Periodic Reporting for period 1 - COAT4LIFE (Eco-friendly corrosion protective coatings based on smart nanotechnology platforms for a circular economy)
Reporting period: 2021-05-01 to 2023-04-30
The circular industrial economy (CIE) manages stocks of manufactured assets such as infrastructure, buildings, vehicles, equipment and consumer goods, to maintain their value and utility as high as possible for as long as possible, and stocks of resources at their highest purity and value.
The major goal of COAT4LIFE is to develop anticorrosion and corrosion sensing innovative platforms in the form of multifunctional coatings to detect and prevent corrosion of metallic structures used in high-performance applications (namely, in the aeronautical and offshore sectors), under a sustainable and eco-fiendly perspective throughout their life-cycle. Thus, COAT4LIFE will contribute to extend the service-life of metallic structures and infrastructures used in different applications, via development of innovative new materials and components, which is fully aligned with key R&D innovation areas associated with CIE and United Nations 2030 Agenda for Sustainable Development.
COAT4LIFE major goal will be achieved through completion of the following technical objectives:
(i) combination of new corrosion sensing (TRL 3-4) with mature and innovative anticorrosion nanoadditive technologies based on the controlled release of chemical species (TRL higher than 5);
(ii) use of machine learning to select corrosion inhibitors for the targeted application;
(iii) modelling and correlation between degradation of substrate and signal detected;
(iv) preparation and optimization of coatings and pre-treatments, followed by scale up of the most promising technologies;
(v) environmental assessment of coating components;
Other objectives relevant within the scope of the call:
(vi) exchange of staff, sharing and transfer of knowledge between research and industry sectors;
(vii) training and mobility of researchers;
(viii) development of innovation-driven and entrepreneurial skills in seconded staff.
The major goal of COAT4LIFE is to develop anticorrosion and corrosion sensing innovative platforms in the form of multifunctional coatings to detect and prevent corrosion of metallic structures used in high-performance applications (namely, in the aeronautical and offshore sectors), under a sustainable and eco-fiendly perspective throughout their life-cycle. Thus, COAT4LIFE will contribute to extend the service-life of metallic structures and infrastructures used in different applications, via development of innovative new materials and components, which is fully aligned with key R&D innovation areas associated with CIE and United Nations 2030 Agenda for Sustainable Development.
COAT4LIFE major goal will be achieved through completion of the following technical objectives:
(i) combination of new corrosion sensing (TRL 3-4) with mature and innovative anticorrosion nanoadditive technologies based on the controlled release of chemical species (TRL higher than 5);
(ii) use of machine learning to select corrosion inhibitors for the targeted application;
(iii) modelling and correlation between degradation of substrate and signal detected;
(iv) preparation and optimization of coatings and pre-treatments, followed by scale up of the most promising technologies;
(v) environmental assessment of coating components;
Other objectives relevant within the scope of the call:
(vi) exchange of staff, sharing and transfer of knowledge between research and industry sectors;
(vii) training and mobility of researchers;
(viii) development of innovation-driven and entrepreneurial skills in seconded staff.
In the frame of WP2-Functional Nanoadditives, different compositions of layered double hydroxides (LDH) based on Zn-Al and Mg-Al intercalated with nitrates were prepared by SMALLMATEK and characterized by UAVR. LDH intercalated with corrosion detection species were successfully prepared by UAVR. In addition, magnetic nanoparticles based on iron oxides were prepared and characterized by UAVR.
In WP3-Surface pre-treatment and characterization, Mg-based alloys the development of the substrate preparing pre-treatment follows the knowledge of the HEREON and UAVR in this project.
In WP4-Coating development, HEREON developed a novel kind of polypyrrole (PPy)/nanocapsules system loaded with zinc salt corrosion inhibitors. The synthesized intelligent PPy nanocapsules can respond to two different external stimuli (pH and redox-responsive) and confer the controlled release of the encapsulated corrosion inhibitors from PPy nanocapsules. Seconded staff from UAVR in SYNPO initiated compatibility testing of different LDH and magnetic nanoparticles with four different coating formulations, including water-based alkyd, acrylic urethane and epoxy-based resins and high solid epoxy-based resins. Also, joint activities of UT and TLB were performed to develop custom equipment for localized corrosion studies (SVET signal channel + operational software) for future studies in COAT4LIFE sample systems.
In WP5-Modelling of structures with corrosion protective coatings, a comprehensive dataset of corrosion inhibition efficiencies for different metals (Al, Fe and Mg) and their alloys was collected from literature. This work was developed in partnership between UAVR, HEREON and SMALLMATEK, having resulted in a published article. Furthermore, the methodology of accelerated degradation tests is under development by LU. The procedure of manufacturing of polymer matrix sample was developed. Bulk properties of the matrix material with and without additives were measured on dummy samples casted in silicone molds. Polymer film draft samples on metal, fiber reinforced composite element, and glass substrates were manufactured to measure coating properties. KTU initiated state-of-the-art mapping of the alternative solutions on modelling of material degradation. A specific emphasis on degradation under sea water conditions was conducted.
In WP6-Environmental behavior, toxicity and life-cycle assessment, procedures associated with synthesis of engineered nanomaterials (WP2) and coating preparation (WP4) have been developed following safe-by-design concepts. Furthermore, the analysis of environmental risks associated with compounds and materials used during production of coating components has been done in a systematic manner as part of an eco-friendly oriented design of multifunctional coatings. Some of the activities associated ecotoxicity assessment of active compounds (pH indicators, dyes) and nanomaterials has been carried out and part of those results were recently published.
In WP7-Upscaling and demonstration activities have not yet started.
In WP8-Dissemination and exploitation, the Impact Maximization team was assembled and worked successfully in WP8 tasks. In addition, sharing of knowledge and experience among project partners, meetings, professional training, master classes during the secondment have occurred. Worth to mention is the first project workshop on “Open Access guidelines” that was organized online by KTU and had participation of different partners as well as people responsible for open access in HEREON and UAVR. Finally, several activities related to preparation and publication of information for the COAT4LIFE website and social media were performed.
In WP3-Surface pre-treatment and characterization, Mg-based alloys the development of the substrate preparing pre-treatment follows the knowledge of the HEREON and UAVR in this project.
In WP4-Coating development, HEREON developed a novel kind of polypyrrole (PPy)/nanocapsules system loaded with zinc salt corrosion inhibitors. The synthesized intelligent PPy nanocapsules can respond to two different external stimuli (pH and redox-responsive) and confer the controlled release of the encapsulated corrosion inhibitors from PPy nanocapsules. Seconded staff from UAVR in SYNPO initiated compatibility testing of different LDH and magnetic nanoparticles with four different coating formulations, including water-based alkyd, acrylic urethane and epoxy-based resins and high solid epoxy-based resins. Also, joint activities of UT and TLB were performed to develop custom equipment for localized corrosion studies (SVET signal channel + operational software) for future studies in COAT4LIFE sample systems.
In WP5-Modelling of structures with corrosion protective coatings, a comprehensive dataset of corrosion inhibition efficiencies for different metals (Al, Fe and Mg) and their alloys was collected from literature. This work was developed in partnership between UAVR, HEREON and SMALLMATEK, having resulted in a published article. Furthermore, the methodology of accelerated degradation tests is under development by LU. The procedure of manufacturing of polymer matrix sample was developed. Bulk properties of the matrix material with and without additives were measured on dummy samples casted in silicone molds. Polymer film draft samples on metal, fiber reinforced composite element, and glass substrates were manufactured to measure coating properties. KTU initiated state-of-the-art mapping of the alternative solutions on modelling of material degradation. A specific emphasis on degradation under sea water conditions was conducted.
In WP6-Environmental behavior, toxicity and life-cycle assessment, procedures associated with synthesis of engineered nanomaterials (WP2) and coating preparation (WP4) have been developed following safe-by-design concepts. Furthermore, the analysis of environmental risks associated with compounds and materials used during production of coating components has been done in a systematic manner as part of an eco-friendly oriented design of multifunctional coatings. Some of the activities associated ecotoxicity assessment of active compounds (pH indicators, dyes) and nanomaterials has been carried out and part of those results were recently published.
In WP7-Upscaling and demonstration activities have not yet started.
In WP8-Dissemination and exploitation, the Impact Maximization team was assembled and worked successfully in WP8 tasks. In addition, sharing of knowledge and experience among project partners, meetings, professional training, master classes during the secondment have occurred. Worth to mention is the first project workshop on “Open Access guidelines” that was organized online by KTU and had participation of different partners as well as people responsible for open access in HEREON and UAVR. Finally, several activities related to preparation and publication of information for the COAT4LIFE website and social media were performed.
Progress beyond state of art includes new coating systems with proven corrosion sensing functionalities, evaluation of ecotoxicity effects associated with newly synthesized nanomaterials and the application of Machine Learning in the selection of corrosion inhibitors for novel anti-corrosion coatings. These findings have already been presented in 7 scientific papers and 13 scientific conferences.
In addition, the project is contributing for the training of young researchers and company staff members in cross-, inter-disciplinary, cutting-edge research areas to generate more durable and environmentally-friendly multifunctional coatings. This will contribute to accelerate the uptake of new technologies by the society.
In addition, the project is contributing for the training of young researchers and company staff members in cross-, inter-disciplinary, cutting-edge research areas to generate more durable and environmentally-friendly multifunctional coatings. This will contribute to accelerate the uptake of new technologies by the society.