Magnetically controlled interface weaving of dual-layer heterogeneous coatings with active and passive anti-corrosion protection

Abstract

Polydimethylsiloxane (PDMS) elastomer exhibiting remarkable corrosion resistance and fouling release properties. However, their performances are often compromised due to the weak interfacial adhesion with rigid substrates. Herein, we have developed an innovative dual-layer heterogeneous coating via magnetic-controlled interface weaving technology, achieving a seamless integration of PDMS with a rigid epoxy (EP) substrate. Magnetic nanoparticles (Fe3O4@MPDA-MBT) were strategically incorporated into the coating system, guided by a magnetic field to facilitate their interfacial migration. This controlled migration of nanoparticles resulted in the formation of interface layer between the EP primer and PDMS topcoat, leading to a sharp increase in PDMS adhesion strength (3.0 MPa), which is over 7 times greater than that of control counterpart (0.4 MPa). Additionally, Fe3O4@MPDA-MBT were selectively enriched adjacent to the metal substrate, thereby endowing the coating with outstanding corrosion resistance, due to the quick releasing of enough MBT inhibitors, as confirmed by electrochemical tests with high corrosion resistance value (2.2 × 108 Ω·cm2). Also, the topcoat PDMS enabled the dual-layer heterogeneous coating to achieve fouling-release and cavitation resistance.