Handbook of Smart Coatings for Materials Protection

Professor Abdel Salam Hamdy Makhlouf is the Vice President of Integrated Mechanical Material Corrosion Consulting (IM2C), Texas, USA, and a Full professor at Central Metallurgical Research and Development Institute. He has 26 years of experience working in R&D with a blend of both industrial and academic leadership as a Professor of Materials Science, and Advanced “nano-bio” Manufacturing Engineering, and Materials Engineering Consultant. He is the recipient of numerous national and international prizes and awards including the Humboldt Research Award for Experienced Scientists, at Max Planck Institute, Germany; Fulbright, NSF, and Dept. of Energy Fellowships, USA; Shoman Award in Engineering Science; and the State Prize of Egypt in Advanced Science and Technology. His research has focused on five critical areas: Energy, Health, Environment, Advanced manufacturing, Advanced materials. Dr. Makhlouf has published over 200 journal articles, as well as 17 books and handbooks for Springer and Elsevier on a broad range of cross‐disciplinary research fields including advanced multifunctional materials, nanotechnology, smart coatings, corrosion, biomaterials, waste/water treatment, and materials for energy applications. Dr. Makhlouf has served as both a Senior Editor and board member of many international journals, as well as reviewer for several international funding agencies in USA, Germany, UK, Qatar, Belgium, EU, Kazakhstan. He is a Consultant/Reviewer for several universities worldwide.

• Contributor contact detailsWoodhead Publishing Series in Metals and Surface EngineeringPrefacePart I: Fundamentals of smart coatings for materials protection1. Corrosion processes and strategies for prevention: an introductionAbstract:1.1 Introduction1.2 Corrosion of metals, alloys and composites: an overview1.3 Wet corrosive environments1.4 Strategies for corrosion inhibition: design and materials1.5 Strategies for corrosion inhibition: protective coatings1.6 Conclusion1.7 Acknowledgement1.8 References2. Smart coatings for corrosion protection: an overviewAbstract:2.1 Introduction2.2 Triggering mechanisms2.3 Self-healing mechanisms2.4 Sensing systems2.5 Future trends2.6 Conclusion2.7 Acknowledgement2.8 References3. Techniques for synthesizing and applying smart coatings for material protectionAbstract:3.1 Introduction3.2 Environmentally friendly smart self-healing coatings3.3 Most common methods and technologies for synthesizing smart coatings3.4 Conclusion3.5 References4. Multi-functional, self-healing coatings for corrosion protection: materials, design and processingAbstract:4.1 Introduction4.2 Key issues in developing multi-functional coatings4.3 Materials for encapsulation of self-healing and anti-corrosion agents4.4 Computer-based simulation4.5 Material testing and function screening4.6 Processing4.7 Guiding principles for designing multi-functional coatings4.8 Case studies and examples4.9 Conclusion and future trends4.10 Acknowledgements4.11 References5. Strategies for developing multi-functional, self-healing coatings for corrosion prevention and other functionsAbstract:5.1 Introduction5.2 Approaches to self-healing of functional coatings5.3 Corrosion and other functions of coatings recovered or enhanced by self-healing5.4 Technologies for creating functional self-healing coatings5.5 Conclusion5.6 Future trends5.7 Sources of further information and advice5.8 References6. Protective coatings for automotive, aerospace and military applications: current prospects and future trendsAbstract:6.1 Introduction6.2 Advances in materials of construction6.3 Advances in surface pre-treatment6.4 Advances in top organic coatings6.5 Optimising the coatings process and testing6.6 Conclusion and future trends6.7 ReferencesPart II: Smart coatings with self-healing properties for corrosion protection7. The use of nano-/microlayers, self-healing and slow-release coatings to prevent corrosion and biofoulingAbstract:7.1 Introduction7.2 Corrosion of different metals: mechanisms, monitoring and corrosion inhibitors7.3 Microbiologically influenced corrosion (MIC) and biofouling: mechanisms, monitoring and control7.4 Inhibition of corrosion and biofilm formation by nanolayers7.5 Self-healing coatings against corrosion and biofilm formation with nano-/microcapsules and nano-/microspheres7.6 Conclusion7.7 References and further reading8. Self-healing anti-corrosion coatings for applications in structural and petrochemical engineeringAbstract:8.1 Introduction8.2 Self-healing mechanisms8.3 Self-healing anti-corrosion coatings based on polyaniline (PANI)-modified ferrites8.4 Self-healing anti-corrosion coatings based on conducting polymer-modified graphene8.5 Conducting polymer coatings based on PANI-modified TiO28.6 Self-healing anti-corrosion coatings using the layer-by-layer approach8.7 Conclusion and future trends8.8 References9. Smart nanocoatings for corrosion detection and controlAbstract:9.1 Introduction9.2 Smart anti-corrosion nanocoatings9.3 Smart self-healing coatings using microcapsules9.4 Synthesis of microcapsules9.5 Physical and mechanical properties of self-healing coatings9.6 Smart nanocoatings for specific applications9.7 Smart self-cleaning nanocoatings9.8 Applications of smart nanocoatings9.9 Conclusion and future trends9.10 References10. Smart self-healing coatings for corrosion protection of aluminium alloysAbstract:10.1 Introduction10.2 Corrosion of aluminium alloys10.3 Conversion coatings with self-healing properties10.4 Hybrid sol–gel self-healing coatings10.5 Sol–gel coatings with corrosion inhibitors10.6 Multilayer coatings combining sol–gel coatings and corrosion inhibitors10.7 Organic polymeric coatings with self-healing properties10.8 Smart organic coating systems with controlled inhibitor release10.9 Smart coatings with micro- and nanocontainers10.10 Conclusion and future trends10.11 References11. Smart stannate-based self-healing coatings for corrosion protection of magnesium alloysAbstract:11.1 Introduction11.2 Developing and testing stannate-based smart coatings11.3 The performance of stannate-based smart coatings11.4 Conclusion11.5 Acknowledgments11.6 References12. Incorporating microcapsules in smart coatings for corrosion protection of steelAbstract:12.1 Introduction12.2 Mechanisms of self-healing in smart anticorrosion coatings12.3 Synthesis of microcapsules12.4 Characterization of microcapsules12.5 Testing the effectiveness of coatings12.6 Conclusion12.7 Acknowledgments12.8 References13. Multi-layer smart coatings for corrosion protection of aluminium alloys and steelAbstract:13.1 Introduction13.2 Developing layer-by-layer (LbL) coatings with active feedback properties13.3 Methods for formation of LbL coatings13.4 Case studies13.5 Conclusion and future trends13.6 References and further reading14. Electro-active polymer (EAP) coatings for corrosion protection of metalsAbstract:14.1 Introduction14.2 The use of electro-active polymers (EAPs) in corrosion protection14.3 Synthesis and properties of particular EAPs14.4 Toxicological properties of poly(2,5-(bis-N-methyl-N-hexylamino) phenylene vinylene (BAM-PPV)14.5 Methods to evaluate corrosion-inhibiting properties of EAPs14.6 Corrosion inhibition of ferrous metals using EAP coatings14.7 Corrosion inhibition of aluminum alloys using EAP coatings14.8 Future trends14.9 Conclusion14.10 Acknowledgment14.11 References15. Microencapsulated indicators and inhibitors for corrosion detection and controlAbstract:15.1 Introduction15.2 Corrosion indicators and corrosion sensing15.3 Corrosion inhibitor delivery systems15.4 Current developments in smart coatings for corrosion sensing and inhibition15.5 pH-sensitive microcapsules and microparticles15.6 Microencapsulation methods15.7 Microcapsules and microparticles for corrosion indication15.8 Microcapsules and microparticles for corrosion inhibition15.9 Conclusion15.10 Acknowledgments15.10 References15.12 Appendix: list of acronymsPart III: Other types of smart coating16. Smart acrylic coatings containing silica particles for corrosion protection of aluminum and other metalsAbstract:16.1 Introduction16.2 The use of acrylic polymers in coatings16.3 Synthesis and characterization of novel acrylic-based copolymers16.4 Sol–gel incorporation of silica nanoparticles16.5 Analyzing crosslinking and key properties in the coating16.6 Conclusion16.7 Acknowledgments16.8 References17. Recent advances in polyaniline (PANI)-based organic coatings for corrosion protectionAbstract:17.1 Introduction17.2 Polyaniline (PANI) as an intrinsically conductive polymer (ICP)17.3 PANI as an anti-corrosion polymer17.4 Mechanisms of PANI as a barrier protective coating17.5 Mechanism of PANI as a corrosion inhibitor17.6 Mechanism of PANI in self-healing coatings with controlled inhibitor release17.7 Conclusion and future trends17.8 References18. Smart self-cleaning coatings for corrosion protectionAbstract:18.1 Introduction18.2 Types of self-cleaning coatings18.3 Techniques for developing self-cleaning coatings18.4 TiO2 as a material for corrosion protection18.5 Conclusion18.6 Future trends18.7 References19. Smart polymer nanocomposite water and oil repellent coatings for aluminumAbstract:19.1 Introduction19.2 Developing super-hydrophobic coatings: materials, processing and characterization19.3 Flame treatment for super-hydrophobicity19.4 Assessing coating properties19.5 Electrical characteristics of the super-hydrophobic coatings19.6 Conclusion19.7 References20. UV-curable organic polymer coatings for corrosion protection of steelAbstract:20.1 Introduction20.2 UV-cured coatings: materials and mechanisms of crosslinking20.3 Additives and pigments20.4 Case studies20.5 Conclusion20.6 Sources of further information and advice20.7 References21. Smart epoxy coatings for early detection of corrosion in steel and aluminumAbstract:21.1 Introduction21.2 In situ early corrosion detection via indicator molecules embedded in a protective coating21.3 Early detection of steel corrosion via ‘turn-on’ fluorescence21.4 Sensing mechanism of the corrosion indicator21.5 Early detection of aluminum corrosion via ‘turn-on’ fluorescence21.6 Future trends21.7 Conclusion21.8 References22. Structural ceramics with self-healing propertiesAbstract:22.1 Introduction22.2 Material development22.3 Self-crack-healing behavior22.4 High-temperature strength of crack-healed specimen22.5 Crack-healing behavior during service22.6 Conclusion22.7 ReferencesIndex