| Anti-corrosion coatings are functional coatings applied widely in the fields of modern chemical industry, energy resources, transportation, marine engineering etc. In our country, most of the early anticorrosive coatings are solvent coatings with high VOC(Volatile Organic Compound) and contain toxic antirust pigments such as red lead and zinc chromate in their composition, which results in the waste of natural resources and environmental pollution. Since 1990s, due to the increasing requirements for environmental protection and resources saving, seeking for replacements of those poisonous raw materials to develop new environmental amicable coatings ,waterborne coatings, solvent less coatings, powder coatings and high solid content coatings has become a main trend of the development of anticorrosive coatings.Waterborne coatings use water as their main solvent or disperse medium. Compared with solvent-based coatings, they contain less or even no organic solvents and are characteristic of low or non-toxicity, non-flammability, non-foreign taste and safety in production and paint process. Because of these merits, they have drawn people's attention long before and are considered by experts to be main products of the world coatings markets in the 21st century. There is also a prosperous future for waterborne coatings in China, where, according to incomplete statistic, about 1 million of the 1.7 million tons of the industry paints required annually need to be replaced by waterborne anti-corrosive coatings. As it is shown, the development and popularization of native waterborne industry paints holds enormous environmental and economic benefits.This paper developed a low cost one coat waterborne anti-corrosion coatings. The article first made a brief overview of the waterborne anti-corrosion coatings. It introduced the basic components of the waterborne coatings and the mechanism of it, and analysis the mechanism of waterborne anti-corrosion coatings. Then entered the experimental part and through analysis contrast and a large number of experiments, the paper first choused suitable raw materials considering the performance and the cost of the paint. Then, according to the ratio of pigment and film materials and the recommended amount, it designed the initial formulation, and it also designed experimental process according to the huge actual production experiences. Then based on the initial formulation, according to the experimental process, the article researched the influence on the performance of the coat of variety of the content of each component of the coat and optimized the initial formulation. Then it got the final formulation. Finally, test the comprehensive performance of the paint. Specific conclusions are as follows:1. The protect function of anti-corrosion coatings is mainly through the barrier of the corrosive medium of the film and the influence of impact current of film's high corrosion resistance properties and the passivation reacted by pigment and substrates. The mechanism of waterborne anti-corrosion is that coating resins reactive group and the activity pigment react with the harmful component of the rust and create stable inhibitory compounds. The coating this paper developed has both reactive properties and stable properties.2. Through analysis contrast and a large number of experiments, the paper first choused suitable raw materials considering the performance and the cost of the paint. Choose styrene-acrylate emulsion as coating resins because of its low cost. Analyzed emulsion PR-71K and HG-54D produced by ROHM AND HAAS with IR. And get the conclusion that they are both styrene-acrylate emulsion.3. According to P/B and the recommended amount, the paper designed the initial formulation: film materials HG-54D emulsion is 50%.Its solid content is 41.5%. According to the ratio formula of pigment and emulsion, pigment content is about 30%. APW-2 is about 8%. 409-1 is about 8%. Talc is about 9%. R-215 is about 5%. Some main additives content is that H100 is 1%, 4000 is 0.12%, 1620 is 0.05%. Other additives and demonized water content is appropriate.4. The paper designed experimental process according to the huge actual production experiences: First mixture demonized water, dispersant, defamer, ammonia and glycol butyl ether. Disperse about 30 minutes. The speed is controlled about 300～500r/min. Then input pigment and detonate and glass beads or ho-beads. Sand it about 60 minutes. The speed is controlled about 1300～1500r/min. After that filer it and get slurry. Then put emulsion, filming auxiliary and appropriate defamer and ammonia in the slurry. Disperse about 30 minutes. The speed is controlled about 300r/min. The last adjust the paint, input thickeners and demonized water, and adjust the viscosity to a appropriate value. In the end get the paint.5. The article researched the influence on the performance of the coat of variety of the content of each component of the coat and optimized the initial formulation. Then it got the final formulation: dispersant H100 is 1.0%～1.2%, wetting agent 4000 is 0.1%～0.5%, defamer 1620 is 0.07%～0.10%, PH Regulator ammonia is 0.20%～0.25%, glycol butyl ether is 3.0%～3.5%, Aluminum tripolyphosphate APW-2 is 7%～9%,zinc phosphate 409-1 is 7%～9%, talc is 8%～10%,R-215 is 4%～6%, detonate SH is 0.10%～0.15%,anti-corrision coating emulsion HG-54D is 45%～55%, filming auxiliary ester alcohol is 1.5%～2.0%, thickeners H400:H600=2:3 is 0.50%～0.75%.6. Test the properties of low-cost one coat anti-corrosion coatings, and get the conclusion that it reaches the command of relative standards. Its viscosity is appropriate and suitable to brush. It has enough thickness, adhesion and drying time is short. Its acid and basic resistance property and Storage Stability is good. Although choose the low-cost raw materials (e.g. emulsion and pigment), it also reach the purpose of improving rushing environment. As a one coat paint, it can be used as both a bottom paint and a noodles paint and don't worry about the matching problem, so the construction is convenient.
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