Functional Coatings

Raj K. Arya, PhD, is an Associate Professor in the Department of Chemical Engineering at Dr. B. R. Ambedkar National Institute of Technology, Jalandhar, India. George D. Verros, PhD, works as a Chemical Engineer for public sector environmental projects in Greece. J. Paulo Davim, PhD, is a Full Professor in the Department of Mechanical Engineering at the University of Aveiro, Portugal.

List of Contributors xxiv

Preface xxx

Part I Introduction and Fundamentals 1

1 Introduction to Functional Coatings 3
Devyani Thapliyal, Sarojini Verma, Kshitij Tewari, Chitresh Kumar Bhargava, Pramita Sen, Simmi Goel, Gargi Ghoshal, George D. Verros, and Raj K. Arya

1.1 Introduction 3

1.2 Various Types of Coatings 5

1.3 Manufacturing of Coatings 12

1.4 Characterization of Coatings 15

1.5 Applications of Coatings 18

1.6 Conclusion 18

2 Innovative Coating Methods for the Industrial Applications 23
Kshitij Tewari, Devyani Thapliyal, Chitresh Kumar Bhargava, Sarojini Verma, Anshi Mehra, Snehil Rana, Arvind K. Gautam, George D. Verros, and Raj K. Arya

2.1 Introduction 23

2.2 Spray Coating 25

2.3 Various Types of Chemical Conversion Coatings 28

2.4 Spin Coating 33

2.5 Drop Casting Coatings 34

2.6 Sol–Gel Coatings 37

2.7 Dip Coating 37

2.8 Blade/Doctor Blade Coating 39

2.9 Self-cleaning Coatings 39

2.10 Composite Coatings 40

2.11 Powder Coatings 41

2.12 Ultraviolet Curing 41

2.13 Electron Beam (EB) Curing Method 43

2.14 Hot Melt Coating (HMC) 44

2.15 Atomic Layer Deposition (ALD) 44

2.16 Electrochemical Plating 45

2.17 Slot/Die Coating 45

2.18 Conclusion 46

3 Coatings Research Institutes, Organizations, Associations, Societies, Academic Departments, and Centers 51
Sarojini Verma, Devyani Thapliyal, Arvind K. Gautam, Chitresh Kumar Bhargava, Kshitij Tewari, Avinash Chandra, Pramita Sen, George D. Verros, and Raj K. Arya

3.1 Introduction 51

3.2 Coatings Organizations 52

3.3 Coating Industries 60

3.4 List of Academic Institutions Dealing with Coatings 60

3.5 Conclusion 82

Part II Functional Protective Coatings 83

4 Anticorrosion Coating: Protective Mechanism and Classifications 85
Kamleshwar Kumar, Shailendra Singh Bhadauria, Amanpreet Kaur, and Raj K. Arya

4.1 Background of Corrosion 85

4.2 Importance of Anticorrosion Coatings 90

4.3 Classification of Anticorrosion Coating 91

4.4 Discussion on Protective Mechanisms and Applications of Anticorrosion Coatings 93

5 Advances in Corrosion-Resistant Coatings: Types, Formulating Principles, Properties, and Applications 110
Ganesh S. Zade and Kiran D. Patil

5.1 Introduction 110

5.2 Types of Corrosion 111

5.3 Factors Affecting the Corrosion 115

5.4 Methods of Corrosion Prevention 119

5.5 Corrosion-Resistant Coatings 120

5.6 Classifications of Corrosion-Resistant Coatings 122

5.7 Formulating Principles of Corrosion-Resistant Coatings 124

5.8 Selection of Raw Material for Coating 131

5.9 Properties of Corrosion-Resistant Coatings 132

5.10 Applications of Corrosion-Resistant Coatings 135

5.11 Recent Advances in Corrosion-Resistant Coatings 136

5.12 Emerging Coating Technologies in Corrosion Protection 140

5.13 Conclusion and Future Aspects of Corrosion-Resistant Coatings 141

5.14 Future Aspects of Corrosion-Resistant Coatings 142

6 Anticorrosion Coating Using Natural Biopolymer 153
S.K. Sundar and Jeel Solanki

6.1 Introduction 153

6.2 Corrosion Environment 155

6.3 Classification of Corrosion 155

6.4 Anticorrosion Techniques 157

6.5 Biopolymers for Anticorrosion Applications 158

6.6 Conclusion and Future Perspectives 165

7 Marine Coatings 168
Vishal Chauhan, Nihar Sakhadeo, and T. Umasankar Patro

7.1 Introduction 168

7.2 Coating Surfaces 171

7.3 Surface Preparations 173

7.4 Coating Methods for Marine Coatings 175

7.5 Performance Analysis of Coating 176

7.6 Coating Defects/Failures 177

7.7 Chemistry of Coating Materials 181

7.8 Classification of Marine Coatings Based on Their Functions 185

7.9 Conclusions and Future Prospects 193

8 Fire-Retardant Coatings for Modern Lightweight Materials: Contemporary and Future Perspectives 202
Anupreet Kaur , Karan Kapoor , Aadhar Mandot , Sachin Kumar Godara , Ashwini Kumar Sood , and Mandeep Singh

8.1 Introduction 202

8.2 Fire 204

8.3 Burning Cycle for Different Fiber/Polymers 205

8.4 Methods of Achieving Flame Retardancy in Textiles 207

8.5 Coatings 212

8.6 Flame Resistant Versus Fire Retardant 217

8.7 Fire-Retardant Coatings and Their Implications on the Environment 218

8.8 Synthesizing Fire-Retardant Coatings 219

8.9 Contemporary Uses for Fire-Retardant Coatings 225

8.10 Eminence of Fire-Retardants Coatings 226

8.11 Shortcomings 226

8.12 Future Perspectives 227

8.13 Conclusion 227

Part III Other Type of Functional Coatings 231

9 Antimicrobial Coatings: Current Mechanisms, Challenges, and Opportunities 233
Sushama Agarwalla, Sunil Kumar Singh, Mohammed Adil Ibrahim, Hemanth Noothalapati, and Suhanya Duraiswamy

9.1 Introduction 233

9.2 Inorganic Nanomaterials as Antimicrobial Agents 234

9.3 Polymer Antimicrobial Coatings 240

9.4 Organic Antimicrobial Coatings 248

9.5 Toxicity and Environmental Consideration 255

9.6 Emerging Trends in Antimicrobial Surfaces and Coating 259

9.7 Summary 262

10 Synthesis Mechanisms for Antimicrobial Polymeric Coatings 275
Devyani Thapliyal, George D. Verros, and Raj K. Arya

10.1 Introduction 275

10.2 Mechanisms of Action of Antimicrobial Agents 276

10.3 Synthesis Methods for Antimicrobial Polymeric Coatings 277

10.4 Applications of Antimicrobial Polymeric Coatings 285

10.5 Challenges and Future Perspectives 286

11 Superhydrophobic Coatings: Insights and Real-World Applications 299
Sonanki Keshri, S. Sudha, Subhajit Roychowdhury, and Kishant Kumar

11.1 Introduction to Functional Coatings 299

11.2 Design of Superhydrophobic Surfaces 304

11.3 Superhydrophobic Materials and Coatings: Emerging Applications 318

11.4 Current Developments and Challenges of Designs of Superhydrophobic Materials 326

11.5 List of Coating Research Institutes 327

11.6 Summary and Perspectives 327

12 Nature-Inspired Sustainable Superhydrophobic/Superoleophobic Coatings for Emulsified Oil/Water Separation 338
Arun K. Singh, Lipika, and Reeta Rani Singhania

12.1 Introduction 338

12.2 Basic Strategies for Oil/Water Emulsion Separation 340

12.3 Coated Surfaces for Emulsified Oil/Water Separation 341

12.4 Conclusion 357

13 Nano-powder Coatings: Manufacturing, Curing, and Applications 365
Dhiraj Kishor Tatar , Jay Mant Jha, Devendra Rai, Yash Jaiswal, Jamna Prasad Gujar , Vinay Raj, and Shanmuk Srinivas Ravuru

13.1 Introduction 365

13.2 Manufacturing of Nano- powder Coatings 367

13.3 Comparisons to Liquid Coatings 368

13.4 Nano- powder Curing Process 369

13.5 Methods to Apply Nano- powder Coatings 370

13.6 Applications of Nano- powder Coatings 374

13.7 Advantages of Nano- powder Coatings 374

13.8 Conclusions 375

14 Icephobic Coatings: Current Trends and Future Perspectives 380
Utkarsha Umesh Gwalwanshi, Jitendra S. Narkhede, Narayanan Rajagopalan, and Ravindra G. Puri

14.1 Introduction 380

14.2 Surface Energy, Contact Angle, and Wettability 381

14.3 Icephobicity 384

14.4 Strategies Involved in Icephobic Coating 387

14.5 Evaluation of Icephobic Coatings 395

14.6 Conclusion and Future Scopes 397

15 Role of Wetting and Dispersing Additives in Coatings 407
Shiv Charan Prajapati and Raj K. Arya

15.1 Introduction 407

15.2 Wetting and Dispersing Additive 408

15.3 Why Wetting and Dispersing Agents Required? 409

15.4 Role of Wetting and Dispersing Additives 409

15.5 Mechanism of Wetting and Dispersing Additive 411

15.6 Wetting and Dispersing Process of Pigments 413

15.7 Chemical Classification of Wetting and Dispersing Agents 416

15.8 Challenges in the Paint Industry 420

15.9 Living Polymerization 420

15.10 Conclusion 421

15.11 Future Recommendations 422

16 Surface Defects—Causes, Prevention, and Remedies 426
Preetam Satish Bharadiya, Utkarsha U. Gwalwanshi, Narayanan Rajagopalan, and Ravindra G. Puri

16.1 Introduction 426

16.2 Surface Coating Defects 428

16.3 Additives to Prevent Surface Defects 439

16.4 Identification of Defects 441

16.5 Future Recommendations 442

17 Machine Learning in Commercialized Coatings 450
Harshit Mittal and Omkar Singh Kushwaha

17.1 Introduction 450

17.2 Machine Learning Methods 454

17.3 Discovery Using Machine Learning 464

17.4 Conclusions 467

17.5 Future Perspectives 468

18 Advanced Characterization Techniques for Functional Coatings 475
Kamleshwar Kumar, Shailendra Singh Bhadauria, Amanpreet Kaur, and Raj K. Arya

18.1 Background of Functional Coatings 475

18.2 Need for Advanced Characterization Techniques 476

18.3 Classifications of Advanced Characterization Techniques 476

18.4 Discussion on Morphological Characterization Techniques 477

18.5 Discussion on Compositional Characterization Techniques 486

18.6 Discussion on Crystallographic Characterization Techniques 492

18.7 Discussion on Mechanical and Thermal Characterization Techniques 498

19 Thermal Characterization of Passive Fire Protection Coatings Using Bayesian Inference 508
Siva K. Bathina, Dharitri Kahali, Mahesh Kumar Tiwari, Deepak Sahu, and Dharmit Nakrani

19.1 Introduction 508

19.2 Inverse Problem 510

19.3 Conclusions 519

20 Sophisticated Characterization Techniques for Structure–Property Evaluation of Functional Coatings 522
Swati Chopra, Jeetendra Kumar Banshiwal, Amit Singh, and Dibeyndu Sekhar Bag

20.1 Introduction 522

20.2 Fundamental Characterization of Functional Coatings 524

20.3 Evaluation of Structure–Property Relationship for Functional Coatings 538

20.4 Current Status and Future Challenges 568

20.5 Concluding Remarks 568

Author's Contribution 570

Acknowledgment 570

Conflicts of Interest 570

References 570

Index 585