Researchers have developed a highly effective dual-layer coating that provides 99.6% protection against iron corrosion. The breakthrough combines a thin molecular primer with a durable polymer layer, creating a strong, long-lasting barrier against rust. This innovation could significantly reduce maintenance costs and extend the lifespan of iron-based materials used in construction, transportation, and manufacturing.

Researchers at the Hebrew University of Jerusalem have developed a highly effective new coating that can protect iron from rust with 99.6% efficiency. Led by Prof. Elad Gross from the NanoCenter and Institute of Chemistry at Hebrew University, the study introduces an innovative two-layer coating system that significantly improves upon existing methods for preventing corrosion. The work is published in the journal Angewandte Chemie International Edition.

Iron is widely used in industries such as construction, transportation, and manufacturing, but it is highly prone to rust when exposed to air and moisture. Rust weakens the metal, leading to structural damage and costly repairs. While protective coatings exist, many tend to degrade over time, offering limited long-term protection.

The new research presents a solution by combining two protective layers that work together to create a strong and long-lasting barrier. The first layer is an ultra-thin coating made of N-Heterocyclic Carbene (NHC) molecules, which form a tight bond with the iron surface.

This primer layer ensures that the second layer—a polymer-based coating—sticks firmly, creating a highly stable and durable protective shield. Thanks to this improved adhesion, the coating remains intact even in harsh conditions, such as prolonged exposure to saltwater.

Experiments showed that this dual-layer system dramatically reduced the amount of corrosion, with tests conducted in a highly corrosive saltwater environment confirming its exceptional efficiency. By forming a strong chemical connection between the iron and the protective layers, this method offers far greater durability than conventional coatings, which often wear down or peel off over time.

“This discovery offers a major leap forward in protecting iron from corrosion,” said Prof. Gross. “By using a specially designed primer, we created a coating that is not only highly effective but also long-lasting. This could reduce maintenance costs, extend the lifespan of iron-based materials, and provide industries with a much more reliable solution.”

This breakthrough has broad implications for industries that rely on iron and steel, from construction and transportation to infrastructure and manufacturing. By reducing the need for frequent repairs and replacements, this coating could also contribute to more sustainable and cost-effective material use.