 h at 70–80 °C, then HBPEUs were mixed with DBTDL and various additives and finally coated on pretreated cold rolled mild steel (MS) substrates by dip coating method. Before applying on MS substrates, viscosity and volume solid of coatings were measured. The molecular structure of HBPEUs was characterized by ATR-FTIR and ¹H NMR analysis. Surface morphology of coated panels was characterized by atomic force microscopy (AFM) and found that coating components were homogeneously distributed and surface was smooth and crack free. Performance of coated substrates was evaluated by various tests such as cross hatch and pull off adhesion, abrasion resistance, scratch resistance, impact resistance, flexibility, and pencil hardness. UV stability of coated substrates was evaluated by UV-whether-o-meter and corrosion resistance property was evaluated by salt spray, humidity, polarization and electrochemical impedance (EIS) test. Results were also compared with polyurethane coating based on linear polyester. HB-P(EUU) coatings showed excellent enhancement in mechanical, durability as well as corrosion resistance properties than their linear counterpart.