Waterborne Polyurethanes Enriched with Graphene-Based Nanostructures: Fabrication, Properties, and Exploring Their Anti-Corrosion Performance

Abstract

Metal corrosion poses a global threat, causing significant economical and environmental damage in various industries. Extensive research has been conductedtodevelopefficientandcost-effectivesolutionstopreventcorrosion while adhering to environmental regulations. Recently, waterborne polyurethanes, prepared by dispersing polyurethanes in water through various methods, have been increasingly used for coating various surfaces due to their advantages such as low emission of volatile organic compounds (VOCs), environmental compatibility, low viscosity, rapid coating capability, and low production cost. Waterborne polyurethane coatings are considered suitable for anti-corrosion applications due to their mechanical strength, flexibility, high abrasion resistance, and the ability to design structures and incorporate various nanoparticles. Recent research has shown that graphene-based nanostructures, such as graphene, graphene oxide (GO), and reduced graphene oxide (rGO), are used as corrosion-inhibiting nanostructures in the formulation of anti-corrosion coatings due to their high surface area and resistance to oxygen, water, and corrosive agents. Incorporating these nanostructures into waterborne polyurethanes has enhanced the anti-corrosion properties of the resulting coatings. However, the application of these nanostructures in waterborne polyurethane matrices faces limitations such as non-uniform dispersion, low stability of aqueous dispersions, and the formation of agglomerates. This review paper elucidates the phenomenon of corrosion and various anti-corrosion testing methods, introducing waterborne polyurethanes and graphene-based nanostructures. Subsequently, it reviews related articles on the preparation of waterborne polyurethane coatings containing different graphene-based nanostructures and their anti-corrosion performance. Additionally, recent advancements in the development of waterborne polyurethane/graphene-based nanostructure anti-corrosion coatings with specific structural features, such as self-healing and ultraviolet curing capabilities, are examined. Furthermore, multi-functional anti-corrosion coatings with properties like anti-fouling, superhydrophobicity, and antibacterial characteristics for specific applications are described. © 2024 Iran Polymer Society. All rights reserved.