CORROSION of metals and fire-related damage are major challenges faced by industries worldwide, leading to enormous economic losses, safety concerns, and increased maintenance costs. To address these challenges, researchers from IIT Bhilai, in collaboration with IIT Patna, have developed a new multifunctional polymer coating that can protect metal surfaces from corrosion while also improving fire safety. A research team from the Department of Chemistry, IIT Bhilai, in collaboration with researchers from IIT Patna, led by Dr Sanjib Banerjee and comprising Nishikanta Singh, Swarup Maity, Soumen Ghosh, and Dr Subrata Chattopadhyay, has developed a new class of multifunctional polymer coatings. Protective coatings are widely used to safeguard metallic structures and devices from environmental degradation. However, most existing coatings are designed to perform only a single function, often requiring multiple layers or additional additives to achieve comprehensive protection. Addressing this challenge, the team engineered a phosphorus- and fluorinecontaining polymer coating capable of integrating several critical functionalities within a single material. The newly developed coating can intelligently adapt to its surroundings while providing multiple layers of protection. It helps prevent rust and corrosion on metal surfaces, adheres strongly without easily peeling off, and improves fire safety by slowing down the spread of flames. Extensive testing showed that the coating remains effective even under harsh conditions such as saltwater exposure and prolonged outdoor weathering.

 

By combining several important functions into a single material, this technology could help extend the lifetime of infrastructure, vehicles, industrial equipment, and safety-related materials while reducing maintenance costs and improving reliability. “Industries often rely on multiple coatings or treatments to achieve corrosion protection, durability, and fire resistance,” said Dr Sanjib Banerjee, who led the research. “Our work demonstrates that these important properties can be integrated into a single coating material, offering a simpler, more efficient, and potentially cost-effective solution for a wide range of applications.” By integrating several important protective functions into a single material platform, this technology supports India’s vision for durable infrastructure, industrial safety, and sustainable manufacturing under initiatives such as Atmanirbhar Bharat, Make in India, PM Gati Shakti, and the National Infrastructure Pipeline. The coating has the potential to enhance the longevity and safety of transportation systems, industrial facilities, marine structures, energy devices, and other critical infrastructure while reducing maintenance requirements and associated economic losses. This research has been published in the world-renowned journal Advanced Functional Materials (Wiley-VCH), highlighting IIT’s growing contribution to advanced materials research for industrial sustainability and infrastructure protection.