Fluorescent material-integrated polymeric anti-corrosion coating: A comprehensive review

Abstract

Corrosion significantly impacts metallic structures, causing severe safety hazards and financial setbacks. Catastrophic failures caused by undetected corrosion, such as the 2013 oil pipeline explosion in Qingdao, China, and the 2014 Kaohsiung explosion in Taiwan, highlight the urgency of effective detection strategies. Globally, corrosion costs exceed $4 trillion annually—6% of global GDP—split between maintenance efforts and damage-related losses. Detecting early-stage corrosion is vital but challenging with conventional methods. Fluorescent material-based polymeric coatings have emerged as a transformative technology for early corrosion detection. These smart coatings incorporate fluorescence-based indicators that react to corrosion byproducts, such as metal ions or acidic species, by altering their fluorescence properties. This provides a real-time, non-invasive method for monitoring metal integrity, enabling early interventions and reducing maintenance costs. This review examines the mechanisms of fluorescence-based corrosion detection, specifically for the types of fluorescent indicators used, their integration into polymeric matrices, and analytical methods for fluorescence monitoring. These coatings offer significant advantages, including continuous monitoring and early warning of corrosion, preventing advanced-stage damage. Challenges remain in optimizing these systems for diverse environments and improving their sensitivity and durability. However, advances in this field promise significant benefits for industries reliant on metal infrastructure. The future lies in integrating these coatings with real-time monitoring systems, leveraging predictive analytics and collaboration between industry and academia. Such innovations will revolutionize corrosion management, making it more proactive, cost-effective, and standardized.