Functional Coatings: Innovations and Challenges

FUNCTIONAL COATINGS A must-own resource for understanding functional coatings and their revolutionary potential Functional coatings are those which provide not only the protection and performance enhancement of a conventional coating, but also offer additional properties tailored to meet the specific requirements of a given industry or application. They have applications in a huge range of sectors, including automotive, aerospace, healthcare, energy, and more. Coatings with properties like fire retardancy, antimicrobial properties, or controlled drug release have the potential to revolutionize entire industries. Functional Coatings offers a comprehensive resource for engineers and researchers looking to understand these coatings and the opportunities they provide. Beginning with an overview of the subject’s foundations and industrial significance, the book analyzes numerous coating methods and their properties, with a particular focus on anticorrosion coatings. The result is an indispensable resource for professionals in virtually any technological industry looking to understand the benefits of a cutting-edge toolkit. Functional Coatings readers will also find: Coverage of synthesis, durability, reproducibility, cost-effectiveness, specialized surface morphology, and environmental friendliness of each coating Detailed discussion of antimicrobial coatings, fire-retardant coatings, self-healing coatings, nanopowder coatings, coatings for marine applications, and many more Applications of additives, machine learning, and sophisticated characterizations, etc. as per industry requirements Functional Coatings is ideal for researchers, engineers, and industry professionals working with any area of technology where coatings have purchase.

Table of Contents:
List of Contributors xxiv Preface xxx Part I Introduction and Fundamentals 1 1 Introduction to Functional Coatings 3 Devyani Thapliyal, Sarojini Verma, Kshitij Tewari, Chitresh Kumar Bhargava, Pramita Sen, Simmi Goel, Gargi Ghoshal, George D. Verros, and Raj K. Arya 1.1 Introduction 3 1.2 Various Types of Coatings 5 1.3 Manufacturing of Coatings 12 1.4 Characterization of Coatings 15 1.5 Applications of Coatings 18 1.6 Conclusion 18 2 Innovative Coating Methods for the Industrial Applications 23 Kshitij Tewari, Devyani Thapliyal, Chitresh Kumar Bhargava, Sarojini Verma, Anshi Mehra, Snehil Rana, Arvind K. Gautam, George D. Verros, and Raj K. Arya 2.1 Introduction 23 2.2 Spray Coating 25 2.3 Various Types of Chemical Conversion Coatings 28 2.4 Spin Coating 33 2.5 Drop Casting Coatings 34 2.6 Sol–Gel Coatings 37 2.7 Dip Coating 37 2.8 Blade/Doctor Blade Coating 39 2.9 Self-cleaning Coatings 39 2.10 Composite Coatings 40 2.11 Powder Coatings 41 2.12 Ultraviolet Curing 41 2.13 Electron Beam (EB) Curing Method 43 2.14 Hot Melt Coating (HMC) 44 2.15 Atomic Layer Deposition (ALD) 44 2.16 Electrochemical Plating 45 2.17 Slot/Die Coating 45 2.18 Conclusion 46 3 Coatings Research Institutes, Organizations, Associations, Societies, Academic Departments, and Centers 51 Sarojini Verma, Devyani Thapliyal, Arvind K. Gautam, Chitresh Kumar Bhargava, Kshitij Tewari, Avinash Chandra, Pramita Sen, George D. Verros, and Raj K. Arya 3.1 Introduction 51 3.2 Coatings Organizations 52 3.3 Coating Industries 60 3.4 List of Academic Institutions Dealing with Coatings 60 3.5 Conclusion 82 Part II Functional Protective Coatings 83 4 Anticorrosion Coating: Protective Mechanism and Classifications 85 Kamleshwar Kumar, Shailendra Singh Bhadauria, Amanpreet Kaur, and Raj K. Arya 4.1 Background of Corrosion 85 4.2 Importance of Anticorrosion Coatings 90 4.3 Classification of Anticorrosion Coating 91 4.4 Discussion on Protective Mechanisms and Applications of Anticorrosion Coatings 93 5 Advances in Corrosion-Resistant Coatings: Types, Formulating Principles, Properties, and Applications 110 Ganesh S. Zade and Kiran D. Patil 5.1 Introduction 110 5.2 Types of Corrosion 111 5.3 Factors Affecting the Corrosion 115 5.4 Methods of Corrosion Prevention 119 5.5 Corrosion-Resistant Coatings 120 5.6 Classifications of Corrosion-Resistant Coatings 122 5.7 Formulating Principles of Corrosion-Resistant Coatings 124 5.8 Selection of Raw Material for Coating 131 5.9 Properties of Corrosion-Resistant Coatings 132 5.10 Applications of Corrosion-Resistant Coatings 135 5.11 Recent Advances in Corrosion-Resistant Coatings 136 5.12 Emerging Coating Technologies in Corrosion Protection 140 5.13 Conclusion and Future Aspects of Corrosion-Resistant Coatings 141 5.14 Future Aspects of Corrosion-Resistant Coatings 142 6 Anticorrosion Coating Using Natural Biopolymer 153 S.K. Sundar and Jeel Solanki 6.1 Introduction 153 6.2 Corrosion Environment 155 6.3 Classification of Corrosion 155 6.4 Anticorrosion Techniques 157 6.5 Biopolymers for Anticorrosion Applications 158 6.6 Conclusion and Future Perspectives 165 7 Marine Coatings 168 Vishal Chauhan, Nihar Sakhadeo, and T. Umasankar Patro 7.1 Introduction 168 7.2 Coating Surfaces 171 7.3 Surface Preparations 173 7.4 Coating Methods for Marine Coatings 175 7.5 Performance Analysis of Coating 176 7.6 Coating Defects/Failures 177 7.7 Chemistry of Coating Materials 181 7.8 Classification of Marine Coatings Based on Their Functions 185 7.9 Conclusions and Future Prospects 193 8 Fire-Retardant Coatings for Modern Lightweight Materials: Contemporary and Future Perspectives 202 Anupreet Kaur , Karan Kapoor , Aadhar Mandot , Sachin Kumar Godara , Ashwini Kumar Sood , and Mandeep Singh 8.1 Introduction 202 8.2 Fire 204 8.3 Burning Cycle for Different Fiber/Polymers 205 8.4 Methods of Achieving Flame Retardancy in Textiles 207 8.5 Coatings 212 8.6 Flame Resistant Versus Fire Retardant 217 8.7 Fire-Retardant Coatings and Their Implications on the Environment 218 8.8 Synthesizing Fire-Retardant Coatings 219 8.9 Contemporary Uses for Fire-Retardant Coatings 225 8.10 Eminence of Fire-Retardants Coatings 226 8.11 Shortcomings 226 8.12 Future Perspectives 227 8.13 Conclusion 227 Part III Other Type of Functional Coatings 231 9 Antimicrobial Coatings: Current Mechanisms, Challenges, and Opportunities 233 Sushama Agarwalla, Sunil Kumar Singh, Mohammed Adil Ibrahim, Hemanth Noothalapati, and Suhanya Duraiswamy 9.1 Introduction 233 9.2 Inorganic Nanomaterials as Antimicrobial Agents 234 9.3 Polymer Antimicrobial Coatings 240 9.4 Organic Antimicrobial Coatings 248 9.5 Toxicity and Environmental Consideration 255 9.6 Emerging Trends in Antimicrobial Surfaces and Coating 259 9.7 Summary 262 10 Synthesis Mechanisms for Antimicrobial Polymeric Coatings 275 Devyani Thapliyal, George D. Verros, and Raj K. Arya 10.1 Introduction 275 10.2 Mechanisms of Action of Antimicrobial Agents 276 10.3 Synthesis Methods for Antimicrobial Polymeric Coatings 277 10.4 Applications of Antimicrobial Polymeric Coatings 285 10.5 Challenges and Future Perspectives 286 11 Superhydrophobic Coatings: Insights and Real-World Applications 299 Sonanki Keshri, S. Sudha, Subhajit Roychowdhury, and Kishant Kumar 11.1 Introduction to Functional Coatings 299 11.2 Design of Superhydrophobic Surfaces 304 11.3 Superhydrophobic Materials and Coatings: Emerging Applications 318 11.4 Current Developments and Challenges of Designs of Superhydrophobic Materials 326 11.5 List of Coating Research Institutes 327 11.6 Summary and Perspectives 327 12 Nature-Inspired Sustainable Superhydrophobic/Superoleophobic Coatings for Emulsified Oil/Water Separation 338 Arun K. Singh, Lipika, and Reeta Rani Singhania 12.1 Introduction 338 12.2 Basic Strategies for Oil/Water Emulsion Separation 340 12.3 Coated Surfaces for Emulsified Oil/Water Separation 341 12.4 Conclusion 357 13 Nano-powder Coatings: Manufacturing, Curing, and Applications 365 Dhiraj Kishor Tatar , Jay Mant Jha, Devendra Rai, Yash Jaiswal, Jamna Prasad Gujar , Vinay Raj, and Shanmuk Srinivas Ravuru 13.1 Introduction 365 13.2 Manufacturing of Nano- powder Coatings 367 13.3 Comparisons to Liquid Coatings 368 13.4 Nano- powder Curing Process 369 13.5 Methods to Apply Nano- powder Coatings 370 13.6 Applications of Nano- powder Coatings 374 13.7 Advantages of Nano- powder Coatings 374 13.8 Conclusions 375 14 Icephobic Coatings: Current Trends and Future Perspectives 380 Utkarsha Umesh Gwalwanshi, Jitendra S. Narkhede, Narayanan Rajagopalan, and Ravindra G. Puri 14.1 Introduction 380 14.2 Surface Energy, Contact Angle, and Wettability 381 14.3 Icephobicity 384 14.4 Strategies Involved in Icephobic Coating 387 14.5 Evaluation of Icephobic Coatings 395 14.6 Conclusion and Future Scopes 397 15 Role of Wetting and Dispersing Additives in Coatings 407 Shiv Charan Prajapati and Raj K. Arya 15.1 Introduction 407 15.2 Wetting and Dispersing Additive 408 15.3 Why Wetting and Dispersing Agents Required? 409 15.4 Role of Wetting and Dispersing Additives 409 15.5 Mechanism of Wetting and Dispersing Additive 411 15.6 Wetting and Dispersing Process of Pigments 413 15.7 Chemical Classification of Wetting and Dispersing Agents 416 15.8 Challenges in the Paint Industry 420 15.9 Living Polymerization 420 15.10 Conclusion 421 15.11 Future Recommendations 422 16 Surface Defects—Causes, Prevention, and Remedies 426 Preetam Satish Bharadiya, Utkarsha U. Gwalwanshi, Narayanan Rajagopalan, and Ravindra G. Puri 16.1 Introduction 426 16.2 Surface Coating Defects 428 16.3 Additives to Prevent Surface Defects 439 16.4 Identification of Defects 441 16.5 Future Recommendations 442 17 Machine Learning in Commercialized Coatings 450 Harshit Mittal and Omkar Singh Kushwaha 17.1 Introduction 450 17.2 Machine Learning Methods 454 17.3 Discovery Using Machine Learning 464 17.4 Conclusions 467 17.5 Future Perspectives 468 18 Advanced Characterization Techniques for Functional Coatings 475 Kamleshwar Kumar, Shailendra Singh Bhadauria, Amanpreet Kaur, and Raj K. Arya 18.1 Background of Functional Coatings 475 18.2 Need for Advanced Characterization Techniques 476 18.3 Classifications of Advanced Characterization Techniques 476 18.4 Discussion on Morphological Characterization Techniques 477 18.5 Discussion on Compositional Characterization Techniques 486 18.6 Discussion on Crystallographic Characterization Techniques 492 18.7 Discussion on Mechanical and Thermal Characterization Techniques 498 19 Thermal Characterization of Passive Fire Protection Coatings Using Bayesian Inference 508 Siva K. Bathina, Dharitri Kahali, Mahesh Kumar Tiwari, Deepak Sahu, and Dharmit Nakrani 19.1 Introduction 508 19.2 Inverse Problem 510 19.3 Conclusions 519 20 Sophisticated Characterization Techniques for Structure–Property Evaluation of Functional Coatings 522 Swati Chopra, Jeetendra Kumar Banshiwal, Amit Singh, and Dibeyndu Sekhar Bag 20.1 Introduction 522 20.2 Fundamental Characterization of Functional Coatings 524 20.3 Evaluation of Structure–Property Relationship for Functional Coatings 538 20.4 Current Status and Future Challenges 568 20.5 Concluding Remarks 568 Author's Contribution 570 Acknowledgment 570 Conflicts of Interest 570 References 570 Index 585