A Comprehensive Review of the Use of Epoxy–Acrylic Hybrid Resins in Anti-Corrosion Paints

Epoxy–acrylic hybrid resins have emerged as advanced binder systems for anticorrosion coatings, combining the superior adhesion, chemical resistance, and barrier properties of epoxy with the flexibility, weatherability, and UV resistance of acrylic polymers. Traditional epoxy coatings often suffer from brittleness and environmental degradation, whereas acrylic coatings alone provide limited corrosion protection. Hybridization offers a synergistic approach to overcome these limitations. This review presents a comprehensive overview of synthesis and hybridization strategies, including interpenetrating polymer networks (IPNs), copolymerization, emulsion polymerization, core–shell structures, and grafting approaches. Mechanisms contributing to enhanced corrosion performance, such as improved barrier properties, mechanical flexibility, adhesion, and environmental durability, are discussed in detail. Performance evaluations from standardized corrosion tests, including salt spray, electrochemical impedance spectroscopy, and immersion studies, demonstrate the effectiveness of hybrid coatings compared with single-component systems. This review also highlights emerging trends in waterborne and low-VOC formulations, nanocomposite hybrids, and smart coatings with self-healing or responsive properties. The review also discusses challenges such as phase compatibility, processing complexity, and long-term durability. Overall, epoxy–acrylic hybrid resins represent a promising approach for developing durable, high-performance, sustainable, and environmentally compliant anticorrosion coatings.

Anticorrosion coatings; Barrier properties; Epoxy–acrylic hybrid; Nanocomposites; Waterborne resins

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