Skip to main content
SpringerLink
Log in

Vapor-based synthesis of bilayer anti-corrosion polymer coatings with excellent barrier property and superhydrophobicity

  • Polymers
  • Published:
Journal of Materials Science Aims and scope Submit manuscript

Abstract

Bilayer polymer coatings that consisted of a highly cross-linked polyethylene glycol diacrylate (PEGDA) bottom layer and nanostructured poly(perfluorodecyl acrylate-co-ethylene glycol diacrylate) (P(PFDA-co-EGDA)) top layer were synthesized via a single-step vapor deposition method. The vapor-synthesized PEGDA single-layer film exhibits excellent barrier performance with oxygen permeability of 0.0066 Barrer, which is more than 16-fold smaller than that of commercial PET packaging film. The P(PFDA-co-EGDA) layer, grown on top of PEGDA, shows conical array structure. Such nanostructure combined with the low surface energy of PFDA moiety enables superhydrophobicity of the coating with water contact angle of 159°. The achieved superhydrophobicity is stable over more than 168 h upon immersion in NaCl solution. The bilayer coating structure imparts a synergistic effect to minimize both the diffusion of water and ions and permeation of oxygen, resulting in a significant drop of corrosion rate to 2.19 × 10−7 mm year−1, a more than 104-fold decrease compared to bare copper.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Figure 1
Figure 2
Figure 3
Figure 4
Figure 5
Figure 6
Figure 7
Figure 8
Figure 9

Similar content being viewed by others

References

  1. Bahlakeh G, Ramezanzadeh B, Saeb MR et al (2017) Corrosion protection properties and interfacial adhesion mechanism of an epoxy/polyamide coating applied on the steel surface decorated with cerium oxide nanofilm: complementary experimental, molecular dynamics (MD) and first principle quantum mechanics. Appl Surf Sci 419:650–669

    Article  Google Scholar 

  2. Yao M, Tang E, Guo C et al (2017) Synthesis of waterborne epoxy/polyacrylate composites via miniemulsion polymerization and corrosion resistance of coatings. Prog Org Coat 113(5):143–150

    Article  Google Scholar 

  3. Wang G, Yang J (2010) Influences of binder on fire protection and anticorrosion properties of intumescent fire resistive coating for steel structure. Surf Coat Technol 204(8):1186–1192

    Article  Google Scholar 

  4. Posner R, Ozcan O, Grundmeier G (2013) Water and ions at polymer/metal interfaces. In: da Silva LFM, Sato C (eds) Design of adhesive joints under humid conditions. Springer, Hamburg, pp 22–52

    Google Scholar 

  5. Thiel PA (1990) The interaction of water with solid surfaces: fundamental aspects. Surf Sci Rep 7:211–385

    Article  Google Scholar 

  6. Eduok U, Xu Z, Szpunar J (2018) Fabricating protective silica/PMDS composite films for Mg alloy: correlating bulk silica reinforcement with barrier performance. J Non Cryst Solids 485(1):47–56

    Article  Google Scholar 

  7. Schriver M, Regan W, Gannett WJ et al (2013) Graphene as a long-term metal oxidation barrier: worse than nothing. ACS Nano 7(7):5763–5768

    Article  Google Scholar 

  8. Ko TJ, Her EK, Shin B et al (2012) Water condensation behavior on the surface of a network of superhydrophobic carbon fibers with high-aspect-ratio nanostructures. Carbon 50(14):5085–5092

    Article  Google Scholar 

  9. Liu T, Yin Y, Chen S et al (2007) Super-hydrophobic surfaces improve corrosion resistance of copper in seawater. Electrochim Acta 52(11):3709–3713

    Article  Google Scholar 

  10. Xiong J, Sarkar DK, Chen XG (2017) Superhydrophobic honeycomb-like cobalt stearate thin films on aluminum with excellent anti-corrosion properties. Appl Surf Sci 407:361–370

    Article  Google Scholar 

  11. Onda T, Shibuichi S, Satoh N, Tsujii K (1996) Super-water-repellent fractal surfaces. Langmuir 12(9):2125–2127

    Article  Google Scholar 

  12. Ostrovskaya L, Diamant H, Witten TA et al (2000) Roughness-induced non-wetting. Europhys Lett 52(2):165–170

    Article  Google Scholar 

  13. Lafuma A, Quéré D (2003) Superhydrophobic states. Nat Mater 2(7):457–460

    Article  Google Scholar 

  14. Zhang X, Shi F, Niu J et al (2008) Superhydrophobic surfaces: from structural control to functional application. J Mater Chem 18(6):621–633

    Article  Google Scholar 

  15. Yu YJ, Kim JG, Cho SH, Boo JH (2003) Plasma-polymerized toluene films for corrosion inhibition in microelectronic devices. Surf Coat Technol 162(2–3):161–166

    Article  Google Scholar 

  16. Kang Z, Lai X, Sang J, Li Y (2011) Fabrication of hydrophobic/super-hydrophobic nano films on magnesium alloys by polymer plating. Thin Solid Films 520(2):800–806

    Article  Google Scholar 

  17. Huang T, Yeh L, Lai G et al (2016) Advanced superhydrophobic electroactive fluorinated polyimide and its application in anticorrosion coating. Int J Green Energy 14(2):113–120

    Article  Google Scholar 

  18. Yang Z, Wang L, Sun W et al (2017) Superhydrophobic epoxy coating modified by fluorographene used for anti-corrosion and self-cleaning. Appl Surf Sci 401:146–155

    Article  Google Scholar 

  19. Syed JA, Tang S, Meng X (2017) Super-hydrophobic multilayer coatings with layer number tuned swapping in surface wettability and redox catalytic anti-corrosion application. Sci Rep 7:4403

    Article  Google Scholar 

  20. Liu Y, Cao H, Chen Y et al (2016) Self-assembled super-hydrophobic multilayer films with corrosion resistance on copper substrate. RSC Adv 6(3):2379–2386

    Article  Google Scholar 

  21. Liu Q, Chen D, Kang Z (2015) One-Step electrodeposition process to fabricate corrosion-resistant superhydrophobic surface on magnesium alloy. ACS Appl Mater Interfaces 7(3):1859–1867

    Article  Google Scholar 

  22. Qing Y, Yang C, Yu N et al (2016) Superhydrophobic TiO2/polyvinylidene fluoride composite surface with reversible wettability switching and corrosion resistance. Chem Eng J 290:37–44

    Article  Google Scholar 

  23. Ishizaki T, Hieda J, Saito N et al (2010) Corrosion resistance and chemical stability of super-hydrophobic film deposited on magnesium alloy AZ31 by microwave plasma-enhanced chemical vapor deposition. Electrochim Acta 55(23):7094–7101

    Article  Google Scholar 

  24. Vilaró I, Yagüe JL, Borrós S (2017) Superhydrophobic copper surfaces with anticorrosion properties fabricated by solventless CVD methods. ACS Appl Mater Interfaces 9(1):1057–1065

    Article  Google Scholar 

  25. Zhang F, Zhao L, Chen H et al (2008) Corrosion resistance of superhydrophobic layered double hydroxide films on aluminum. Angew Chemie Int Ed 47(13):2466–2469

    Article  Google Scholar 

  26. Ozaydin-Ince G, Coclite AM, Gleason KK (2012) CVD of polymeric thin films: applications in sensors, biotechnology, microelectronics/organic electronics, microfluidics, MEMS, composites and membranes. Rep Prog Phys 75(1):1–42

    Article  Google Scholar 

  27. Dimitrakellis P, Gogolides E (2018) Hydrophobic and superhydrophobic surfaces fabricated using atmospheric pressure cold plasma technology: a review. Adv Colloid Interface Sci 254:1–21

    Article  Google Scholar 

  28. Lau KKS, Gleason KK (2006) Initiated chemical vapor deposition (iCVD) of poly(alkyl acrylates): an experimental study. Macromolecules 39(10):3688–3694

    Article  Google Scholar 

  29. Gupta M, Kapur V, Pinkerton NM, Gleason KK (2008) Initiated Chemical Vapor Deposition (iCVD) of conformal polymeric nanocoatings for the surface modification of high-aspect-ratio pores. Chem Mater 20(4):1646–1651

    Article  Google Scholar 

  30. Coclite AM, Howden RM, Borrelli DC et al (2013) 25th anniversary article: CVD polymers: a new paradigm for surface modification and device fabrication. Adv Mater 25(38):5392–5423

    Article  Google Scholar 

  31. Chan K, Gleason KK (2005) Initiated chemical vapor deposition of linear and cross-linked poly (2-hydroxyethyl methacrylate) for use as thin-film hydrogels. Langmuir 21(9):8930–8939

    Article  Google Scholar 

  32. Coclite AM, Ozaydin-Ince G, D’Agostino R, Gleason KK (2009) Flexible cross-linked organosilicon thin films by initiated chemical vapor deposition. Macromolecules 42(21):8138–8145

    Article  Google Scholar 

  33. Ye Y, Song Q, Mao Y (2011) Single-step fabrication of non-leaching antibacterial surfaces using vapor crosslinking. J Mater Chem 21(3):837–842

    Article  Google Scholar 

  34. Sun M, Wu Q, Xu J et al (2016) Vapor-based grafting of crosslinked poly(N-vinyl pyrrolidone) coatings with tuned hydrophilicity and anti-biofouling properties. J Mater Chem B 4(15):2669–2678

    Article  Google Scholar 

  35. Wang J, Wu L, Zhou J et al (2013) Construction of a novel painting system using electrodeposited SiO2 film as the pretreatment layer. Corros Sci 68:57–65

    Article  Google Scholar 

  36. Ye Y, Zhao H, Wang C et al (2018) Design of novel superhydrophobic aniline trimer modified siliceous material and its application for steel protection. Appl Surf Sci 457:752–763

    Article  Google Scholar 

  37. Chatham H (1996) Review: oxygen diffusion barrier properties of transparent oxide coatings on polymeric substrates. Surf Coat Technol 78:1–9

    Article  Google Scholar 

  38. Gao X, Sheng D, Liu X et al (2016) Tailoring morphology to improve the gas-barrier properties of thermoplastic polyurethane/ethylene-vinyl alcohol blends. Polym Eng Sci 56(8):922–931

    Article  Google Scholar 

  39. Tao R, Anthamatten M (2012) Condensation and polymerization of supersaturated monomer vapor. Langmuir 28(48):16580–16587

    Article  Google Scholar 

  40. Wacaser BA, Dick KA, Johansson J et al (2009) Preferential interface nucleation: an expansion of the VLS growth mechanism for nanowires. Adv Mater 21(2):153–165

    Article  Google Scholar 

  41. Coclite AM, Gleason KK (2012) Global and local planarization of surface roughness by chemical vapor deposition of organosilicon polymer for barrier applications. J Appl Phys 111(7):2929–2941

    Article  Google Scholar 

  42. Gupta M, Gleason KK (2006) Initiated chemical vapor deposition of poly(1H,1H,2H,2H-perfluorodecyl acrylate) thin films. Langmuir 22(24):10047–10052

    Article  Google Scholar 

  43. Xu J, Asatekin A, Gleason KK (2012) The design and synthesis of hard and impermeable, yet flexible, conformal organic coatings. Adv Mater 24(27):3692–3696

    Article  Google Scholar 

  44. Coclite AM, Shi Y, Gleason KK (2012) Grafted crystalline poly-perfluoroacrylate structures for superhydrophobic and oleophobic functional coatings. Adv Mater 24(33):4534–4539

    Article  Google Scholar 

  45. Khorsand S, Raeissi K, Ashrafizadeh F (2014) Corrosion resistance and long-term durability of super-hydrophobic nickel film prepared by electrodeposition process. Appl Surf Sci 305:498–505

    Article  Google Scholar 

  46. Li Y, Ge B, Men X et al (2016) A facile and fast approach to mechanically stable and rapid self-healing waterproof fabrics. Compos Sci Technol 125:55–61

    Article  Google Scholar 

  47. Yagüe JL, Gleason KK (2013) Enhanced cross-linked density by annealing on fluorinated polymers synthesized via initiated chemical vapor deposition to prevent surface reconstruction. Macromolecules 46(16):6548–6554

    Article  Google Scholar 

  48. Chang CH, Huang TC, Peng CW et al (2012) Novel anticorrosion coatings prepared from polyaniline/graphene composites. Carbon 50(14):5044–5051

    Article  Google Scholar 

  49. Li X, Bandyopadhyay P, Nguyen TT et al (2018) Fabrication of functionalized graphene oxide/maleic anhydride grafted polypropylene composite film with excellent gas barrier and anticorrosion properties. J Memb Sci 547:80–92

    Article  Google Scholar 

Download references

Acknowledgements

We thank Prof. Haichao Zhao and Ms. Shihui Qiu for the assistance with the electrochemical tests. We are grateful for the funding support from the National Natural Science Foundation of China (51873093), Technology Foundation for Selected Overseas Chinese Scholars by Ministry of Personnel of China, and Ningbo “3315” Innovation Initiative. This work was also sponsored by K. C. Wong Magna Fund in Ningbo University.

Author information

Authors and Affiliations

  1. Faculty of Materials Science and Chemical Engineering, Ningbo University, Ningbo, 315211, People’s Republic of China

    Ying Chen & Yumin Ye

  2. Department of Chemistry, Southern University of Science and Technology, Shenzhen, 518055, People’s Republic of China

    Zhong-Ren Chen

Authors
  1. Ying Chen
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Yumin Ye
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Zhong-Ren Chen
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Yumin Ye.

Electronic supplementary material

Below is the link to the electronic supplementary material.

Supplementary material 1 (DOCX 867 kb)

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Chen, Y., Ye, Y. & Chen, ZR. Vapor-based synthesis of bilayer anti-corrosion polymer coatings with excellent barrier property and superhydrophobicity. J Mater Sci 54, 5907–5917 (2019). https://doi.org/10.1007/s10853-018-03232-7

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s10853-018-03232-7

Search

Navigation