Graphene-like two-dimensional nanosheets-based anticorrosive coatings: A review

doi:10.1016/j.jmst.2022.04.032

Abstract

Abstract:

In recent years, graphene has been widely employed in the field of metal corrosion protection owing to its outstanding impermeability and chemical stability, with examples of such metal protection including pure graphene coatings and graphene-based composite coatings. But the conductive graphene could promote the electrochemical reaction at the interface and accelerate the corrosion of metal substrates. More emerging graphene-like 2D nanosheets are attracting research attention for the application of metal anticorrosion, because of their barrier properties and poor conductivity, mainly including boron nitride (BN), molybdenum disulfide (MoS₂), zirconium phosphate (ZrP), and titanium carbide (MXene). In this review, the application of these graphene-like 2D nanosheets to metal protection is comprehensively reviewed. First, the general preparation methods of 2D nanosheets are briefly introduced. Second, surface functionalization of 2D nanosheets, including covalent and non-covalent modification, is described in detail. Third, the anticorrosion performance and optimization measures of pure 2D nanosheets coatings are summarized. Next, the protection performance, anticorrosive mechanism, and optimizations of 2D nanosheets composite coatings are presented. Finally, the future development of 2D nanosheets-based anticorrosive coatings has been prospected, and the challenges in the industrial application are discussed.

Key words: Two-dimensional nanomaterials, Surface functionalization, Polymer composite coatings, Metal, Corrosion protection

Yumin Zhang, Jiulong Sun, Xinzhe Xiao, Ning Wang, Guozhe Meng, Lin Gu. Graphene-like two-dimensional nanosheets-based anticorrosive coatings: A review[J]. J. Mater. Sci. Technol., 2022, 129: 139-162.

Figures/Tables 24

Fig. 1. Three-dimensional representation of the structure of BN, MoS2, MXene, ZrP, BP, and mica nanosheets.

Fig. 2. Number of published articles involving anticorrosion of graphene-like 2D nanosheets.

Fig. 3. Summary of preparation and surface modification of 2D nanosheets and their use for anticorrosive coatings.

Table 1. Comparison of advantages and disadvantages of different preparation methods of 2D nanosheets [21].

Preparation method	Advantage	Disadvantage
Mechanical exfoliation	high crystal quality, clean surface, and large lateral size	low production yield always needs a substrate, hard to control accurately the size and shape of nanosheets, more suitable for lager layered crystals
Liquid exfoliation	precise to regulate the concentration, lateral size, and thickness of synthesized nanosheets, the obtained volume of sheets alters from hundreds of milliliters to liters	relatively low yield, small lateral size, the used polymers, and surfactants are usually harmful
Chemical vapor deposition	produce ultrathin 2D nanosheets	high temperature and high vacuum, complicated and low efficient, needs the desired substrate, the complicated transfer process
Wet-chemical method	high reaction yield, easier control of size and morphology, very good dispersion in organic or aqueous media	difficult to control the final morphology, hard to achieve single-layer nanosheets

Fig. 4. Summary of preparation methods of boron nitride nanosheets [25?-27,33???-37].

Fig. 5. (a) Process of exfoliation of layered α-ZrP [68]. (b) Exfoliation of DGA-intercalated ZrP nanoplatelets with ionic liquids [71]. (c) Schematic illustrations of interlayer spacing of α-ZrP treated with different organic modifiers: (A) cyclohexylamine, (B) dodecylamine, and (C) an equal mixture of cyclohexylamine and dodecylamine [72].

Fig. 6. Summary of functionalization methods of boron nitride nanosheets [94???-98,102,104,105].

Fig. 7. (a) Schematic illustration of the functionalization of nanosheets of 1T-MoS2 and 1T-MoSe2 with para-substituted iodobenzenes [106]. (b) Preparation process of the functional MoS2 modified with L-cysteine [107]. (c) Synthesis of MoS2-PAN and pyro-MoS2-PAN [109].

Fig. 8. (a) Possible mechanism for the evolution of hierarchical MoS2@RGO [113]. (b) Schematic graph of the preparation process of EP/SiO2-MoS2 composite coating [114].

Fig. 9. (a) Schematic illustration for the preparation routes: F-ZrP and ALSR/F-ZrP nanocomposite [125]. (b) Preparation of ZrP single-layer nanosheets; grafting reaction on the surface of ZrP single-layer nanosheets [126]. (c) Illustration of the synthetic procedure of functionalized α-zirconium phosphate [128]. (d) Proposed mechanism for the surface modification of ZrP disks for PNIPAM grafting [129].

Fig. 10. (a) A diagram illustrating the preparation of hydrophobic MXene film. Insert photograph: contact angle of hydrophilic and hydrophobic MXene film [134]. (b) Schematic diagrams of PPy-MXene coated textile SCs [137].

Fig. 11. (a) Schematic illustration for the preparation of MnO2/MXene@C [139]. (b) Schematic illustration of the procedure for preparing the phosphate ion-modified RuO2/Ti3C2 composite (PRT) [140].

Fig. 12. (a) Antibacterial mechanism diagram of Cu, G/Cu, h-BN/Cu samples [151]. (b) Diagram of biological corrosion mechanism of Cu and h-BN/Cu samples [152].

Fig. 13. (a) CAs and SAs for water and cetane in MoS2 films and cetane drop placed on 4-MoS2 films [155]. (b) Schematic diagram of MoST/Graphit-iC coating deposition process [156].

Fig. 14. (a) State of 1 mg/mL nanoplate dispersion after standing in water for 2 h [171]. (b) Interaction between h-BN and CAT- [171]. (c) Preparation of h-BN-rGO@PDA/PVB composite coating [172]. (d) Schematic representation of the preparation of h-BN@PDA and h-BN-Fe3O4 [173]. (e) Schematic illustration of the preparation of the BN(OH)x-PrGO filler [174].

Fig. 15. (a) Synthesis mechanism of SiO2-MoS2 core-shell nanoparticles and corrosion resistance mechanism of SiO2-MoS2/epoxy composite coating [178]. (b) Preparation of KZPM filler and its action mechanism in coatings [179].

Fig. 16. (a) Schematic diagram for the preparation of the PDA-ZrP/ WER nanocomposite coating and how PDA-ZrP improves the barrier properties of the coating [181]. (b) Process of exfoliation and functionalization of α-ZrP (f-ZrP) and the preparation of f-ZrP/WEP nanocomposite coatings [133]. (c) Schematic illustration of the fabrication process of the composite containing coating and the structure of PANI/a-ZrP composite [184]. (d) Corrosion mechanism of neat epoxy coating and composite containing coating [184].

Fig. 17. (a) Schematic illustration of preparation of the amino functionalized Ti3C2Tx [190]. (b) Schematic illustration of fabrication process of the wrapping structure of Ti3C2/graphene hybrid [192]. (c) Schematic diagram of preparation of T/EP-on-MAO [191]. (d) Schematic representation of the preparation of Ti3C2Tx nanosheets and the process for the synthesis of Ti3C2Tx/PANI composites (TPCs) [193].

Fig. 18. (a) Schematic illustration exhibiting the synthesis mechanism of ultrathin MNSs. (b) Schematic illustrations of the steps of the preparation of MNS/EP coatings and the barrier mechanism. (c) Bode-phase plots and Bode-modulus plots for MNS/EP samples after two months of immersion [20].

Fig. 19. Multi-scale graphene-based coating systems and computational models [198].

Fig. 20. Schematic of the interaction and passivation behavior of different graphene-coated metals [204].

Fig. 21. (a) Schematic diagrams of the anticorrosion mechanisms for graphene-based composite coatings. (b) Schematic of the interfacial interaction between graphene and coating matrix. The illustrations of (c) homogenously dispersed, (d) aligned, and (e) connected graphene layers in the coating matrix [198].

Fig. 22. Schematic representation of visualization of 3D macrodispersion of fillers in organic-inorganic composites. The inorganic fillers modified and bound with AIE molecules are dispersed inside the organic matrix, and then directly visualized by CFM [205].

Fig. 23. Schematic illustration about the formation of cylindrical mesoporous PDA on HA nanosheets and BTA loading process [209].

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