This study aims to demonstrate the excellent protective performance of functionalized graphene oxide (fGO) flakes in acrylic cataphoretic coatings. The filler content provides an important contribution in improving the chemical and mechanical resistance of the acrylic matrix. The morphology of the fillers was first investigated by optical and electron microscopy, analysing the distribution of the fGO flakes within the polymer matrix. After that, the flakes were added to the cataphoretic bath in different concentrations, resulting in four series of samples. The cathodic delamination of the coatings was assessed with cathodic polarization cycles and with measurements carried out with a scanning Kelvin probe. Finally, the abrasion resistance at the macroscopic and microscopic level was studied by scrub testing and scratching atomic force microscopy analysis, respectively. The incorporation of fGO at the optimized concentration of 0.2 wt.% greatly increases the cathodic delamination resistance of the acrylic matrix, resulting in an effective barrier against the effects of absorbed aggressive substances. Graphene-based fillers also enhance abrasion resistance, thanks to their high mechanical strength. Thus, this work demonstrates the great protective benefits that can be obtained when using fGO flakes as reinforcing fillers in cataphoretic coatings.
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