Coating Technology Innovations in Materials Science

New open-access review paper, free to download: https://lnkd.in/dtYievgx "Hydrogen barrier coatings: Application and assessment", International Journal of Hydrogen Energy, Vol. 180 (2025), 151666. By Ehsan Akbari Kharaji a, Majid Shafaie b, Elizabeth Sackett a, John Wood c, Milos Djukic d, Shirin Alexander e a Faculty of Science and Engineering, Department of Materials Science and Engineering, Swansea University / Prifysgol Abertawe, UK b Department of Mechanical Engineering, Amirkabir University of Technology - Tehran Polytechnic, Iran c AkzoNobel, Gateshead, UK d University of Belgrade, Faculty of Mechanical Engineering University of Belgrade, Serbia e Faculty of Science and Engineering, Department of Chemical Engineering, Swansea University, UK Highlights • A comprehensive review linking coating deposition methods to hydrogen permeation. • Comparative analysis of metallic, ceramic, polymeric, and hybrid multilayer barriers. • Polymer-based and nanostructured coatings emerge as promising hydrogen barriers. • Permeation testing methods critically assessed for accuracy and cross-comparison. • Future directions highlight scalable, durable, and sustainable coatings for the hydrogen economy. Hydrogen embrittlement (HE) threatens the structural integrity of industrial components exposed to hydrogen-rich environments. This paper provides a comprehensive review of current advancements in hydrogen barrier coatings (HBCs), with an emphasis on their permeability characteristics, applied deposition techniques, and, in particular, the emerging role of polymer-based systems. This paper examines the mechanisms of action, environmental implications, and the potential of coatings to transform hydrogen infrastructure, enabling the safe and efficient operation of hydrogen technologies. It also highlights the emerging role of polymeric and hybrid multilayer coatings with direct implications for advanced and reliable hydrogen production, storage, and transport infrastructure. ESIS Technical Committee TC21 Hydrogen Embrittlement and Transport of the European Structural Integrity Society (ESIS) Elsevier #hydrogenembrittlement #hydrogen #coating #mechanicalengineering #engineering #oilandgas #materials #energy

In 2024, advancements in corrosion control technologies have introduced innovative methods to protect materials across various industries. Here are ten notable technologies: 1. Smart Coatings: These advanced coatings are equipped with sensors & self-healing properties, enabling them to detect early signs of corrosion and autonomously repair damage, thereby extending the lifespan of structures and equipment. 2. Plasma Electrolytic Oxidation (PEO): PEO is an electrochemical surface treatment that generates oxide coatings on metals like aluminum, magnesium, & titanium. The process employs high potentials to create plasma discharges, resulting in thick, crystalline oxide layers that enhance wear and corrosion resistance. 3. Ionic Liquid Corrosion Inhibitors: Research has highlighted the potential of N⁺-containing ionic liquids as sustainable corrosion inhibitors for steel surfaces. These substances form effective barrier films, offering an eco-friendly alternative to traditional inhibitors. 4. Electrogalvanization: This process involves electroplating zinc onto steel to provide corrosion protection. The zinc layer acts as a sacrificial anode, preventing the underlying steel from corroding. Advancements in electrolyte compositions have improved the efficiency and effectiveness of this method. 5. Microbial Corrosion Inhibition: Utilizing specific microorganisms to form protective biofilms can inhibit corrosion. These biofilms consume oxygen and release antimicrobial compounds, creating a barrier that protects metal surfaces from corrosive elements. 6. Ultra-Low Fouling Coatings: Developed to prevent the adhesion of contaminants, these coatings are particularly beneficial in marine applications. They reduce biofouling on ship hulls, leading to improved fuel efficiency & reduced maintenance costs. 7.Cathodic Protection Systems: This technique involves making the metal surface to be protected the cathode of an electrochemical cell.It includes methods like galvanic protection,using sacrificial anodes, and impressed current systems, which apply external current to counteract corrosion. 8.ECTFE Coatings: Ethylene chlorotrifluoroethylene(ECTFE) is a fluoropolymer used as a protective coating due to its excellent chemical resistance and durability. It’s applied in industries like chemical processing and pharmaceuticals to protect equipment from corrosive substances. 9. Hybrid Cathodic Protection Systems: Combining galvanic and impressed current methods, these systems offer the restorative capabilities of impressed current systems with the reactive nature of galvanic anodes, providing efficient and adaptable corrosion protection. 10. Advanced Metallizing Techniques: Innovations in metallizing, such as thermal spraying of protective metal coatings, have enhanced corrosion management. These techniques provide robust barriers against corrosive environments, especially in industrial applications. #assetintegrity #corrosion #inspection

🚀 Exciting News from NC State! Our research team has developed a groundbreaking laser technique to create ultra-high temperature ceramics, such as hafnium carbide (HfC), more efficiently and with less energy. This innovation has significant impacts for industries requiring materials that can withstand extreme heat, such as aerospace and nuclear energy. Traditional methods involve heating materials in furnaces at temperatures above 2,200°C, which is time-consuming and energy-intensive. Our new approach uses a 120-watt laser to sinter a liquid polymer precursor in an inert environment, transforming it into solid ceramic without the need for such extreme conditions. This technique offers two main applications: 1. Coating: Applying ultra-high temperature ceramic coatings to materials like carbon composites. 2. 3D Printing: Creating complex ceramic structures layer by layer, enabling more versatile and precise manufacturing. This advancement not only streamlines the production process but also opens new possibilities for designing components that can endure extreme environments. For more details, read the full article here: https://lnkd.in/eE2Wh2TR #Innovation #MaterialsScience #NCStateResearch #AdvancedManufacturing

What if automotive coatings didn’t just protect against corrosion but actively improved how we join steels? That’s exactly the question we explored in our latest collaborative paper on galvannealed (GA) coatings and laser brazing of advanced high-strength steels (AHSS) published in the Journal of Materials Science & Technology (IF: 14.3)! Traditionally, coatings are seen as a challenge in joining structural materials because they diminish wettability, introduce porosity, and quite often, weaken the joint. But this recent study shows another side to the story. GA coatings, enriched with Fe, don’t just survive the weld-brazing process but they can enhance it by refining the joint microstructure, and contributing to stronger, more reliable joints. This shows that coatings can be actively engineered not just for corrosion resistance, but also as enablers of advanced manufacturing. Imagine coatings that protect the substrate and optimize joining which unlocks lighter, safer, and more efficient vehicles! Special thanks to Xiaoye Zhao for the invitation to contribute on this paper and congratulations to all the authors: Hanwen Yang, PhD, Emanuel Santos, Adrian Gerlich, and Y. Norman Zhou! Could “joining-friendly” coatings be the next frontier in automotive innovation? I’d love to hear your thoughts. For those interested, the full paper is here: https://lnkd.in/e3k92vSE   American Welding Society CWB Group Lincoln Electric and Lincoln Electric Canada IPG Photonics ArcelorMittal University of Waterloo Massachusetts Institute of Technology University of Calgary

Breakthrough in Corrosion Science: New Electrochemical Method Measures Polymer Coating Degradation in Real Time A Hidden Battle on Metal Surfaces Now Revealed with Greater Precision Corrosion beneath protective coatings has long posed a serious challenge in fields ranging from automotive to energy infrastructure. Now, researchers have developed a novel electrochemical technique to directly measure the degradation rate of polymer coatings on iron—offering a powerful tool to assess the durability of painted or coated metal surfaces without invasive sampling. This advancement sheds light on the early stages of failure caused by cathodic disbondment and promises improved longevity predictions for critical infrastructure. Understanding the Degradation Challenge • The Protective Role of Polymer Coatings: • Paint or polymer coatings act as barriers that prevent corrosive elements like oxygen and water from reaching metal surfaces. • These coatings are used extensively in applications like pipelines, marine structures, automobiles, and bridges. • The Problem of Cathodic Disbondment: • When coatings are scratched or contain manufacturing defects, they can fail prematurely due to a process called cathodic disbondment. • This occurs when oxygen and water infiltrate the coating, triggering the oxygen reduction reaction (ORR) at the buried metal interface. • The ORR generates reactive species that degrade the coating, leading to rapid corrosion underneath. • Challenges in Measuring Corrosion Rates: • Because the reaction occurs beneath a protective layer, traditional measurement techniques struggle to access the buried interface. • Techniques like potentiodynamic polarization require a counter electrode and can perturb the system, making real-world modeling difficult. Innovation in Electrochemical Sensing • Novel Electrochemical Technique: • The new approach circumvents limitations of traditional methods by enabling non-destructive measurement of the degradation rate at the metal-coating interface. • The method provides insights into the kinetics of the ORR without the need to remove or damage the protective coating. Why This Matters Corrosion costs the global economy billions of dollars annually, not just in repair but in lost productivity and environmental risk. This breakthrough offers a leap forward in predictive maintenance and materials engineering. By enabling accurate, non-invasive measurement of how fast coatings degrade, industries can prevent failures before they happen, reduce unplanned outages, and enhance safety across sectors. As infrastructure ages and environmental stressors increase, innovations like this one are essential to keeping our built environment resilient and secure. Black Rhino Protective Services BlackRhinoGroup.com Scaling now.