International Research Journal of Engineering and Technology (IRJET)
e-ISSN: 2395-0056
Volume: 12 Issue: 10 | Oct 2025
p-ISSN: 2395-0072
www.irjet.net
Recent Developments in Surface Coating for Corrosion Protection: A Review A. Athulya Department of Metallurgical and Materials Engineering National Institute of Technology, Srinagar --------------------------------------------------------------------***---------------------------------------------------------------------
Abstract - Corrosion is a major industrial issue causing severe material degradation and economic losses. Surface coatings serve as an efficient and economical approach to mitigate corrosion by providing a barrier between the metal surface and its environment. This paper reviews recent advancements in coating technologies such as nanocomposite coatings, sol–gel coatings, plasma-assisted processes, and environmentally friendly alterna- tives to traditional chromium-based systems. It also highlights emerging smart and self-healing coatings and the integration of AI-assisted monitoring for sustainable corrosion control. Key Words: Corrosion, Surface Coating, Nanocomposite, Sol–gel, Self-healing, Eco-friendly coatings, AI monitoring
INTRODUCTION: Corrosion is an electrochemical process leading to the degradation of metals in the presence of moisture, oxygen, or aggressive environments. Globally, corrosion results in massive economic losses and safety risks in industries such as automotive, aerospace, marine, and construction. Surface coatings are one of the most effective and economical means of corrosion protection due to their versatility and adaptabil- ity. Traditional coatings like zinc, nickel, and chromium are effective but face challenges in environmental compliance and long-term performance. Recent developments have focused on nanocomposite, sol–gel, plasma, and smart coatings that enhance corrosion resistance and sustainability
TYPES OF COATING TECHNIQUES A. Electrochemical and Electroplating Coatings Electroplating is one of the oldest and most reliable coat- ing techniques, used for depositing metal coatings such as zinc, nickel, and chromium. Recent innovations like pulse electrodeposition and alloy coatings (e.g., Zn–Ni, Ni–W) have shown improved corrosion resistance and hardness. Nanoparti- cle incorporation (SiO2, Al2O3, TiO2) leads to nanocomposite coatings with superior wear and corrosion resistance [1].
Fig. 1: Electroplating process setup.
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