Carbon dot enhanced electrodeposited coatings for advanced early-stage corrosion sensing

Abstract

This work explores a novel approach for metal corrosion by integrating carbon dots (CDs) into electrodeposited (ED) coatings. We detail the synthesis and properties of CDs, making them suitable for corrosion detection. Characterization techniques like Fourier Transform Infrared Spectroscopy (FTIR), Scanning electron microscope (SEM), Energy Dispersive X-ray Analysis (EDX), Fluorescent Microscopy and Photoluminescence Spectroscopy (PL).A Design of Experiment (DOE) optimized parameters like CD concentration, curing temperature, and voltage for improved coating performance. The optimized conditions (0.4 wt% M-CDots, 165 °C curing, and 36.2 V) resulted in enhanced adhesion and corrosion resistance.CD-infused coatings demonstrated superior adhesion and mechanical stability compared to controls. Electrochemical tests confirmed a 10 % improvement in corrosion resistance and PL study demonstrated an approximately 60 % enhancement in emission intensity. The adhesion was not affected by introducing carbon dots to the coating. Monitoring the onset of metal corrosion on samples in salt spray cabinets was achieved through the use of a UV source. The photoluminescence of M-CDs offered real-time, non-destructive monitoring of early-stage corrosion through quenching in the presence of exposed metal surfaces.This research presents a significant advancement by integrating CD-based sensing into corrosion-resistant coatings, holding promise for various industries and leading to improved safety, reduced maintenance costs, and extended equipment lifespans. Notably, the biocompatible and disposable nature of CD-based sensors further enhances their practical application.