Within WP2 – Functional Nanoadditives, various compositions of layered double hydroxides (LDHs) based on Zn-Al and Mg-Al intercalated with nitrates were synthesized by SMT and characterized by UAVR. Additionally, LDHs intercalated with corrosion detection species were successfully prepared by UAVR. Magnetic nanoparticles (MNPs) based on iron oxides were also synthesized and characterized by UAVR.
In WP3 – Surface Pre-treatment and Characterization, procedures for the surface pre-treatment of metal alloys intended for subsequent coating applications were developed by HEREON and UAVR. Sol-gel formulations incorporating polyhedral oligomeric silsesquioxanes (POSS) and/or organosilanes were also developed. LDH-based corrosion inhibitors and sensing additives were integrated into these formulations. Sol-gel layers were applied to both aluminum alloys and steel (SMT/SINTEF), and electrochemical assessments were conducted (SMT/UT/TLB).
Under WP4 – Coating Development, extensive studies on the dispersion of SiNCs, LDHs, and MNPs were carried out through collaboration between academic partners (UAVR, HEREON) and industrial partners (SYNPO, COL). The stability of two polymeric systems in saltwater environments was evaluated. Coating/inhibitor/indicator combinations were tested for corrosion protection on AA2024, AZ31 magnesium alloy, and steel substrates.
In WP5 – Modelling of Structures with Corrosion-Protective Coatings, a predictive machine learning (ML) model for evaluating the performance of anticorrosion additives was developed (UAVR, HZG/HEREON). A comprehensive experimental database of tested chemicals was compiled, and an ML model based on artificial neural networks was implemented. Mechanical properties of coatings and substrate systems were assessed (LU, KTU, SYNPO, COL), and degradation modeling under freshwater and seawater conditions was performed using both analytical and finite element methods.
For WP6 – Environmental Behavior, Toxicity, and Life-Cycle Assessment, synthesis procedures for engineered nanomaterials (WP2) and coating preparation (WP4) were developed following safe-by-design principles. Environmental risks associated with the materials and compounds used in coating production were systematically analyzed as part of an eco-conscious design strategy. Life cycle assessments (LCA) were conducted for three different coatings (UAVR).
In WP7 – Upscaling and Demonstration, the most promising additives and coating components were scaled up (SMT, SYNPO, COL) and made available for further testing. Various coating formulations were developed by combining these components and applied to different substrates for validation (COL, SYNPO). The new coatings demonstrated improved performance compared to existing materials.
Within WP8 – Dissemination and Exploitation, the project resulted in 12 peer-reviewed scientific publications and one MSc thesis. Findings were presented at over 30 international conferences. Several coating formulations showed strong potential for commercialization. The next steps include co-development of enhanced coatings among partners and implementation of a market entry strategy outlined in the final exploitation plan.
