A novel kind of waterborne epoxy coating pigmented by nano-sized aluminium powders on high strength steel was formulated. Several coatings with different pigment volume content (PVC) were prepared. The coating morphology was observed using scanning electron microscopy (SEM), and the electrochemical properties were investigated by electrochemical impedance spectroscopy (EIS). Immersion test and neutral salt spray test were also conducted to investigate the corrosion resistance of the coating. It is demonstrated that the critical pigment volume content (CPVC) value is between 30% and 40%. The coating with PVC of 30% exhibits good corrosion resistance in 3.5% (mass fraction) NaCl solution.
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