New coating forms strong, lasting rust barrier for iron with 99.6% efficiency

Yahoo

12-06-2025

A new dual-layer coating has been developed that offers 99.6% protection against iron corrosion.
Iron gives modern infrastructure strength, from soaring skyscrapers to vital bridges.
However, a persistent, unseen foe is always at play, eroding its strength: rust.
Iron corrodes when exposed to air and moisture, causing structural damage, safety risks, and extremely high maintenance costs. Current protective solutions are often inadequate, providing only temporary defense against this persistent problem.
The researchers from Hebrew University of Jerusalem focused on developing a strong, durable shield for iron that would protect it for decades.
"This discovery offers a major leap forward in protecting iron from corrosion," said Professor Elad Gross, who led the development.
"By using a specially designed primer, we created a coating that is not only highly effective but also long-lasting. This could reduce maintenance costs, extend the lifespan of iron-based materials, and provide industries with a much more reliable solution," Gross added.
Metals naturally corrode over time, but the rate for each differs. Iron is known to rust quickly, but gold and silver can resist deterioration for decades or centuries.
A study conducted some time ago indicated that the global expense of corrosion amounted to a whopping US$2.5 trillion. Though protective coatings are available, many frequently break down, failing to provide lasting protection.
This development features a dual-layer coating: a thin molecular primer paired with a tough polymer layer. Overall, it creates a durable, long-lasting barrier against rust.
The coating development follows a two-pronged approach.
First, an ultra-thin molecular primer made of N-Heterocyclic Carbene (NHC) forms an incredibly tight, chemical bond directly with the iron surface.
Acting as the ultimate bond, this primer ensures the tough polymer layer adheres strongly, creating an unbreakable protective barrier.
The coating remains intact, even in the harshest conditions, like excessive and prolonged exposure to highly corrosive saltwater.
Under rigorous testing, the dual-layer coating proved remarkably effective at reducing corrosion.
Moreover, thanks to this strong connection, the coating is tougher than standard options that tend to wear down or flake off.
The coating, if widely adopted, promises to increase the durability of iron-based products in construction, transportation, and manufacturing.
It could reduce maintenance costs for bridges, pipelines, and ships.
'By reducing the need for frequent repairs and replacements, this coating could also contribute to more sustainable and cost-effective material use,' the researchers noted.
A recent report indicates that the 'corrosion inhibitor market' is valued at $8.93 billion and is predicted to grow by 3.6% annually between 2025 and 2030.
Earlier, researchers from the Indian Institute of Technology (IIT) - Bombay developed a novel technique to measure the degradation rate of protective coatings on iron.
Reportedly, the team used the combination of hydrogen permeation-based potentiometry (HPP) and electrochemical impedance spectroscopy (EIS). This technique could lead to precise measurement of degradation right where the organic coating meets the metal.
The new findings were published in the journal Angewandte Chemie International Edition.