Recent developments in polymer-based composite anticorrosion coatings: materials, mechanisms and applications

• A.K. Nomozov^1,2, Kh.S. Beknazarov³, N.B. Chorieva¹, Kh.Ch. Mirzakulov⁴, K.S. Arifdjanova⁵, A.S. Mukimov³, A.A. Pardaev⁶ and N.D. Ashurova⁷

¹ Department of Chemical Engineering, Termez State University of Engineering and Agrotechnologies, Termez, 190111, Uzbekistan
² Department of Medical and Biological Chemistry, Termez branch of Tashkent Medical Academy, Termez, 190111, Uzbekistan
³ Faculty of chemistry, Termez State University, Termez, 190100, Uzbekistan
⁴ Network Center for “Retraining and Advanced Training of Pedagogical Personnel” at the Tashkent Institute of Chemical Technology, Tashkent, 100011, Uzbekistan
⁵ Department of Chemical Technology of Inorganic Substances, Tashkent Institute of Chemical Technology, Tashkent, 100011, Uzbekistan
⁶ Faculty of Foreign Philology, English Language Teaching Methodology. Termez State University. Termez, 190100. Uzbekistan
⁷ Department of Pathological Anatomy, Forensic Medicine, Medical Law Termez branch of Tashkent Medical Academy, Termez, Uzbekistan

Abstract: Corrosion of metallic materials presents a critical threat to the longevity and performance of industrial infrastructure, prompting the evolution of polymer-based composite anticorrosion coatings. Recent advancements in this field have focused on integrating functional nanofillers – such as graphene oxide, metal oxides, clay minerals, and conducting polymers – into polymer matrices to enhance mechanical durability, chemical stability, and barrier efficiency. This review highlights the latest strategies in the design, synthesis, and application of advanced composite coatings, including multilayered architectures, self-healing systems, and stimuli-responsive (smart) materials. Emphasis is placed on the correlation between microstructure and anticorrosion performance, with discussion of synthesis routes like in-situ polymerization, sol-gel processing, and electrophoretic deposition. Furthermore, the mechanisms of protection – ranging from passive barrier formation to active inhibition through encapsulated agents – are critically evaluated using electrochemical and surface analysis techniques. While laboratory results demonstrate significant improvements in corrosion resistance, challenges related to large-scale processing, environmental impact, and long-term durability remain. The review outlines emerging directions for future development, including green materials, multifunctional systems, and industrial scalability of smart, adaptive coating technologies.

Keywords: anticorrosion coatings, corrosion inhibitors, polymer coatings, composite coatings

Int. J. Corros. Scale Inhib., 2025, 14, no. 3, 1362-1390
doi: 10.17675/2305-6894-2025-14-3-18

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