Corrosion and Adhesion Behavior of Recycled High Density Polyethylene (HDPE) Coated Mild Steel

This research utilized 100% recycled HDPE as a powder coat on mild steel (used as a simulated automotive chassis). The recycled HDPE as a powder form was applied to mild steel using electrostatic powder coating equipment. The coated steel was characterized, and the corrosion property was determined by immersion in NaCl, and H2SO4 solutions. Scanning Electron Microscope (SEM) analysis revealed that the coating was non-porous and on average, 80 μm thick. Corrosion test in 5% H2SO4 acid solution was performed in accordance with ASTM standards ASTM C694-90a and ASTM G31. All specimens showed corrosion, specifically on the edges and sharp corners, with a maximum corrosion rate of 12.54 mm/year. Corrosion test was also performed in a 5% NaCl salt solution in compliance with ASTM B895-16 and ASTM D610-08 standards. Visual inspection suggested that the samples were corroded mildly as some corrosion products can be seen at the bottom of the beaker. However, no measurable weight loss was found. After corrosion tests, the coated samples were subjected to adhesion tape test according to the ASTM standard D3359 adhesion by tape test. The tape tests provided a 5B, which is the maximum for a tape test, for as coated samples, and a minimum 4B for samples performed immersion tests in salt solution. These results suggested that a well adhesion was achieved between the steel substrate and DHPE coating. This study indicated that the recycled content HDPE would be a viable candidate to protect chassis from road salt corrosion.



Work Title Corrosion and Adhesion Behavior of Recycled High Density Polyethylene (HDPE) Coated Mild Steel
Open Access
  1. A Rahman
  2. M Abu-Ayyad
  3. Issam Abu-Mahfouz
  4. Joshua Bachert
License In Copyright (Rights Reserved)
Work Type Article
  1. International Journal of Scientific & Engineering Research
Publication Date September 1, 2020
Deposited January 12, 2022




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  • Added Creator A Rahman
  • Added Creator M Abu-Ayyad
  • Added Creator Issam Abu-Mahfouz
  • Added Creator Joshua Bachert
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