Researchers at the Indian Institute of Technology Bhilai, in collaboration with the Indian Institute of Technology Patna, have developed an advanced multifunctional polymer coating capable of simultaneously protecting metal surfaces from corrosion and enhancing fire safety, marking a significant breakthrough in advanced materials research with wide-ranging industrial applications.

The research, led by Dr. Sanjib Banerjee of the Department of Chemistry, Indian Institute of Technology Bhilai, was carried out by a team comprising Nishikanta Singh, Swarup Maity, Soumen Ghosh, and Dr. Subrata Chattopadhyay in collaboration with researchers from the Indian Institute of Technology Patna. The findings have been published in the internationally acclaimed journal Advanced Functional Materials (Wiley-VCH), underscoring India's growing contribution to next-generation materials research.

 

Corrosion of metallic structures and fire-related damage continue to pose major challenges across industries, resulting in substantial economic losses, safety risks and increased maintenance expenditure. Conventional protective coatings are generally designed to perform only a single function, often requiring multiple layers or additional additives to achieve comprehensive protection. Addressing this limitation, the research team has engineered a phosphorus- and fluorine-based polymer coating that integrates multiple critical protective functions into a single material.

 

The newly developed coating intelligently responds to environmental conditions while providing comprehensive protection. It effectively prevents rust and corrosion on metallic surfaces, exhibits strong adhesion to minimise peeling, and significantly enhances fire resistance by slowing the spread of flames. Extensive laboratory evaluations demonstrated that the coating maintains its performance even under harsh operating conditions, including prolonged exposure to saltwater, outdoor weathering and fluctuating environmental conditions.

 

According to Dr. Sanjib Banerjee, industries currently depend on multiple coatings and treatments to achieve corrosion resistance, durability and fire protection. The newly developed material demonstrates that these essential properties can be integrated into a single coating system, offering a simpler, more efficient and potentially cost-effective solution for a broad spectrum of industrial applications.

 

The coating is expected to extend the operational life of infrastructure, transportation systems, industrial equipment, marine structures, energy devices and other critical assets by reducing corrosion, improving durability and enhancing fire safety. Its robust adhesion and long-term stability are also expected to lower maintenance requirements and improve operational reliability.

 

The innovation supports the Government of India's vision of building durable infrastructure, promoting industrial safety and advancing sustainable manufacturing under national initiatives such as Atmanirbhar Bharat, Make in India, Prime Minister Gati Shakti, and the National Infrastructure Pipeline. By integrating multiple protective functions into a single material platform, the technology has the potential to reduce maintenance costs, improve infrastructure resilience and minimise economic losses associated with corrosion and fire damage.

 

The publication of this research in Advanced Functional Materials, one of the world's leading journals in advanced materials science, highlights the growing research capabilities of the Indian Institute of Technology Bhilai in developing innovative technologies for industrial sustainability and infrastructure protection.

 

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