Prolonged Immersion Research Articles

Intrusion kinetics and interfacial degradation mechanism of PU-steel system in chloride ion environment: a multiscale study

This study utilised density functional theory (DFT) to predict the movement pathways and rates of chloride ions within polyurethane (PU), as well as their molecular dynamics and charge distribution during the erosion process. Fourier-transform infrared spectroscopy (FTIR), X-ray photoelectron spectroscopy (XPS), and electrochemical tests revealed chemical and electrochemical changes at the PU/steel interface after immersion in sodium chloride solution. Shear strength and nanoindentation tests were used to examine the impact of microscale erosion on macroscale mechanical properties. The results showed that chloride-ion penetration into PU requires overcoming a substantial energy barrier driven by the concentration gradient between the saline solution and PU. After immersion in sodium chloride solution, the −N=C=O functional groups in PU were disrupted, reducing chemical stability and molecular elasticity. This process accelerates the hydrolysis of ester bonds, leading to a decline in interfacial mechanical properties. Electrochemical results showed that the resistance of the PU coating decreased over time, indicating a transition in the electrochemical reactions that eventually led to interfacial corrosion. After prolonged immersion, both the interfacial shear strength and modulus significantly decreased, whereas the shear ductility initially increased but later decreased.

Breathable graphene oxide/polyurethane layered membrane for chemical protective clothing

Chemical protective clothing is crucial for shielding operators from toxic and hazardous substances. However, the limited moisture permeability of these garments significantly affects worker comfort and functionality over long periods. In this study, we introduce a novel graphene oxide/polyurethane composite membrane with an innovative alternating layer structure and improved interlayer bonding, produced through a simple, scalable layer-by-layer assembly method. The outstanding L-GO/PU membrane offers robust chemical protection for up to 24 h against harmful agents like mustard gas and dichloromethane, while also showing excellent resistance to both acidic and alkaline solutions. With a moisture permeability of 3116 g m−2 d-1, this membrane ensures optimal comfort during extended use. Additionally, it demonstrates remarkable resistance to swelling, maintaining its structural integrity for 27 days during prolonged immersion in water. The L-GO/PU composite stands out as an excellent choice for chemical protective gear, combining high toxicity resistance with superior moisture management capabilities.

The mechanical and hydrochemical properties of cemented calcareous soil under long-term soaking

This study investigates the impact of long-term water immersion on the mechanical and hydrochemical properties of cemented calcareous soil, emphasizing the critical role of carbonate content in mechanical performance. Utilizing hydrochemical analysis and triaxial testing, the research revealed that prolonged immersion disrupts the acid-base balance of the solution, resulting in an increased concentration of ions and chemicals. Significant dissolution of carbonates and soluble minerals occurs, which reacts with carbon dioxide to generate bicarbonate ions, thereby elevating the alkalinity of the soaking solution. Additionally, the gradual dissolution of clay minerals compromises the cementitious structure, leading to particle reorientation and interlocking. The study quantitatively assesses the changes in soil properties, demonstrating a substantial reduction in soil cohesion by up to 86.1% and an increase in the internal friction angle by 37.5%. Furthermore, the gradual dissolution of clay minerals compromises the cementitious structure, resulting in particle reorientation and interlocking that contribute to the observed mechanical changes. The findings underscore the importance of understanding the effects of extended immersion on the stability and engineering applicability of cemented calcareous soils.

Exploration of Metal Ion Release from Nickel-Chromium Denture Material: The Role of Saliva pH and Immersion Duration

Nickel chromium (NiCr) is a fixed denture material. Nickel has good physical, and mechanical properties, cheap, but it has low corrosion resistance. One way to increase corrosion resistance is to modify the metal surface by silver plating using the electroplating method. This study examines the effect of saliva pH and immersion time of NiCr metal with silver plating on the release of nickel, chromium, and silver ions. Laboratory experimental studies were 27 samples of NiCr with silver plating (Ø= 10 x 10 x 2 mm) immersed in saliva and divided into 9 groups (n=3): group I (pH 5 for 5 days), group II (pH 7 for 5 days), group III (pH 9 for 5 days), group IV (pH 5 for 10 days), group V (pH 7 for 10 days), group VI (pH 9 for 10 days), group VII (pH 5 for 15 days), group VIII (pH 7 for 15 days), group IX (pH 9 for 15 days). Nickel, chromium, and silver ions release was measured using atomic absorption spectrophotometry. The data obtained were analyzed using two-way ANOVA and post hoc LSD with a 95% confidence level (α =0.05). The results showed a significant difference between salivary pH and immersion time on the ion release (p<0.05). The release of nickel and silver ions increases at acidic pH, while the release of chromium ions increases at alkaline pH. Prolonged immersion (for 15 days) in saliva increases the release of nickel and chromium ions but decreases the release of silver ions.

Electrochemical noise characterization of corrosion behavior for NiCrAl-NiC coating

The electrochemical noise analysis (including frequency domain and wavelet analyses) method is used to characterize the corrosion behavior of NiCrAl-NiC Abradable Seal Coating (ASC) at different immersion times. By converting EN data to frequency domain analysis, the slope (k values) of current power spectral density (PSD) curves of NiCrAl-NiC ASC increases with prolonged immersion time, suggesting a transition from localized corrosion to pitting. Wavelet analysis results indicate that the D7-D8 detail coefficients control the wavelet energy throughout the immersion process, and with increasing immersion time, the electrochemical activity on the NiCrAl-NiC ASC surface decreases. The electrochemical noise analysis can effectively explain the corrosion behaviors of NiCrAl-NiC ASC.

Study on Oil Resistance of Polyurethane Protective Material

Abstract The polyurethane protective tape is a new type of protective material made by coating high performance pressure-sensitive adhesive on polyurethane elastomers, which is widely used in aviation. During its operational life, the polyurethane protective tape inevitably comes into contact with oil, and its oil resistance directly impacts its lifespan. This study focuses on the polyurethane protective tape and conducts immersion tests in No. 15 aviation hydraulic fluid, aircraft gear oil 4450 and RP3 aviation kerosene at room temperature. A comparative analysis was also conducted on the tensile strength, tear resistance, fracture morphology, chemical structure, and thermophysical properties before and after immersion. The research indicates that the tensile properties of polyurethane protective tapes remain essentially unchanged after immersion in RP3 aviation kerosene. After being immersed in No.15 aviation hydraulic fluid and aircraft gear oil 4450, the tensile strength of the polyurethane protective tape gradually decreases. Furthermore, compared to No.15 aviation hydraulic fluid, the rate of tensile strength reduction in polyurethane protective tape immersed in aircraft gear oil 4450 is more rapid. The resistance to tearing of polyurethane protective tapes diminishes gradually with prolonged immersion, with the rate of decline being greater for aircraft gear oil 4450 than for No.15 aviation hydraulic fluid, and even greater for RP3 aviation kerosene. The decrease in mechanical properties of polyurethane protective tapes after immersion in oil is attributed to the swelling effect of the oil, which reduces the intermolecular forces within the polyurethane material and leads to a decrease in physical cross-linking. This process is physical aging, with no evident chemical aging occurring.

Mussel-inspired polydopamine (PDA)-grafted 2D-Ti3C2 MXene nanosheets tailored ZnAl-layered double hydroxides (LDH); Toward designing a smart self-healing epoxy composite coating

The constant challenge of corrosion significantly compromises the durability and functionality of metal substrates, propelling the demand for advanced protective solutions. This study introduces a novel smart epoxy coating system modified with a three-component nanocomposite integrating polydopamine (PDA)-modified Ti3C2 MXene with ZnAl-layered double hydroxides (LDH), intercalated with phosphate (P) and glutamate (Gl) ions as corrosion inhibitors. The innovative approach leverages the synergistic impacts of barrier protection, ion exchangeability, and self-healing capabilities to offer superior anti-corrosion performance. In the solution phase, the EIS results revealed a notable increase in resistance values, with MPLG samples exhibiting a 2.45-fold and MPLP samples a 2.17-fold enhancement compared to the blank specimen after 96 h of immersion. Furthermore, the data obtained from EIS demonstrated a significant enhancement in the barrier effects of the epoxy coating upon the addition of MPLG and MPLP. This enhancement was evidenced by a significant increase in the impedance values, which were observed to be 103-fold higher following a prolonged immersion period of 140 days. The self-healing properties, confirmed through EIS, FE-SEM, and EDX/Mapping analyses, indicated the formation of a stable corrosion-protective layer over the damaged areas, thus providing active protection. Adhesion assessments further underscored the coatings' durability, with MPLG and MPLP samples demonstrating minimal delamination. Collectively, these findings emphasize the potential of the proposed PDA-modified MXene@ZnAl-LDH nanocomposite as a multifaceted solution to corrosion challenges, promising significant advancements in the longevity and reliability of coated metal surfaces.

Effect of introduction of MXene on low energy plasma electrolytic oxidation

This article discusses the development of 2D MXene-containing coatings on magnesium alloy LA91, which are produced using low-energy plasma electrolytic oxidation (LePEO) processing. The coatings enhance substrate corrosion resistance and offer improved wear resistance. Notably, the coatings exhibit increased corrosion and wear resistance, as well as higher microhardness, while simultaneously reducing the voltage required for the PEO process. The addition of MXene to electrolyte enhances its conductivity, leading to the incorporation of MXene into the oxide coating. Despite a reduction in coating thickness, the resulting coatings demonstrate excellent corrosion resistance, wear resistance, and hardness. The MXene-enriched PEO coatings show impressive performance metrics compared to the MgLi alloy substrate. The corrosion current density of the MXene-enriched coatings is only 3.3 % of that of the MgLi alloy, while the average friction coefficient is reduced to 39.9 %, and the hardness is 6.6 times greater. Additionally, the coatings exhibit enduring corrosion resistance during prolonged immersion and neutral salt spraying tests. These performance improvements are attributed to MXene's ability to hinder the transmission of corrosive media, as well as its interlayer shear and self-lubrication properties, which enhance wear resistance.

Assessing the effect of different biodiesels on corrosion of nickel alloy

This investigation explores the corrosion behaviour of Ni alloy (UNS718), which is a potential material for storing biodiesel and making engine components. The study also examines the connection between Ni alloy corrosion and biodiesel degradation. Immersion tests were conducted using in-house biodiesels to evaluate the corrosion rates of Used Cooking Oil (UCOB), Karanja oil (KOB), and Jatropha oil (JOB) biodiesels on Ni alloy (UNS718). The results highlighted the role of corrosion product morphology and the formation of corrosion-driven pitting, cracks, etc., on Ni alloy when exposed to different biodiesels such as KOB, JOB, and UCOB. The study utilized gravimetric techniques to measure the corrosion rate and advanced analytical tools such as FESEM, EDS, XPS, NMR and XRF. It revealed decreased corrosion rates of Ni alloys with prolonged biodiesel immersion. For example, after 2160 h, Jatropha biodiesel exhibited a corrosion rate of 0.000699 mm/year, while the corrosion rates of Ni alloy exposed to UCOB and KOB were 0.001398 mm/year and 0.001048 mm/year, respectively. The study also suggests a detailed mechanism of Ni alloy corrosion when exposed to different biodiesels such as Karanja, Jatropha, and Used Cooking Oil.

Investigating dynamics, etiology, pathology, and therapeutic interventions of Caligus clemensi and Vibrio alginolyticus co-infection in farmed marine fish

This study investigated a disease outbreak characterized by caligid copepod infestations and subsequent secondary bacterial infections in European seabass (Dicentrarchus labrax) and flathead grey mullet (Mugil cephalus) cultivated at a private facility in the Deeba Triangle region of Egypt. Moribund fish displayed brown spots on the skin, tongue, and gills, along with lethargy and excess mucus. The fish suffered severe infections, exhibiting external hemorrhages, ulcers, and ascites. The fish had pale, enlarged livers with hemorrhaging. Comprehensive parasitological, bacteriological, molecular, immunity and histopathological analyses were conducted to identify the etiological agents and pathological changes. Caligid copepod infestation was observed in wet mounts from the buccal and branchial cavities of all examined fish, and the caligids were identified as Caligus clemensi through COI gene sequencing and phylogenetic analysis. Vibrio alginolyticus was confirmed as a secondary bacterial infection through biochemical tests, recA gene sequencing, and phylogenetic analyses. Antibiotic susceptibility testing revealed resistance to β-lactams, aminoglycosides, and trimethoprim-sulfamethoxazole in V. alginolyticus isolates. Upregulation of the inflammatory marker IL-1β in gill and skin tissues indicated a robust cell-mediated immune response against the pathogens. Histopathological examination revealed severe tissue damage, hyperplasia, hemorrhage, and congestion in the gills, along with hepatocellular degeneration and steatosis in the liver, providing initial insights into this outbreak. A comprehensive therapeutic regimen was implemented, comprising prolonged hydrogen peroxide immersion baths, followed by the application of the nature-identical plant-based compound Lice-less and probiotic Sanolife Pro-W supplementation. This integrated approach effectively eliminated C. clemensi infestations, controlled secondary bacterial infections, and restored fish health, reducing morbidity and mortality rates to minimal levels.

Comparison of thermogravimetry response of alkali-activated slag and Portland cement pastes after stopping their hydration using solvent exchange method

AbstractThe critical step for any subsequent instrumental analysis of cementitious binders is to stop their hydration reactions, i.e., to remove free water. One of the most available techniques is a solvent exchange method. However, the solvents are known to be strongly bound in ordinary Portland cement (OPC) paste and alter the results of thermogravimetric analysis (TGA) and sensitive hydrates, while their effect on TGA response of alkali-activated slag (AAS) has not been comprehensively investigated. Therefore, the objective of this paper is to track the effects of fundamental aspects of the solvent exchange on the TGA response of AAS with different sodium activators (hydroxide, carbonate, waterglass) and to support these results by X-ray diffraction and effluent gas analysis. All solvents used (acetone, diethyl ether, isopropyl alcohol, ethanol, and methanol) affected the TGA response of all tested pastes, and their effect was enhanced by prolonged immersion time. All solvents induced an additional mass loss at around 800 °C and, especially for OPC paste, increased in situ carbonation, even in an inert atmosphere. Methanol and ethanol had a detrimental effect on ettringite and decreased the basal distance of the C–(A)–S–H gel, while they only marginally affected gaylussite. For AAS, hydration stoppage by washing out the alkali-rich pore solution with water was also investigated and can usually be recommended (except for its detrimental effect on gaylussite), as it is more efficient than organic solvents, which lack solubility for activators. Methanol and ethanol are the most suitable alternatives, particularly for NaOH.

Galvanic Corrosion Behavior of Zn and Al Couples in NaCl Solution

Multi-materialization is being promoted in automotive structural materials, and fuel economy is being improved by replacing steel with aluminum and other lightweight metallic materials. Automotive steel is often galvanized for corrosion protection, and galvanic corrosion of aluminum and zinc in an atmospheric environment is a very important issue in evaluating automotive durability. Zinc is usually considered to be an anode when combined with aluminum, but its galvanic corrosion behavior can be complicated by environmental conditions because the corrosion potentials of the two are relatively close. Therefore, the objective of this study is to investigate the galvanic corrosion behavior of the couples consisting of zinc and aluminum under corrosive environmental conditions.The galvanic couple used in this study was fabricated from AA1050 Al and zinc plates. The width and length of both plates are 10 mm and 15 mm, respectively. After connecting lead wires to each plate, both plates were embedded in epoxy resin. To fabricate coplanar galvanic couples in this study, both plates were placed separately along the surface from a gap size of 500 um. The surfaces of the galvanic pairs were polished with SiC paper to JIS 2000 grit and cleaned with EtOH. The test solutions used in this study were aqueous NaCl solutions of various concentrations from 0.01 to 2 M, prepared with Milli-Q water and reagent grade chemicals. Galvanic currents and corrosion potentials were measured to investigate the galvanic corrosion behavior of the couples after 72 hours of galvanic corrosion experiments in the test solutions.The results of the galvanic corrosion test showed that the immersion potentials of the galvanic couples were lower at higher NaCl concentrations. The galvanic current decreased with immersion time, finally reaching about 1 uA in all NaCl solutions. The results of the electrochemical impedance measurements for galvanic couples in various NaCl concentrations showed that the impedance gradually increased with immersion time. It was also found that the impedance can be expressed as an electrical equivalent circuit consisting of two time constants, and that the impedance increases at intermediate frequencies between 0.1 and 1 Hz, which is thought to correspond to the dissolution reaction of Zn. This was the same trend as the behavior of the galvanic current. These results suggest that prolonged immersion reduces the galvanic current and the dissolution rate of zinc due to the passivation of the A1050 surface and the suppression of cathodic reactions.

Innovative Nanocomposite Coating for Aluminum Alloy in the Aircraft Manufacturing Industry with Increased Mechanical Strength, Flame Retardancy, and Corrosion Resistance

AbstractNanocomposites containing impermeable two‐dimensional materials are of significant interest for protecting metals against corrosion. Incorporating 4‐aminobutyltriethoxysilane (ABES) functionalized tantalum nitride (TaN) into a coating matrix enhances the barrier effect due to TaN's notable chemical and thermal stability. When integrated with graphitic carbon nitride (GCN) in polyurethane (PU), functionalized TaN significantly improves corrosion resistance and fire‐retardant capabilities. Electrochemical evaluations of aluminum coated with varying amounts of functionalized TaN/GCN in PU demonstrated substantial enhancements in protective behavior in chloride environments. The PU nanocomposite exhibited superior flame retardancy, with significant reductions in peak heat release rate (PHRR), total heat release (THR), and total smoke production (TSP) compared to pure PU. Flame retardancy tests demonstrated increased thermal stability, attributed to the synergistic effects between GCN and silanized TaN. Electrochemical impedance spectroscopy (EIS) measurements showed a high coating resistance of 8.89×1011 Ω cm2 for PU/functionalized TaN/GCN, even after 40 days of electrolyte exposure. Additionally, the PU/functionalized TaN/GCN coating demonstrated exceptional water repellency, indicated by a water contact angle (WCA) of 164°. Mechanical tests revealed that PU/functionalized TaN/GCN exhibited favorable adhesion strength and hardness, maintaining integrity even under prolonged immersion. These findings suggest that this nanocomposite is a promising coating component for aerospace applications. The integration of functionalized TaN/GCN within the PU matrix presents a novel approach to developing multifunctional coatings with enhanced performance across various metrics essential for aerospace materials.

Resveratrol/epoxidized soybean oil bio-based non-isocyanate polyurethane: High strength, recyclability and adhesive applications

Advancing bio-based non-isocyanate polyurethanes (NIPUs) is vital for fostering sustainable development. This study, inspired by the concept of "rigid and flexible" successfully utilized resveratrol, epoxidized soybean oil, and carbon dioxide (CO2) to produce a novel type of NIPUs (CRSOP) with outstanding mechanical properties, recyclability, and adhesive properties. Test results reveal that CRSOP demonstrates a tensile strength of 20.85 MPa and an elongation at break surpassing 160 %. The synthesized CRSOP shows excellent recyclability, with a recycling efficiency of over 80 % even after three cycles. Additionally, the rich polar groups in CRSOP contribute to its exceptional adhesion on diverse substrates such as copper (5.29 MPa), steel (7.48 MPa), aluminum (6.12 MPa), glass (4.71 MPa), and polytetrafluoroethylene (1.75 MPa). Even after prolonged immersion in organic solvents, CRSOP maintains a lap shear strength comparable to the initial value, demonstrating outstanding environmental tolerance. This paper showcases a superior-performing NIPUs derived from renewable resources and simultaneously expands its extensive application in the adhesive field.

The flexural mechanical properties and mesoscopic mechanisms of fracture failure of HPC with ASR inhibition measures under prolonged alkaline solution immersion

The flexural mechanical properties and mesoscopic mechanisms of fracture failure of HPC with ASR inhibition measures under prolonged alkaline solution immersion

Boosting solvent resistance and structure stability of degradable polyester through extended-chain crystal structure: A preliminary case of oil/water separation membrane

Developing polymer-based oil/water separation membranes has emerged as a promising approach for wastewater, and fabrication of environmental-friendly separation membranes is becoming a vital issue for sustainable development. Currently, the application of degradable polyesters for oil/water separation is severely limited due to their inferior resistance to various solvents. Herein, we report a new kind of separation membrane of degradable aliphatic polyester based on extended-chain crystals. Though significant improvements in the crystalline structure, including crystallinity and thermodynamic stability, the polyester membranes gain outstanding solvent resistance, maintaining their structural integrity even after prolonged immersion in diverse solvents for up to 100 days. Meanwhile, the hydrophobic and lipophilic characteristic of aliphatic polyester is well inherited in the separation membrane, imparting exceptional wettability to various solvents. Consequently, the extended-chain crystal porous membranes exhibit excellent flux performance and good separation efficiency for solvent and water mixtures and emulsions. In addition, the extended-chain crystal structure gives the membrane outstanding mechanical properties. This work provides the first membrane application report of extended-chain crystal in degradable aliphatic polyester and reveals the potential of extended-chain crystal materials to deliver superior performance and extensive application.

Permeability and barrier layer properties of a woven carbon fibre polymer composite as battery packaging

Carbon fibre reinforced polymer (CFRP) laminates are used in various studies as Li-ion polymer (LiPo) battery packaging. However, their suitability as a packaging material is not well understood. The present study investigates the liquid absorption (water and lithium bis(trifluoromethanesulfonic)imide (LiTFSI) electrolyte immersion tests) and barrier layer properties (water vapour transmission rate (WVTR) and oxygen transmission rate (OTR) tests) of a 200 gsm woven CFRP laminate to assess its suitability as a battery packaging material. This is the first study to show that prolonged immersion in battery electrolyte does not change the mechanical properties of a woven CFRP laminate. Hence, the CFRP laminate may be suitable for structural battery components, such as current collectors and electrodes. However, CFRP should not be used as battery packaging, as OTR and WVTR values of the CFRP laminate were found to be five and one order of magnitudes higher than typical battery pouch materials (i.e. aluminium foil), respectively.

Employing limestone and calcined clay for preserving the strain-hardening response of PET fiber-reinforced cementitious composites

The degradation of polyethylene terephthalate (PET) fibers in alkaline environments limits their use in strain-hardening cementitious composites (SHCC). Prolonged PET exposure to alkaline environments has a detrimental effect on its mechanical performance, mainly due to the physicochemical transformation caused by alkaline hydrolysis. This study presents a tailored cementitious matrix design containing high amounts of limestone and calcined clay, replacing 75 wt% of Portland cement, to attain and maintain the strain-hardening response of composites incorporating PET fibers as dispersed reinforcement. Analytical and mechanical tests were carried out at different curing ages, ranging from 7 to 60 days, to study the effects of aging on virgin PET fibers, both within the matrix and outside it (in the pore solution). The results showed a pronounced degradation of the PET fibers in the test pore solution at pH 12.5, manifested by a progressive reduction in the load-bearing capacity of the individual fibers with prolonged immersion. Conversely, when the PET fibers were aged in-matrix under laboratory conditions and tested under tension, the performance of the corresponding composites showed resilience to aging, exhibiting reasonable tensile strength and remarkable strain capacities that exceeded 4 %.

Advanced treatment and reuse of dye wastewater using thermo-irreversible on/off switch starch with disruption of dissolution/precipitation dynamic equilibrium

The development of irreversible on/off switching materials is a potential strategy for unidirectional capture and encapsulation of pollutants, preventing the pollutant leakage problem resulting from the reversible dissolution of flocculants. Herein, a thermo-irreversible on/off switch starch (TISS) is prepared through modifying starch by etherification grafting glycidyl phenyl ether and 2,4-bis(dimethylamino)-6-chloro-[1,3,5]-triazine. It breaks the dissolution/precipitation dynamic equilibrium across heating–cooling cycles by thermal-induced irreversible coil-to-globule self-assembly of polymer chains, resulting in a 50-fold decrease in polymer solubility. Particularly, TISS shows a superior double-locking effect on pollutants and flocculants through its unique irreversible conformation memory capability, leading to a high-quality reuse water. 99.9 % of reactive brilliant red dye and 97.9 % of TISS remain fixed within sludge flocs even after prolonged immersion in cold water at 24 °C for 60 days. Furthermore, direct recycling and reuse of dye-bath energy can be realized through the isothermal flocculation and dyeing method, showing a 75 % decrease in energy consumption after three cycles compared to traditional dyeing techniques. This work presents a novel approach to constructing an irreversible pollutant delivery system using thermo-irreversible on/off switch starch, addressing the problems of high energy dissipation and water quality fluctuations during wastewater treatment.

Multifunctional nanocomposite coating for aluminium alloy: Corrosion resistance, flame retardancy, and mechanical enhancement for automotive components

Aluminium alloys are utilized in the automotive industry for components such as engine blocks, wheels, chassis, and body panels. Their lightweight nature helps reduce vehicle weight, leading to improved fuel efficiency and lower emissions. The development of nanocomposites incorporating impermeable two-dimensional materials holds significant promise for safeguarding metals against corrosion. By introducing N-aminoethyl-3-aminopropyltrimethoxysilane (AAMS) functionalized molybdenum nitride (MoN) into a coating matrix, the barrier effect can be significantly enhanced owing to its remarkable chemical and thermal stability. This enhancement is further amplified through the incorporation of functionalized MoN into graphitic carbon nitride (GCN) within a polyurethane (PU) matrix, resulting in improved corrosion protection and fire-retardant properties. Through electrochemical techniques conducted in marine environments, the protective efficacy of aluminium coated with polyurethane, alongside varying concentrations of functionalized MoN/GCN, was assessed. The resulting PU composite exhibited superior flame-retardant capabilities, manifesting in substantial reductions in peak heat release rate (PHRR), total heat release (THR), and total smoke production (TSP) compared to pure PU formulations. Electrochemical impedance spectroscopy (EIS) measurements revealed a notable enhancement in coating resistance (5.65 × 1011 Ω. cm2), even following 500 h of exposure to the electrolyte. Furthermore, the newly formulated PU composite, featuring functionalized MoN/GCN, demonstrated exceptional water repellency with a water contact angle (WCA) of 157°. This remarkable hydrophobicity underscores its potential for applications requiring protection against moisture ingress. Additionally, the PU composite exhibited commendable mechanical properties, boasting an adhesive strength of 19.1 MPa within the PU substrate. This enhanced adhesive strength ensures the coating's integrity even after prolonged immersion periods. Given its multifaceted benefits, the PU composite incorporating functionalized MoN/GCN emerges as a promising candidate for integration into automotive industries as a viable coating component. Its ability to concurrently provide corrosion protection, flame retardancy, water repellency, and mechanical robustness underscores its potential to enhance the durability and longevity of automotive components, thereby contributing to improved performance and longevity in harsh operating environments.