Effective Corrosion Protection Research Articles

The influence of pH electrolyte on the electrochemical deposition and properties of cerium oxide thin films

Thin cerium oxide layers cathodically deposited on zinc were studied. These electrochemically deposited coatings provide effective corrosion protection and require less deposition time compared to chemical conversion coatings. The kinetics of their formation depend on various factors, such as temperature, applied current density, electrolyte composition, pH, and agitation. In this study, the effect of bath solution pH was investigated, with coatings produced at room temperature from aqueous cerium nitrate solutions. Chronopotentiometry, linear sweep voltammetry, and electrochemical impedance spectroscopy (EIS) were used to monitor the deposition process, while scanning electron microscopy and energy-dispersive spectroscopy were performed to characterize the deposits. Corrosion resistance was evaluated through potentiodynamic tests in a 3.5% NaCl solution. The results indicate that the electrolyte pH significantly influences the cerium electrodeposition process. Based on the findings, the cerium oxide coating obtained from a pH 4 solution exhibited lower corrosion current density, higher polarization resistance, and superior anti-corrosion performance.

Enhanced Corrosion Protection of Printed Circuit Board Electronics using Cold Atmospheric Plasma-Assisted SiOx Coatings.

The miniaturization and widespread deployment of electronic devices across diverse environments have heightened their vulnerability to corrosion, particularly affecting copper traces within printed circuit boards (PCBs). Conventional protective methods, such as conformal coatings, face challenges including the necessity for a critical thickness to ensure effective barrier properties and the requirement for multiple steps of drying and curing to eliminate solvent entrapment within polymer coatings. This study investigates cold atmospheric plasma (CAP) as an innovative technique for directly depositing ultrathin silicon oxide (SiOx) coatings onto copper surfaces to enhance corrosion protection in PCBs. A systematic investigation was undertaken to examine how the scanning speed of the CAP deposition head impacts the film quality and corrosion resistance. The research aims to determine the optimal scanning speed of the CAP deposition head that achieves complete surface coverage while promoting effective cross-linking and minimizing unreacted precursor entrapment, resulting in superior electrical barrier and mechanical properties. The CAP coating process demonstrated the capability of depositing SiOx onto copper surfaces at various thicknesses ranging from 70 to 1110 nm through a single deposition process by simply adjusting the scanning speed of the plasma head (5-75 mm/s). Evaluation of material corrosion barrier characteristics revealed that scanning speeds of 45 mm/s of the plasma deposition head provided an effective coating thickness of 140 nm, exhibiting superior corrosion resistance (30-fold) compared to that of uncoated copper. As a proof of concept, the efficacy of CAP-deposited SiOx coatings was demonstrated by protecting an LED circuit in saltwater and by coating printed circuits for potential agricultural sensor applications. These CAP-deposited coatings offer performance comparable to or superior to traditional conformal polymeric coatings. This research presents CAP-deposited SiOx coatings as a promising approach for effective and scalable corrosion protection in miniaturized electronics.

Achieving a super-strengthening functional composite coating from ZnO doped snail shell particulate for mitigation of mild steel towards improved microstructural, corrosion, and opto-electrical properties

Long-lasting protective coatings are essential, particularly under harsh operating conditions. Surface coatings provide a flexible alternative; electrodeposition is becoming an established approach for protecting steel. The intent of this study is to determine how effectively zinc oxide (ZnO) coatings for mild steel corrosion protection effect when integrated with snail shell particle (SSP). The experimental setup consisted of producing a coating bath with ZnO and SSP particles, then electrodeposting the mixture under conditions onto polished steel surfaces. The created coatings were subjected to an array of tests, including electrical conductivity and resistivity testing, morphological analysis using SEM/EDS, corrosion testing in a 1M HCl solution, hardness testing. The findings show that when SSP content increases, steel corrosion rates significantly decrease, suggesting improved corrosion resistance from 21.85(mm/yr) to 12.80(mm/yr), and polarization resistance of 4.47E+01(Ω) to 8.00E+01(Ω). Morphological examination shows that SSP particles are dispersed throughout the coating matrix, which promotes adhesion and stability. Also, coatings with more SSP show better electrical characteristics. Overall, the study shows how ZnO-SSP coatings can shield mild steel components from adverse conditions and have prospective uses in sectors where surfaces resistant to corrosion are needed.

Anticorrosion properties of flavonoids for rust-free building materials: a review

Abstract Rust-free building materials are crucial for ensuring the durability and structural stability of constructions. Corrosion, a widespread issue affecting metals like steel, copper, and concrete, can be effectively managed with the help of corrosion inhibitors. One effective method for corrosion inhibition involves the application of corrosion-inhibiting coatings, which form resilient and tightly adherent films on metal surfaces. Flavonoids, renowned for their diverse biological activities, demonstrate significant anticorrosive properties. They contain beneficial compounds such as antioxidants and chelating agents. The efficacy of plant extracts as corrosion inhibitors is influenced by their organic constituents, particularly phenols and flavonoids. Flavonoids act by creating a protective film that serves as a barrier, shielding the metal surface from corrosive agents and limiting their access to the metal. This contributes to the prevention of corrosion. The integration of flavonoids into building materials has the potential to transform corrosion prevention practices, leading to improved durability, reduced maintenance costs, and a more environmentally friendly built environment. This article explores the promising prospects of flavonoids as an innovative and sustainable approach to corrosion prevention in building materials. Additionally, it aims to stimulate further research endeavors, fostering the development of effective and eco-friendly corrosion protection strategies for the construction industry.

Preparation and corrosion behavior of MAO based MOFs coatings with excellent film-forming and adhesion properties

Magnesium (Mg) alloys can be applied in many fields, but their poor corrosion resistance limits their widespread applications. Metal-organic frameworks (MOFs) are often used as fillers in the field of corrosion protection due to their poor adhesion. In order to improve the film-forming performance and adhesion of MOFs coatings, and enhance the corrosion resistance of AZ31 Mg alloys, various MOFs coatings were prepared on the Mg alloy micro-arc oxidation (MAO) coating. The results demonstrated that the MAO facilitated film-forming of MOFs and enhanced their adhesion. Moreover, MOFs crystals can seal the pores of MAO, capture corrosive ions, and form insoluble chelates, significantly improving the corrosion resistance of Mg alloys. Among them, the Ce-MOF exhibited the highest corrosion resistance and the lowest corrosion rate, with a corrosion current density of 8.68 × 10−8 A/cm2 after immersing for 30 min. Moreover, MOFs coatings exhibited good stability and durability, and even after immersing in 3.5 wt% NaCl solution for 14 days, their corrosion protection effects were still superior than MAO.

A purine derivative for the modulation of the corrosion behavior of nickel aluminum bronze in seawater: a comprehensive and in-depth investigation on the corrosion inhibition mechanism

6-mercaptopurine (SMP), recognized for its biological activity, is investigated for its corrosion inhibition mechanism on nickel-aluminum bronze (NAB) in seawater, demonstrating a high efficiency of 99.6%. The physical adsorption of SMP on the NAB surface contributes to the multilayer structural arrangement of SMP. The Cu+-SMP complex is generated on the surface of NAB, which possesses a corrosion protection effect. SMP alters the semiconductor properties of corrosion product layer and reduces the carrier concentration. SMP can adsorb better on uncorroded NAB surfaces. This study holds significant importance in unraveling the mechanisms behind the corrosion behavior of NAB surfaces regulated by SMP.

Facile fabrication of slippery liquid infused porous surface with self-repairing mesoporous structure and slippery attributes for magnesium alloy corrosion protection

The slippery liquid infused porous surface (SLIPS) with excellent anti-corrosion properties have been widely reported in recent years. Unfortunately, most of the previously reported SLIPS struggles to provide long-term effective corrosion protection for magnesium (Mg) alloys owing to the lack of effective mesoporous structure self-repairing capability. Herein, a SLIPS with a self-repair microstructure and slippery attributes was fabricated, which consisted of a MnOOH layer and a superhydrophobic active carbon/hydroxyl-modified hexagonal boron nitride (AC/BNO) coating. The abundant mesoporous structure of the AC favors the formation of a dense lubricant layer on the SLIPS. The addition of BNO as a two-dimensional filler creates a “labyrinth effect” within SLIPS, which enhances its overall corrosion resistance. In addition, MnOOH offers a self-repair microstructure and slippery attribute ability for SLIPS. Once the SLIPS is damaged, the damaged area undergoes structural and slippery attributes repair through the spontaneous reaction of MnOOH with Mg2+ and OH− to form Mn-Mg layered double hydroxides (LDH) with mesoporous structure for restoration. Moreover, the SLIPS not only exhibited excellent mechanical stability and anti-contamination performance, but electrochemical experiments also indicated that the corrosion protection efficiency of both the original and self-repaired SLIPS was greater than 99 %, demonstrating excellent corrosion resistance. Therefore, compared with traditional SLIPS, this study not only utilizes AC as storage container to avoid the complex mesoporous structure preparation process but also provides new insights for the sustainable development of SLIPS by regenerating new mesoporous structures and restoring the slippery attributes.

Investigating the Synergistic Corrosion Protection Effect of an Alloy Element and Corrosion Inhibitor on Steel Reinforcement Using Machine Learning and Electrochemical Impedance Spectroscopy

Steel reinforcement in marine concrete structures is vulnerable to chloride-induced corrosion, which compromises its structural integrity and durability. This study explores the combined effect of the alloying element Cr and the smart corrosion inhibitor LDH-NO2 on enhancing the corrosion resistance of steel reinforcement. Employing a machine learning approach with a support vector machine (SVM) algorithm, a predictive model was developed to estimate the polarization resistance of steel, considering Cr content, LDH-NO2 dosage, environmental pH, and chloride concentration. The model was rigorously trained and validated, demonstrating high accuracy, with a correlation coefficient exceeding 0.85. The findings reveal that the addition of Cr and application of LDH-NO2 synergistically improve corrosion resistance, with the model providing actionable insights for selecting effective corrosion protection methods in diverse concrete environments.

A novel strategy for constructing active anti-corrosive coatings by embedding three-dimensional fiber networks

The corrosion protection effectiveness of micro/nanocontainer-based intelligent coatings significantly depends on their dispersion within the coating matrix. Inspired by the bionic concept of a ‘vascular network’ we designed a polylactic acid (PLA) three-dimensional fiber network incorporating the pH-responsive TiO2-8-hydroxyquinoline (TiO2-8HQ) nanotubes using electrospinning technology. These TiO2-8HQ@PLA networks are crosslinked and evenly dispersed on the Mg alloy surface, responsive to local pH variations. The encapsulated 8HQ inhibitors release rapidly in alkaline conditions, transporting through the network to enable continuous self-healing in multi-defect areas. An epoxy coating applied over the network forms a novel vascular network intelligent coating. Electrochemical and surface analysis tests reveal that 2 %TiO2-8HQ@PLA-EP provides the most enduring corrosion resistance over 50 days in a 3.5 wt% NaCl solution, with a coating resistance of 2.33 × 106 Ω cm2 and charge transfer resistance of 4.81 × 106 Ω cm2. Additionally, the network enhances adhesion strength (38.01 MPa) and surface wettability (104.25° ± 0.15°), significantly improving the coating’s physical barrier performance. The combination of the micro/nanocontainers technology and vascular network innovative design provides a unique insight into active corrosion control on diverse metals.

Self-Healing Performance of Cellulose-Based Gel Coating with Highly Loaded Hybrid Inhibitor

The self-healing performance of an ethyl-cellulose-based gel coating with different corrosion inhibitors was investigated in this work. Various contents of 11 alkyl imidazoline (IMO-11) were pre-loaded into the gel coating. The EIS results of scratched coatings with inhibitors confirmed the self-healing performance of the coating. As the inhibitor contents increased, the improved self-healing effect was attributed to inhibitor release, while the increased inhibitor content would also affect the film-forming ability and mechanical properties of the composite coating, and lead to the accelerated failure of the coating. Different contents of thiourea and sodium oleate were added to the gel coating with 25% IMO-11. It was hoped that the hybrid inhibitor in the coating would obtain the synergistic effect of different inhibitors during the self-healing progress. The SEM and FT-IR results indicate the hybrid inhibitor was successfully loaded into the gel coating. The EIS and morphology results of scratched coatings confirmed the enhance effect of the synergistic inhibitor on the self-healing performance of the coating. The high content of the hybrid inhibitor could enhance the corrosion protection effect of the intact gel coating. Once the coating is damaged, the fast released inhibitor could extend the corrosion protection time. The synergistic effect difference of thiourea and sodium oleate with IMO-11 did not show much difference in the coating self-healing effect in this work.

The Synergistic Effect of Graphene Oxide in Epoxy Resin on Photocured Coating Films with Anticorrosion and Antibacterial Properties.

In this work, graphene oxide (GO) and epoxy-functionalized graphene oxide (GOSi) are chosen as additives and incorporated into epoxy resin (EP) for nanocomposite photo-coating films (GO/EP and GOSi/EP series). Compared to GO/EP, the GOSi/EP nanocomposite demonstrates strong binding and excellent dispersibility, highlighting covalent bonding between GOSi and the epoxy coating. Furthermore, GOSi/EP-based films demonstrated superior thermal stability and adhesion performance on galvanized steel plates. The corrosion performance of the coated galvanized steel is investigated using electrochemical impedance spectroscopy (EIS) and polarization curve analysis (Tafel). The effectiveness of corrosion protection is evaluated based on a combination of photoreactivity, crosslinking density, dispersity, and adhesion properties. Out of all the treated films, the film based on 0.1GOSi/EP exhibited the highest percentage of inhibition (98.89%) and demonstrated superior long-term anticorrosion stability. In addition, the 0.1GOSi/EP based formulation showed remarkable antibacterial activity against S. aureus, resulting in a 92% reduction. This work demonstrates the development of a facile, environmentally friendly functionalized graphene oxide/epoxy photocured film with superior dual functionalities in both anticorrosion and antibacterial properties. These advancements hold promising potential for impactful practical applications.

Study of the corrosion protection effect of the new composition based on gossypol resin in the hydrogen sulfide formation water

We investigated the impact of a new composition (HS-1) composed of gossypol resin and IB-1 reagent taken in the ratio of 3:1 on the corrosion rate in the hydrogen sulfide formation water under laboratory conditions. Concentrations of 20, 40, 60 and 80 mg/l of the new composition were used. The formation water sample taken from well No. 1082 of "Bibiheybatneft" OGPD, SOCAR was used as an corrosion medium. The corrosion effects were also investigated at the concentrations of 50, 100, 150 and 200 mg/l of gossypol resin and 10, 15, 20 and 25 mg/l of IB-1 inhibitor. When the concentration of gossypol resin in the formation water increased by 50–200 mg/l, the corrosion protection effect took a value in the range of 60–82%. When the concentration of IB-1 inhibitor varied between 10–25 mg/l in a hydrogen sulfide medium, the protection effect was between 65–90%. Increasing the concentration of new HS-1 composition in the range of 30–80 mg/l resulted in an increase in its corrosion protection effect between 74–98%. It was found that the optimal consumption rate of gossypol resin, IB-1 inhibitor and HS-1 composition for corrosion protection in an aggressive medium with hydrogen sulfide was 200 mg/l, 25 mg/l and 80 mg/l, respectively.

Improving the Corrosion Resistance of Anodized Al 1050 Alloy by Sealing in Cerium-Containing and Mixed Sodium Phosphate Mono Basic and Calcium Nitrate Solutions

This investigation presents results on the improvement of the corrosion-protective effect of consecutive sealing treatments of anodized Al 1050 (AlAnod). The treatments were performed in cerium-containing and mixed NaH2PO4 + Ca(NO3)2 solutions. The changes of the surface morphology, structure and chemical composition, chemical state of the elements, and basic corrosion parameters of the studied systems were investigated by SEM, EDXS, XRD, XPS, and a complex of electrochemical techniques (PDP, EOCP vs. timeplot, chronoamperometric transients, Rp and CR at EOCP, etc.). The results obtained show that the basic components of the obtained sealing conversion layers (before and after exposure to model Cl−-containing corrosion media) are characterized by Ca10(PO4)6(OH)2, AlO(OH), CePO4, and CeAlO3 (after the corrosion tests, they are converted to insoluble Me-PO3 and Me-P4O10). We conclude that the observed decrease in the corrosion rate of Al and the corresponding increase in the polarization resistance are accomplished by the two-step sealing treatment, which fills up the AlAnod pores with insoluble deposits.

Detection and Analysis of Corrosion on Coated Metal Surfaces Using Enhanced YOLO v5 Algorithm for Anti-Corrosion Performance Evaluation

This study addresses the severe corrosion issues in the coastal regions of southern China by proposing an improved YOLO v5-GOLD-NWD model. Utilizing corrosion data from the National Center for Materials Corrosion and Protection Science of China, a dataset was constructed for metal-surface corrosion under different protective coatings. This dataset was used for model training, testing, and comparison. Model accuracy was validated using precision, recall, F1 score, and prediction probability. The results demonstrate that the proposed improved model exhibits better identification precision in metal corrosion detection, achieving 78%, a 4% improvement compared to traditional YOLO v5 models. Additionally, through identification and statistical analysis of corrosion image datasets from five types of coated metal specimens, it was found that powder epoxy coating, fluorocarbon coating, epoxy coating, and chlorinated rubber coating showed good corrosion resistance after 24 months of exposure. Conversely, Wuxi anti-fouling coating exhibited poor corrosion resistance. After 60 months of natural exposure, the powder epoxy coating specimens had the highest corrosion occurrence probability, followed by chlorinated rubber coating and epoxy coating, with fluorocarbon coating showing relatively lower probability. The fluorocarbon coating demonstrated relatively good corrosion resistance at both 24 and 60 months of exposure. The findings of this study provide a theoretical basis for enhancing the corrosion protection effectiveness of steel structures in coastal areas.

Simultaneously Regulating Electrochemical Corrosion Behavior and Wettability of Magnesium-Neodymium Alloy by Self-Layered Chemical Conversion Coating.

Rapid corrosion in aqueous solutions of magnesium alloys is one of the major obstacles to their wide application, and coating plays a crucial role in their corrosion protection. Recently, protection- and function-integrated coatings have attracted much attention in the research field of magnesium alloys. In this work, a simple chemical conversion process is proposed to fabricate a composite coating on a magnesium-neodymium alloy through immersion in an aqueous solution made of Ca(OH)2 and NaHCO3. After the immersion process, a coating consisting of two spontaneously formed layers is acquired. The top flower-like layer is composed of Mg5(OH)2(CO3)4∙4H2O, Mg(OH)2 and CaCO3, and the inner dense layer is speculated to be Mg(OH)2. Electrochemical impedance spectroscopy, polarization tests, and hydrogen evolution are combined to evaluate the corrosion resistance in simulated body fluid, simulated seawater solution, and simulated concrete pore solution, which reveals that the coated sample has better corrosion resistance than the uncoated one. After the coated sample is modified with fluorinated silane, a water-repellent surface can be achieved with an average water contact angle of 151.74° and a sliding angle of about 4°. Therefore, our results indicate that effective corrosion protection and potential self-cleaning ability have been integrated on the surface of the magnesium alloy in this study. In addition, the formation mechanism of the self-layered coating is discussed from the viewpoint of the interaction between the substrate and its external solution.

Effect of Voltage and concentration of polyetherimide on surface morphology and corrosion properties of AZ91D by electro-spin coating

Magnesium alloys, particularly AZ91D, exhibit promising mechanical properties but are susceptible to corrosion, limiting their widespread industrial applications. This manuscript investigates the impact of voltage and concentration of Polyetherimide (PEI) on surface morphology and corrosion characteristics of AZ91D through electro-spin coating. PEI, known for its high strength and corrosion resistance, is applied using an eco-friendly electro-spin coating method. The study optimizes polymer concentration and applied voltage to enhance the anticorrosive properties of AZ91D. Atomic force microscopy (AFM) and scanning electron microscopy (SEM) reveal the morphological alterations, while electrochemical corrosion tests provide insights into the corrosion resistance. The results show that a moderate PEI concentration (15 %) at 14 kV voltage exhibits the most favorable corrosion resistance, emphasizing the need to optimize both parameters for enhanced protection of AZ91D against corrosion. The results contribute to developing economical and effective corrosion protection techniques for magnesium alloys, mainly for automotive applications.

Ab initio exploration of modified carbon nanotubes as potential corrosion inhibitors

In order to develop novel unexplored potential corrosion inhibitors, covalently modified single-walled carbon nanotubes (SWCNT) via benzoic (–PhCOOH) and aniline (–PhNH2) groups are being investigated as corrosion inhibitors for the first time. Utilizing a comprehensive approach, this study employed density functional theory (DFT), Monte Carlo (MC), and molecular dynamics simulations (MD) to assess the adsorption behavior of modified nanotubes as corrosion inhibitors on the Cu(111) surface within a simulated aqueous HCl corrosion medium. The results provided molecular information on the adsorption capability, geometry adsorption centers, and adsorption energies (Eads) of carbon nanotubes on the surface of Cu(111). The adsorption energy values unveiled robust interactions between SWCNT–PhCOOH and SWCNT–PhNH2 inhibitors and the Cu(111) surface, suggesting a highly effective corrosion protection mechanism. The calculated Eads values exhibited notable ranges, spanning from –260.82 to –308.18 kcal/mol for SWCNT–PhCOOH and –220.92 to –261.01 kcal/mol for SWCNT–PhNH2 with the maximum probability values, representing the most favorable adsorption scenarios, determined to be –292.96 and –229.39 kcal/mol, respectively. A key insight from Monte Carlo simulations underscored the inherent spontaneity of the adsorption process, corroborated by the consistently negative Eads values. These findings collectively underscore the substantial affinity of the inhibitors to the copper surface, contributing to a deeper comprehension of their corrosion inhibition capabilities.

Durable slippery liquid-infused porous surfaces for effective corrosion protection of aluminum alloy in ethylene glycol-water solutions

Aluminum (Al) alloys are extensively utilized in liquid-cooling heat dissipation systems owing to their superior strength-to-weight performance, ease of processing, and high thermal conductivity. However, they are susceptible to corrosion in the cooling medium, such as ethylene glycol-water solutions. This study presents a straightforward and cost-effective method to create a slippery liquid-infused porous surface (SLIPS) designed to effectively prevent corrosion of the 6061 Al alloy in ethylene glycol-water solutions. Micro/nano hierarchical structures were achieved on the SLIPS through plasma electrolytic oxidation and hydrothermal treatment. Following the modification of low-surface-energy materials and the infusion of silicone oil, the SLIPS exhibited an outstanding slippery property, allowing ethylene glycol-water droplets to effortlessly slide down the inclined surface at an angle of 1.1°. Additionally, the SLIPS demonstrated remarkable anti-corrosion performance against ethylene glycol-water solutions, with a minimum corrosion current density (Icorr) of 2.4 × 10−10 A·cm−2. Crucially, long-term immersion test results on corrosion resistance revealed that the SLIPS provided reliable corrosion protection for the 6061 Al alloy, exhibiting an Icorr increased by 4 orders of magnitude compared to a smooth substrate. These findings hold significant potential for advancing the widespread application of SLIPS in liquid-cooling heat dissipation systems.

Exploring Sustainable Coating Solutions for Applications in Highly Corrosive Environments

To protect carbon steel from degradation via corrosion, it is usually coated using a multilayer system of paints composed of petroleum-based polymers. The chemical industry is currently moving towards more sustainable chemistry, in which one of the main objectives is to reduce fossil fuel use and the derived raw materials. However, the replacement of petroleum-based raw materials with those that are bio-based is not straightforward since the properties of these new materials are often inferior to the traditional ones. One of the most used resins in primer paints is Diglycidyl ether bisphenol A (DGEBA). This is an epoxy resin synthesized from bisphenol A (BPA), a toxic and carcinogenic petroleum-based compound. This study investigates the substitution of the primer coating in a three-layer coating system with two different types of primer coating formulations, one which is partially bio-based and another that is BPA-free. The corrosion protection effectiveness of these sustainable coatings is assessed not only at the laboratory scale but also in real offshore conditions. Moreover, the adhesion of the different coating systems is evaluated before and after each ageing test. The results reveal that these novel coatings exhibit comparable performance to conventional paints while providing a more sustainable corrosion protection alternative.

Co-electrodeposition of superhydrophobic NiCo/CeO2 coating with hierarchical nano/micro structure for corrosion protection of plain carbon steel

This study aimed to develop an effective corrosion protection strategy for carbon steel by employing a superhydrophobic NiCo coating modified with CeO2 nanoparticles through the co-electrodeposition method. The superhydrophobicity was achieved by adjusting the composite coating's morphology and surface roughness. The synergistic impact of CeO2 and EDA crystal modifier on the coating's morphology, composition, topography, corrosion protection performance, and wetting properties was systematically investigated. The SEM results revealed the formation of a flower-like nano/micro morphology in the presence of EDA, and this morphology was preserved with the addition of 4 g/L CeO2 into the electrolyte. Surface wettability was significantly influenced by the hierarchical nano/micro structure of the deposited coating, with an enhanced superhydrophobicity observed in the presence of CeO2. The increase in surface roughness and compaction, achieved by incorporating CeO2 nanoparticles into the hierarchical structure of the NiCo coating, played a pivotal role in creating a superhydrophobic surface. Furthermore, polarization and EIS tests demonstrated that the superhydrophobic NiCo-EDA/CeO2 coating exhibited excellent anti-corrosion performance for the carbon steel substrate. In this case, Ecorr shifted towards positive values, icorr decreased, and both charge transfer resistance and coating resistance showed a considerable increase compared to other studied coatings. The alteration of metal wettability to a superhydrophobic state, combined with the barrier role of the coating and the presence of ceramic reinforcements (CeO2), offers comprehensive protection to the steel substrate. This approach holds great promise for effectively controlling the corrosion rate of widely used engineering metals.