Trivalent cerium-doped zinc phosphate composite coating: A novel solution to the wear-corrosion coupling issue

A novel cerium-doped zinc phosphate (Ce-ZP) composite coating was developed to enhance corrosion resistance and tribological performance in marine environments. XRD, XPS, IR, and Raman spectroscopy confirmed successful cerium incorporation into the Zn 3 (PO 4 ) 2 lattice, while ESEM and EDS analyses demonstrated a uniform microstructure. The Ce-ZP composite, incorporated into an epoxy-phenolic-PTFE matrix, exhibited low friction, high wear resistance, and superior corrosion protection. Electrochemical studies revealed a synergistic effect between Ce 3+ and Zn 2+ , forming passivation films that prolonged the coating’s lifespan. Compared to traditional zinc phosphate inhibitors, Ce-ZP demonstrated faster activation, improved durability, and enhanced stability. The tribological analysis confirmed that PTFE provided lubrication, Ce-ZP reinforced mechanical strength, and the synergistic corrosion-wear resistance mitigated wear-corrosion coupling damage. These findings indicate that Ce-ZP coatings offer a promising solution for high-salinity and corrosive marine environments.