Stimulus Responsive Zeolitic Imidazolate Framework to Achieve Corrosion Sensing and Active Protecting in Polymeric Coatings

A Novel Self-Healing Anticorrosive Inhibitor for Pipeline Corrosion Protection in Geothermal Well Systems

The growing demand for energy coupled with the need for environmental sustainability underscores the importance of advancing renewable energy technologies. Among these, geothermal energy stands out as a clean and sustainable resource with substantial potential for heating and power generation. However, the corrosion of materials in geothermal facilities presents a significant operational challenge. This study explores the development of a self-healing anticorrosive coating based on microcapsule technology to address this issue. The proposed coating releases corrosion inhibitors from the microcapsules upon damage, enabling autonomous repair. Microcapsules were fabricated with an oil-soluble imidazoline oleate corrosion inhibitor encapsulated in urea-formaldehyde resin and incorporated into an epoxy resin matrix. The resulting composite coating demonstrated enhanced self-healing properties. Key parameters, including the core-to-wall ratio, healing duration, and microcapsule concentration, were systematically examined for their influence on self-healing efficiency. The performance of the composite was rigorously evaluated through simulated geothermal water corrosion tests under conditions representative of geothermal systems. The results indicate that microcapsules with a core-to-wall ratio of 3:1, using OP-10 as an emulsifier at 0.5 wt % of the core material, exhibited optimal structural integrity and encapsulation efficiency (74.6% core content, 85.7% coating efficiency). Additionally, epoxy resin composites with microcapsule concentrations greater than 20 wt % exhibited effective self-healing of artificially induced damage, demonstrating superior anticorrosive properties crucial for geothermal applications. These findings suggest that the developed self-healing composite holds great potential for mitigating corrosion in geothermal energy systems, contributing to the durability and efficiency of geothermal facilities.

Environmentally Friendly Photoluminescent Coatings for Corrosion Sensing

Although an increasing number of studies are being devoted to the field of corrosion, with topics from protection to sensing strategies, there is still a lack of research based on environmentally eco-friendly materials, which is essential in the transition to sustainable technologies. Herein, environmentally friendly composites, based on photoluminescent salts dispersed in vegetable oil-based resins, are prepared and investigated as corrosion sensing coatings. Two salts NaA, where A- is a lanthanide complex anion (with Ln = Nd3+, and Yb3+), are incorporated into the resins as active functional fillers and different coatings are prepared on carbon steel substrates to assess their functional properties. The influence exerted by a corrosive saline solution on the morphology, structural, and photoluminescent properties of the coatings is evaluated, and their suitability for the practical detection of the early corrosion of coated carbon steel is demonstrated. The photoluminescence of the composite coatings depends on the corrosion time, with the effect being more important for the coatings doped with Nd3+. The present work shows that the composites obtained are suitable candidates for corrosion sensing coating applications, offering improved sustainability.

Self-Indicating Polymer Prodrug Nanoparticles for pH-Responsive Drug Delivery in Cancer Cells and Real-Time Monitoring of Drug Release

Amphiphilic self-indicating and responsive polymer-based prodrugs have generated much interest as potential stimuli-responsive intelligent drug delivery systems (DDS) due to their ability to selectively deliver drugs to the cancer cells and to monitor real-time cellular uptake of the drug by imaging technique(s). In this direction, we have synthesized a new pH-responsive N-vinyl-2-pyrrolidone and coumarin-based fluorescent self-indicating polymeric prodrug (SIPD), poly(NVP)-b-poly(FPA.DOX-r-FPA-r-CA). This block copolymer prodrug self-assembled into stable micellar nanoparticles under physiological conditions that reduced undesirable drug leakage to normal cells but resulted in the release of the anticancer drug doxorubicin (DOX) in cancer cells because of acidic pH-induced cleavage of imine bonds between DOX and the copolymer. While the polymer was found to be highly biocompatible with both normal (HEK-293) cells and cancer (MCF-7) cells even at high concentrations by MTT assay, the polymer prodrug nanoparticles showed toxicity even higher than that of free DOX in cancer cells. Phase contrast microscopy also depicted the cytotoxic effects of the nanoparticles on cancer cells. The coumarin units present in the polymer served as a fluorescence resonance energy transfer (FRET) pair with the covalently attached DOX molecules, which was established by steady-state and time-resolved fluorescence spectroscopy. Furthermore, confocal microscopy results confirmed the FRET phenomenon, as the fluorescence intensity of coumarin in the micellar nanoparticles remained quenched initially in MCF-7 cells but recovered with time as the DOX molecules were released and gradually shifted toward the targeted nucleus. All of these studies implied that the synthesized prodrug nanoparticles may provide another viable option for delivering chemotherapeutic drugs into cancer cells with a capability of real-time monitoring of drug release.

Self-healing and corrosion-sensing multifunctional coatings containing pH-sensitive TiO2-based composites

Polyelectrolyte-encapsulated nanocontainers can effectively respond to changes of pH and thus control the on-demand release of corrosion inhibitors. A pH-responsive release system (Phen-Tpp@MTNs-PDDA) was developed based on the cationic polyelectrolyte poly dimethyl diallyl ammonium chloride (PDDA) encapsulated mesoporous TiO2 nanocontainers (MTNs) loaded with 1,10-phenanthroline (Phen) and tripolyphosphate ions (Tpp) corrosion inhibitors. The epoxy coating (EP) embedded with Phen-Tpp@MTNs-PDDA (Phen-Tpp@MTNs-PDDA/EP) demonstrates superior self-healing properties and confers long-term protection on the metal substrate through the cooperative effect of Phen and Tpp. Simultaneously, this hybrid coating is endowed with corrosion sensing capability based on the color development originating from the interaction of Phen and carbon steel. This self-healing and corrosion-sensing multifunctional coating provides an effective strategy for the corrosion protection of metals.

A Super-Adhesive 2D Diamond Smart Nanofluid with Self-Healing Properties and Multifunctional Applications

Smart responsive materials are capable of responding to external stimuli and, compared to traditional materials, can be effectively reused and reduce usage costs in applications. However, smart responsive materials often face challenges such as the inability to repair extensive damage, instability in long-term performance, and inapplicability in extreme environments. This study combines 2D diamond nanosheets with organic fluorinated molecules to prepare a smart nanofluid (fluorinated diamond nanosheets, F-DN) with self-healing and self-adhesion properties. This smart nanofluid can be used to design various coatings for different applications. For example, coatings prepared on textured steel plates using the drop-casting method have excellent superhydrophobic and high oleophobic properties; coatings on titanium alloy plates achieve low friction and wear in the presence of lubricating additives of F-DN in perfluoropolyether (PFPE). Most impressively, coatings on steel plates not only provide effective corrosion resistance but also have the ability to self-heal significant damage (approximately 2 mm in width), withstand extremely low temperatures (-64 °C), and resist long-term corrosion factors (immersion in 3.5 wt % NaCl solution for 35 days). Additionally, it can act as a "coating glue" to repair extensive damage to other corrosion-resistant organic coatings and recover their original protective properties. Therefore, the smart nanofluid developed in this study offers diverse applications and presents new materials system for the future development of smart responsive materials.

Polyaniline Microspheres with Corrosion Inhibition, Corrosion Sensing, and Photothermal Self-Healing Properties toward Intelligent Coating

A smart coating integrating functions of corrosion inhibition, self-healing, and corrosion-sensing was developed based on a polyaniline (PANI) microsphere-loading corrosion sensing probe (8-hydroxyquinone, 8-HQ). The PANI microsphere was prepared in a facile one-pot process via the combination of photopolymerization and an emulsion template. The 8-HQ-loaded PANI microsphere achieved three synergetic effects simultaneously: corrosion inhibition, corrosion sensing, and photothermal self-healing abilities. Benefiting from the corrosion inhibition effect of PANI, the coating with the PANI microsphere exhibited significantly enhanced anticorrosion behavior. After soaking in NaCl solution for 35 days, its impedance was maintained at 1.26 × 109 Ω·cm2, nearly 3 orders of magnitude higher than that of pure resin coating. Meanwhile, the encapsulated 8-HQ exhibited pH-responsive release behavior thanks to the pH-responsive characteristics of PANI, which could chelate with Al3+ ions to form 8-HQ-Al3+ coordinates with a conspicuous fluorescence, achieving a real-time corrosion diagnosing function. Moreover, benefiting from the photothermal property of PANI, the coating with the PANI microsphere displayed rapid crack closure behavior under NIR light irradiation, and the healing efficiency could reach 83.56% under near-infrared irradiation. This work presents an innovative strategy for fabricating an intelligent self-healing, self-reporting, and anticorrosion coating, which provides a new vision to prolong the lifetime of metals.

A novel epoxy coating with nanocatalytic anticorrosion performance achieved by single-atom Fe-N-C catalyst

In view of the critical importance of oxygen to corrosion evolution, to starve corrosion via depleting oxygen in coatings is a promising strategy. In this work, a novel nanocatalytic anticorrosion concept is proposed to design new coating with outstanding corrosion resistance. Different from the passive barrier of traditional coatings and self-repair after corrosion of current stimuli-feedback coatings, such coating could spontaneously eliminate internal diffused oxygen and greatly suppress the corrosion process. As a proof of concept, single-atom Fe-N-C electrocatalyst with isolated FeN₄ active sites is synthesized by a simple confined carbonization method, exhibiting excellent oxygen reduction performance (E_1/2 = 0.902 V). In composite coating, the evenly dispersed Fe-N-C compensates for the coating defects and serves as oxygen scavengers, which could actively adsorb and consume ambient oxygen, thereby preventing oxygen penetration to the metal substrate surface, eliminating the oxygen contribution to corrosion and significantly boosting the anticorrosion performance of epoxy coating. This in-situ mediation for oxygen in coating prevents metal substrate from receiving new supply of oxygen, while imparting active anticorrosion property to the coating.

Designing Smart Microcapsules with Natural Polyelectrolytes to Improve Self-Healing Performance for Water-Based Polyurethane Coatings

Active anticorrosive organic coatings adopting microcapsules (MCs) have lately attracted extensive attention as they were proven to be effective to minimize metal corrosions and offer a long-lasting protection performance. Herein, a novel environmental-friendly active corrosion protection system was designed for aluminum alloy 2024 (AA2024) based on water-based polyurethane coatings with the addition of water and alkaline pH-responsive smart MCs, which is fabricated by utilizing 2-mercaptobenzothiazole (2-MBT) as an inhibitor, halloysite clay nanotubes (HNTs) as an inhibitor carrier, and the natural polyelectrolytes ε-poly-l-lysine (ε-PLL) and sodium alginate (SA) as layer-by-layer (LBL) encapsulation polyelectrolytes. Salt spray tests and electrochemical measurements prove that the scratched coatings with embedded MCs possess an excellent self-healing performance by forming an adsorption layer of released 2-MBT on the AA2024 surface, thereby providing over 90% inhibition efficiency within 6 days' immersion. The UV-vis spectrophotometer results further showed that the release of 2-MBT is a three-stage long-term process sensitive to water and alkaline pH value, while the outward release rate is both regulated by the solubility of 2-MBT and the SA layer. The fabricated MCs not only offer a great promise to provide an excellent self-healing performance but also shed light on the future design of advanced MCs on demand based on the LBL technique.

Metal organic frameworks (MOFs) as multifunctional nanoplatform for anticorrosion surfaces and coatings

Corrosion of metallic materials is a long-standing problem in many engineering fields. Various organic coatings have been widely applied in anticorrosion of metallic materials over the past decades. However, the protective performance of many organic coatings is limited due to the undesirable local failure of the coatings caused by micro-pores and cracks in the coating matrix. Recently, metal organic frameworks (MOFs)-based surfaces and coatings (MOFBSCs) have exhibited great potential in constructing protective materials on metallic substrates with efficient and durable anticorrosion performance. The tailorable porous structure, flexible composition, numerous active sites, and controllable release properties of MOFs make them an ideal platform for developing various protective functionalities, such as self-healing property, superhydrophobicity, and physical barrier against corrosion media. MOFs-based anticorrosion surfaces and coatings can be divided into two categories: the composite surfaces/coatings using MOFs-based passive/active nanofillers and the surfaces/coatings using MOFs as functional substrate support. In this work, the state-of-the-art fabrication strategies of the MOFBSCs are systematically reviewed. The anticorrosion mechanisms of MOFBSCs and functions of the MOFs in the coating matrix are discussed accordingly. Additionally, we highlight both traditional and emerging electrochemical techniques for probing protective performances and mechanisms of MOFBSCs. The remaining challenging issues and perspectives are also discussed.

Design of Nanostructured Protective Coatings with a Sensing Function

Nanostructured multilayered coatings for metals are prepared to simultaneously provide a function of corrosion mitigation and of corrosion sensing for copper substrates. Silica nanocapsules, embedded in one layer of the coating, are used as a host for a corrosion inhibitor and as a sensor, which detect changes of pH value and release inhibitors via an optical signal. Furthermore, another layer in the coating exists in a nanonetwork loaded with another corrosion inhibitor, which is impregnated with a hydrophobic polymer. We demonstrate that a specific arrangement of layers leads to an optimum anticorrosion and sensing performance while the sensing signal can be prolonged for a long time. It is the first time that the fluorophore detecting corrosion is conjugated to the nanosensor and that nanofibers and nanocapsules are used simultaneously to load and release corrosion inhibitors for anticorrosion applications.