Polymer Composite Coatings Research Articles

Styrene-butadiene-styrene-based nanocomposites as self-healable antibacterial coatings

This study presents the development of self-healing antibacterial polymeric composite coatings to minimize infection risks and ensure adaptability for large spaces by using readily available materials and scalable, efficient fabrication techniques. These coatings were prepared by incorporating 300–400 nm solid silica particles capped with a polydopamine layer of ~40 nm thickness and decorated with silver nanoparticles within a styrene-butadiene-styrene matrix. The aqueous dispersion of filler particles upon exposure to near-infrared 808 nm light exhibits a temperature increase of ~15 °C caused by the photothermal activity of polydopamine in synergy with silver nanoparticles. This photothermal activity of fillers helps to achieve the complete healing of micron-sized scratches of nanocomposite films with light intensities as low as 1.19 W/cm2 over 10 min (total energy fluence of 716 J/cm2), demonstrating promising results for real-world applications. Additionally, the coatings exhibit significant enhancement in antibacterial activity, reducing bacterial colony counts by >99.9 %. These findings underscore the potential of such coatings to reduce the risk of pathogenic infections in clinical settings while offering sustainable and eco-friendly solutions.

Experimental analysis of polymer-composite coated steel components under quasi-static loading

In recent years, there has been new interest in understanding the mechanical failures of the polymer-composites used for fairing the hull and the superstructure of large vessels. There aren’t any background studies looking into the failures of these thick coated structures and this study is attempting to bridge the gap in research by studying the monotonic flexural behaviour of these structures to investigate the reasons for its failures. The objective is to study the monotonic flexural behaviour of three popular particulate composite materials used as coatings on megayacht vessels and obtain an initial understanding of their behaviour and interaction with the steel substrate. The methods presented are both analytical and standard testing procedures for the examination of the flexural stress-strain response of the thick polymer-composite coated steel specimens. The results of this work suggest that different failure mechanisms have been observed in the three examined coating systems. It has been shown that the experimental data suggested no significant interaction between the steel and the polymer-composite material. The findings suggest that it is possible to enlarge the design space of the polymer-composite coatings by reducing the applied thickness of the materials. Results also have shown that the presence of voids cause reduction in strength by 20% and reduction in deformation by 30%. The study concluded to a two-step methodology involving analytical and experimental methods investigating the mechanical response of composite polymers applied on hull and superstructure substrates which is presented for the first time in this paper.

Review on Superhydrophobic Polymer Composite Coating Materials and its Coating Technology for Advanced Applications

ABSTRACT Researchers all over the world are working to produce improved polymeric materials suitable for cutting-edge advanced applications that will eventually replace traditional materials. Polymeric materials that display super hydrophobic characteristics are quite valuable and interesting when it comes to the development of things with lotus leaf surface effects. In recent decades, super hydrophobic surfaces (SHS) have been considered as key parameter, and superhydrophobic coatings are vital to achieve materials with hydrophobic surface. The most crucial criteria influencing super hydrophobic surfaces are low surface free energy and higher surface roughness. Explorations on superhydrophobic surfaces (SHS) are very interesting because of their importance in varied nature of industrial, engineering and bio-medical applications. Superhydrophobic membranes have made a lot of curiosity recently, especially for efficient oil-water separation application. A major exploitation of these SHS is to increase the corrosion resistance of surfaces exposed to corrosive environments as well as their long-term chemical stability and maintaining the superhydrophobic characteristics. The other major important sectors utilize these materials to achieve ultra-superhydrophobic behavior are space and aerospace, defense, automotive, marine, water-oil separation, biomedical-engineering, and sensors. Superhydrophobic surfaces repel water primarily due to their surface texture and physicochemical properties. The present article deals with the basic and fundamental principles, importance and applications of superhydrophobic behavior of materials, including different analytical and fabrication techniques used to study and to ascertain the super hydrophobic properties of the materials.

Advances in interfacially engineered surface‐functionalized fillers for multifunctional polymer composite coatings

AbstractThe demand for multifunctional, high‐performance materials has driven advancements in surface‐functionalized fillers for polymer composite coatings. Despite progress, integrating multiple protective properties within a single hybrid formulation remains a challenge. This review explores recent developments in surface and interfacial engineering of biosourced fillers, including nanocellulose, and 2D materials like graphene oxide, MXenes, and layered double hydroxides, all of which have the potential to enhance the chemical resistance, mechanical strength, and thermal stability of polymer coatings. Key strategies include physical/chemical surface treatments, nanostructuring, and multiscale engineering to optimize cohesion, adhesion, and multivalent interactions among fillers, matrices, and substrates. The role of computational modeling in performance prediction and optimization is also discussed. The review concludes with current challenges and future directions, highlighting the importance of surface functionalization and interfacial engineering in developing next‐generation, multifunctional, and protective polymer coatings.Highlights Functionalized fillers boost polymer coatings' performance. 2D nanomaterials enhance coatings' resistance to corrosion, wear, and fire. Bio‐based fillers offer sustainable solutions for lightweight, robust coatings. Advanced interfacial engineering improves adhesion and coating durability. Modeling accelerates coating design by predicting interfacial interactions.

Temperature dependences of the electrochemical parameters of adaptive composite polymer coatings during long-term exposure in corrosive media

Temperature dependences of the electrochemical parameters of adaptive composite polymer coatings during long-term exposure in corrosive media

Polymer Composite Coatings Enhanced with Superhydrophobic Properties for Flexible Electronics Applications: A Review

ABSTRACT Flexible electronics have revolutionized various industries by offering lightweight and conformable solutions for diverse applications. However, their vulnerability to environmental factors, particularly moisture, remains a critical challenge. Polymer composite coatings enriched with superhydrophobic properties have gained considerable attention as a promising solution to safeguard flexible electronics. The present research report is a comprehensive review of the recent advancements in the development and application of superhydrophobic polymer composite coatings in flexible electronics, highlighting its potential applications in sensors and EMI shielding. The improvement in superhydrophobic characteristics hinges upon the choice of materials, fabrication techniques, surface morphology, and topographical features. This review article elaborates on the selection criteria for various organic and inorganic fillers suitable for polymers possessing innate hydrophobic or conducting properties. The different materials used as fillers in polymer matrix for fabricating superhydrophobic coating, the factors affecting the superhydrophobic properties of surfaces, and the superhydrophobic properties of fabricated surfaces using different materials have been reported.

Elaboration and investigation of formulated polymer composites as some potential anticorrosion coatings for brass surface in 3.5% NaCl solution: theoretical approaches

ABSTRACT Polymer composite derivatives [(TGEMM/MDA/0%, TGEMM/MDA/6%, TGP/MDA/0%, and TGP/MDA/6%)] were elaborated through using tetraglycidyl ether of methyl-α-D-mannopyranoside (TGEMM) and 2,3,4,5-tetraglycidyloxy pentanal (TGP) as matrices, methylene dianiline (MDA) as curing agent and glass system (1-x) (2Bi2O3 - B2O3) - x BaO (with x = 0% and 6%) as filler. Different composites prepared were investigated as some potential anticorrosive protection coatings for brass electrode in sodium chloride medium (3.5% NaCl). Polymer composite coatings were characterized using FTIR spectroscopy, SEM/EDS, EFM, PDP, and EIS techniques. The anticorrosive protection efficiencies increase with increasing charge incorporated in composites, in the following order: TGP/MDA/0% < TGEMM/MDA/0% < TGP/MDA/6% < TGEMM/MDA/6% and the later achieving a maximum of 90.67% (EFM), 95.45% (PDP), and 97.86% (EIS), respectively. SEM/EDS characterization suggests a smooth surface in the presence of composite derivatives, which is more significant in the presence of TGEMM/MDA/6%. DFT calculations and MD simulations confirm the data obtained by experimental study and offer insights into its structural properties.

Waterborne Intumescent Fire-Retardant Polymer Composite Coatings: A Review.

Intumescent fire-retardant coatings, which feature thinner layers and good decorative effects while significantly reducing heat transfer and air dispersion capabilities, are highly attractive for fire safety applications due to their effective prevention of material combustion and protection of materials. Particularly, the worldwide demand for improved environmental protection requirements has given rise to the production of waterborne intumescent fire-retardant polymer composite coatings, which are comparable to or provide more advantages than solvent-based intumescent fire-retardant polymer composite coatings in terms of low cost, reduced odor, and minimal environmental and health hazards. However, there is still a lack of a comprehensive and in-depth overview of waterborne intumescent fire-retardant polymer composite coatings. This review aims to systematically and comprehensively discuss the composition, the flame retardant and heat insulation mechanisms, and the practical applications of waterborne intumescent fire-retardant polymer composite coatings. Finally, some key challenges associated with waterborne intumescent fire-retardant polymer composite coatings are highlighted, following which future perspectives and opportunities are proposed.

Assessment of the synergy of hydrophobicity and thermal conductivity in epoxy/graphite oxide composite coatings

AbstractIn various industrial applications, especially within the internal pipes of heat exchanger devices, there is a crucial need for surface coatings that offer both superhydrophobic properties and high thermal conductivity. Achieving the balance between these two characteristics is essential for optimizing heat transfer performance along metal pipe walls and mitigating the formation of water droplets on the surface. This research focuses on the development of polymer composite coatings to address these dual requirements, providing protection against humid environments, resistance to dew formation, and simultaneous enhancement of thermal conductivity. The key challenge lies in selecting a coating type that provides low surface energy and polarity, thereby achieving the desired hydrophobic properties while also maintaining adequate thermal conductivity. This study formulates polymer composite coatings utilizing laser‐modified epoxy resin and strategically integrates graphite oxide particles. These graphite particles undergo modification through oxidation to enhance compatibility with epoxy. In conjunction with graphite oxide modification, the resulting laser‐modified coatings exhibit super‐hydrophobic characteristics with an enhanced water contact angle of 162° and a low contact angle hysteresis (&lt;5°). Furthermore, the epoxy/graphite oxide composite coatings demonstrate improved thermal conductivity, marking a significant 261% increase compared to pure epoxy, elevating it from .234 to .846 W/mK.

Tunable Dual Self-Healing Composite Coatings with Self-Assembled Structures Regulated by Janus Nanoparticles.

The durability of concrete structures can be enhanced in a convenient and permanent manner through the surface protection of cementitious materials with composite polymer coatings. However, polymer coatings are susceptible to various mechanical and physical deterioration in complex and variable environments. In this paper, the theory of polymer microstructure regulation was employed to improve the sustainability of the protective performance of composite coatings. The self-assembled core-shell structure regulated by amphiphilic Janus nanoparticles is employed to modify the tunable polystyrene acrylate-polysiloxane self-healing coatings. The results demonstrate that the adhesion strength of the prepared self-assembled coating reached 3.7 MPa, which is sufficient to resist the damage to the microstructure of cementitious materials caused by physical erosion, seepage, and ionic corrosion. The self-healing coating, regulated by Janus particles, exhibited a residual creep of only 57.03% and a maximum loss angle tangent of 0.381. Furthermore, the material exhibited a superior shape memory function due to the presence of strong hydrogen bonding. The regulated self-healing coating repaired the polymer structural damage under mechanical and thermal deformation by bridging and filling effects. The coating demonstrated a tensile strength recovery of up to 71.23% in a wetted state, accompanied by a rapid restoration of its electrochemical properties and corrosion resistance. Furthermore, the self-healing emulsion penetrates the substrate defects and forms numerous polymer crystalline particles that effectively fill the microcracks.

Polymer transfer film formation from cryogenic to elevated temperatures

This study reports on the tribological performance of aromatic thermosetting co-polyester (ATSP) and polyether ether ketone (PEEK)-based polymer composite coatings mixed with PTFE filler. The coatings were tested across a wide temperature range from −180 to 110 °C to simulate the environmental temperatures on Titan, Moon, and Mars, which are of particular interest for NASA’s future exploratory missions. An experimental setup was developed to conduct the pin-on-disk experiments under dry sliding conditions and extreme temperature and contact pressure. Transfer film formation and its characteristics were found to play significant roles in the tribological performance, and the characteristics of the film were temperature-dependent. The XPS and SEM analysis indicated the increase of the PTFE content in the transfer film as the temperature decreased to cryogenic conditions. The coefficient of friction did not follow a linear trend with temperature and was minimum at 110 °C and maximum at −180 °C. ATSP coating showed superior performance with lower friction and unmeasurable wear at all temperatures, whereas PEEK coating exhibited maximum wear at 25 °C followed by −180, and 110 °C.

Carbon Nanotube–Polymer Composite Coating on the Anode Surface for Enhancing the Performance of Zn-Ion Batteries

Carbon Nanotube–Polymer Composite Coating on the Anode Surface for Enhancing the Performance of Zn-Ion Batteries

Electrophoretic Deposition of 58S Bioactive Glass- Polymer Composite Coatings on 316L Stainless Steel: An Optimization for Corrosion, Bioactivity, and Cytocompatibility.

This study presents a facile fabrication of 58S bioactive glass (BG)-polymer composite coatings on a 316L stainless steel (SS) substrate using the electrophoretic deposition technique. The suspension characteristics and deposition kinetics of BG, along with three different polymers, namely ethylcellulose (EC), poly(acrylic acid) (PAA), and polyvinylpyrrolidone (PVP), have been utilized to fabricate the coatings. Among all coatings, 58S BG and EC polymers are selected as the final composite coating (EC6) owing to their homogeneity and good adhesion. EC6 coating exhibits a thickness of ∼18 μm and an average roughness of ∼2.5 μm. Herein, EC6 demonstrates better hydroxyapatite formation compared to PAA and PVP coatings in simulated body fluid-based mineralization studies for a period of 28 days. Corrosion studies of EC6 in phosphate-buffered saline further confirm the higher corrosion resistance properties after 14 days. In vitro cytocompatibility studies using human placental mesenchymal stem cells demonstrate an increase in cellular viability, attachment, and higher proliferation compared to the bare SS substrate. EC6 coatings promote osteogenic differentiation, which is confirmed via the upregulation of the OPN and OCN genes. Moreover, the EC6 sample exhibits improved antibacterial properties against Escherichia coli and Staphylococcus aureus compared to the uncoated ones. The findings of this work emphasize the potential of electrophoretically fabricated BG-EC composite coatings on SS substrates for orthopedic applications.

Polymer composite coatings subjected to sliding wear under simulated lunar temperature and dust conditions

Due to the detrimental effect of lunar dust on tribological components, it is imperative to develop bearing materials and surfaces which can survive and mitigate dust at the interface while operating under lunar environmental conditions. This issue is poised to become more significant in the near future, with lunar exploration evolving beyond the short probing missions of the Apollo era. Therefore, this study aims to investigate the combined effect of temperature and lunar dust on the tribological performance of aromatic thermosetting copolyester (ATSP) and polyether ether ketone (PEEK) -based polymer composite coatings from −150 to 110 °C. The experiments were conducted using a flat pin-on-disk configuration under dry sliding conditions, sliding speed of 0.25 m/s, 17.5 MPa contact pressure, and nitrogen gas environment. It was found that metal-on-polymer coating sliding results in dust embedment and accumulation on the softer material, which yields high friction and two-body abrasive wear. The chemical analysis of transfer film on the metal pin surface indicated a mixture of dust and polymer phases, which increased with increasing temperature, and thus resulted in deteriorated tribological performance. Self-mating polymer coatings yielded lower friction coefficient and wear due to a better dust mitigation resulting in three-body wear at the interface. The ATSP-based coatings showed higher wear resistance at all temperatures, particularly under self-mating sliding condition.

Study on the erosion and corrosion resistance of graphene oxide and polymer composite coatings

Study on the erosion and corrosion resistance of graphene oxide and polymer composite coatings

Effects of curing temperature and addition of functionalized graphene oxide on corrosion barrier performance of phenol furfural polymer-amino phenolic resin composite

Phenol furfural polymer (PFP) blended amino phenolic resin (APR) and functionalized graphene oxide (FGO) dispersed PFP/APR polymer composite coatings were fabricated and evaluated their barrier performance on mild steel (MS) corrosion at different curing temperatures without using any conventional hardeners. The PFP was synthesized by condensation polymerization and blended with the prepared APR to get PFP/APR polymer composite. The GO was functionalized with 4-(trifluoromethyl) benzohydrazide (TFB) and dissipated in PFP/APR composite matrix. The synthesized materials were characterized by FT-IR, Raman, XRD, XPS, EDS, SEM and TEM techniques. The thermal stability of GO and FGO was analyzed using TGA. The fabricated composite materials were coated on MS surface and their surface morphology, anti-corrosion potential and hydrophobic character were evaluated by SEM, optical images, electrochemical impedance spectroscopy (EIS), salt spray analysis (SSA) and contact angle measurements (CA). At 70 °C curing temperature, the PFP/APR coating showed maximum coating resistance (Rc) of 1.39 × 105 Ω cm2 and charge transfer resistance (Rct) of 2.63 × 105 Ω cm2 on 60th day of immersion in 3.5 wt% NaCl solution. Addition of 0.2 wt% FGO into PFP/APR matrix reduced the ideal curing temperature to 50 °C and exhibited an admirable barrier performance even after 90 days of immersion in saline medium with a reliable Rc and Rct values of 1.24 × 105 Ω cm2, 1.93 × 105 Ω cm2 respectively, and coating capacitance (Qc) in the range of 10−9 F/cm2. The cross linking of resin and blockade of defects by nanofiller make the material highly durable and superior in extensive corrosive environment.

Surface functionalization of hydroxyapatite nanoparticles for biomedical applications.

This review completely covers the various aspects of hydroxyapatite (HAp) nanoparticles and their role in different biological situations, and provides the surface and interface contents on (i) hydroxyapatite nanoparticles and their hybridization with organic molecules, (ii) surface designing of hydroxyapatite nanoparticles to provide their biocompatibility and photofunction, and (iii) coating technology of hydroxyapatite nanoparticles. In particular, we summarized how the HAp nanoparticles interact with the different ions and molecules and highlighted the potential for hybridization between HAp nanoparticles and organic molecules, which is driven by the interactions of the HAp nanoparticle surface ions with several functional groups of biological molecules. In addition, we highlighted the studies focusing on the interfacial interactions between the HAp nanoparticles and proteins for exploring the enhanced biocompatibility. Such studies focus on how these interactions affect the hydration layers and protein adsorption. However, the hydration layer state involves diverse molecular interactions that can alter the shape of the adsorbed proteins, thereby affecting cell adhesion and spreading on the surfaces. We also summarized the relationship between the surface properties of the HAp nanoparticles and the hydration layer. Furthermore, we spotlighted the cytocompatible photoluminescent probes that can be developed by designing HAp/organic nanohybrid structures. We then emphasized the importance of photofunctionalization in theranostics, which involves the integration of diagnostics and therapy based on the surface design of the HAp nanoparticles. Furthermore, the coating techniques using HAp nanoparticles and HAp nanoparticle/polymer composites were outlined for fusing base biomaterials with biological tissues. The advantages of HAp/biocompatible polymer composite coatings include the ability to effectively cover porous or irregularly shaped surfaces while controlling the thickness of the coating layer, and the addition of HAp nanoparticles to the polymer matrix improves the mechanical properties, increases the roughness, and forms the morphologies that mimic bone nanostructures. Therefore, the fundamental design of hydroxyapatite nanoparticles and their surfaces was suggested from various aspects for biomedical applications.

Universal Approach to Integrating Reduced Graphene Oxide into Polymer Electronics.

Flexible electronics have sparked significant interest in the development of electrically conductive polymer-based composite materials. While efforts are being made to fabricate these composites through laser integration techniques, a versatile methodology applicable to a broad range of thermoplastic polymers remains elusive. Moreover, the underlying mechanisms driving the formation of such composites are not thoroughly understood. Addressing this knowledge gap, our research focuses on the core processes determining the integration of reduced graphene oxide (rGO) with polymers to engineer coatings that are not only flexible and robust but also exhibit electrical conductivity. Notably, we have identified a particular range of laser power densities (between 0.8 and 1.83 kW/cm2), which enables obtaining graphene polymer composite coatings for a large set of thermoplastic polymers. These laser parameters are primarily defined by the thermal properties of the polymers as confirmed by thermal analysis as well as numerical simulations. Scanning electron microscopy with elemental analysis and X-ray photoelectron spectroscopy showed that conductivity can be achieved by two mechanisms-rGO integration and polymer carbonization. Additionally, high-speed videos allowed us to capture the graphene oxide (GO) modification and melt pool formation during laser processing. The cross-sectional analysis of the laser-processed samples showed that the convective flows are present in the polymer substrate explaining the observed behavior. Moreover, the practical application of our research is exemplified through the successful assembly of a conductive wristband for wearable devices. Our study not only fills a critical knowledge gap but also offers a tangible illustration of the potential impact of laser-induced rGO-polymer integration in materials science and engineering applications.

Nanoparticle-based nanocomposite coatings with postprocessing for enhanced antimicrobial capacity of polymeric film.

Bacterial adhesion and biofilm formation on surfaces pose a significant risk of microbial contamination and chronic diseases, leading to potential health complications. To mitigate this concern, the implementation of antibacterial coatings becomes paramount in reducing pathogen propagation on contaminated surfaces. To address this requirement, our study focuses on developing cost-effective and sustainable methods using polymer composite coatings. Copper and titanium dioxide nanoparticles were used to assess their active antimicrobial functions. After coating the surface with nanoparticles, four different combinations of two postprocessing treatments were performed. Intense pulsed light was utilized to sinter the coatings further, and plasma etching was applied to manipulate the physical properties of the nanocomposite-coated sheet surface. Bacterial viability was comparatively analyzed at four different time points (0, 30, 60, and 120 min) upon contact with the nanocomposite coatings. The samples with nanoparticle coatings and postprocessing treatments showed an above-average 84.82% mortality rate at 30 min and an average of 89.77% mortality rate at 120 min of contact. In contrast, the control sample, without nanoparticle coatings and postprocessing treatments, showed a 95% microbe viability after 120 min of contact. Through this study, we gained critical insights into effective strategies for preventing the spread of microorganisms on high-touch surfaces, thereby contributing to the advancement of sustainable antimicrobial coatings.

Structure and Properties of Multilayer Nanocomposite Coatings of Polyvinyl Alcohol with Aluminum Oxide Nanoparticles

The nanocomposite polymer – inorganic materials formation, the study of their morphology and mechanical properties at the nanolevel is acute in the development of new materials for various functional purposes, including medical ones. As a result of the research the technique for producing singleand multilayer films of polyvinyl alcohol and composite polymer coatings with aluminum oxide nanoparticles by the spin coating method has been developed. It is shown that the optimal mass content of aluminum oxide nanoparticles in suspension for the formation of uniform composite coatings is 0.625 %. Based on experimental data on the structuralmorphological and mechanical properties of the formed coatings obtained by atomic force microscopy, it has been found that an increase in the number of layers of composite coatings leads to an increase in the number of conglomerates which, in turn, increases the surface roughness of the films. The modulus of elasticity of single-layer films of polyvinyl alcohol is (509.5 ± 10 %) MPa. In the case of composite coatings with aluminum oxide nanoparticles, changes in the elastic modulus have been established for multilayer coatings: an increase to 559.0 MPa (5 layers) and a decrease to 415.2 MPa (10 layers). The modulus of elasticity of the investigated single-layer coatings is significantly reduced in the range of 20−40 ºС. The smallest values after exposure to temperatures have been determined for films with nanoparticles (236.2 ± 10 %) MPa. Nanocomposites demonstrate an increase in the contact angle with an increase in the number of layers of composite coatings up to 20. A subsequent increase in the thickness of the coatings (the number of layers) leads to an increase in the hydrophilicity of the nanocomposites. The developed compositions of nanocomposite films are promising as sorption coatings.