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Journal of Polymer & Composites Original Research

Hybrid Nanoclay–Polymer Coatings with Embedded Corrosion-Sensing Microchips for Predictive Maintenance Systems

  1. Y. Sherlin Nisha Department of Mathematics, Sri Sairam Engineering College, Chennai
  2. Nagasrisaihari Sunkara Department of Mechanical Engineering, VNR vignana Jyothi Institute of Engineering and Technology, Hyderabad
  3. Parameswari. S Department of Chemistry, Velammal Institute of Technology, Kolkata
  4. S.Rama Department of Physics, St.Joseph's College of Engineering, Chennai
  5. Hari Banda Faculty of Engineering and Technology, Villa College
  6. Rajabharathi B Department of Mechanical Engineering, Academy of Maritime Education and Training (AMET), Deemed to be University, Chennai
  7. Jagath Narayana Kamineni Department of Mechanical Engineering, Sri Venkateswara College of Engineering, Tirupati
  8. Sheik Mydeen S Department of Chemistry, Sethu Institute of Technology, Thoothukudi
  9. S. M. Prakash Department of Chemistry, DMI College of Engineering, Chennai

Abstract

Polymer-composite coatings provide a versatile route for combining corrosion protection, barrier reinforcement, and functional monitoring within a single material architecture. In this study, an epoxy-based polymer composite reinforced with organically modified montmorillonite (OMMT) was developed as a multifunctional protective coating and integrated with an embedded corrosion-sensing microchip. OMMT contents of 0.5, 1.0, 1.5, and 2.0 wt.% were incorporated into the epoxy polymer-composite matrix through mechanical stirring and ultrasonication, while neat epoxy served as the reference. The nanoclay phase was introduced to modify polymer-composite morphology, increase polymer–nanofiller interfacial area, enhance transport tortuosity, and reduce continuous diffusion pathways for water and chloride ions. The polymer-composite coatings were characterized using X-ray diffraction, FESEM–EDS, electrochemical impedance spectroscopy, and microchip-based corrosion sensing. XRD evaluated clay intercalation and structural changes within the epoxy polymer composite, whereas FESEM–EDS examined morphology, porosity, nanoclay dispersion, and elemental distribution. EIS assessed the barrier performance of the polymer-composite coatings during immersion in 3.5 wt.% NaCl solution. The embedded microchip monitored physicochemical changes associated with moisture ingress, ionic penetration, and coating degradation. Overall, the protective behaviour of the system is governed by polymer-composite architecture, nanoclay dispersion, polymer–clay interactions, and barrier continuity, while the sensing element adds real-time condition-monitoring capability. This multifunctional polymer-composite concept offers a promising basis for smart coatings intended for predictive maintenance of metallic structures while retaining the epoxy matrix as the continuous protective phase.

Keywords

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