Advanced Corrosion Protection through Coatings and Surface Rebuilding

Corrosion is a costly and dangerous phenomenon that affects many industries, leading to significant economic losses and, in some cases, catastrophic failures. It is a natural process that occurs when a metal is exposed to an environment that contains oxygen and moisture. As a result, the metal corrodes and eventually fails, leading to costly repairs and replacements. Fortunately, many methods are available to protect metals from corrosion [1,2]. One of the most effective and widely used methods is the application of coatings and surface rebuilding.

Coatings are thin layers of materials that are applied to a metal surface to protect it from corrosion. These coatings can be made from a variety of materials, including polymers, ceramic, and metal alloys [3]. Coatings can be applied in a variety of forms, such as paints, plating, and electroplating. The type of coating chosen for a particular application will depend on the desired level of protection, the cost, and the environment to which the metal will be exposed. Coatings can also provide corrosion protection in a number of ways. One of the main benefits of coatings is that they provide a barrier between the substrate (the material being protected) and the environment [4]. This barrier can prevent moisture, oxygen, and other corrosive agents from coming into contact with the substrate, which can significantly reduce the risk of corrosion. Another benefit of coatings is that they can act as sacrificial layers, which means that they will corrode before the substrate does. This can provide an additional layer of protection for the substrate and extend its lifespan. Moreover, coatings can provide cathodic protection, which means that they can inhibit the corrosion process by acting as an electron donor or acceptor [5]. This can help to prevent the build-up of corrosion products on the surface of the substrate and can significantly reduce the risk of corrosion. Overall, coatings can provide effective corrosion protection by creating a barrier between the substrate and the environment, acting as a sacrificial layer, and providing cathodic protection [6].

Surface rebuilding involves the use of high-temperature welding or brazing to repair damaged metal surfaces. This process is often used to repair corroded and pitted surfaces, as well as to restore the original shape and size of the metal. Surface rebuilding can also be used to create a protective layer on the surface of the metal, which can help to prevent further corrosion [7]. Additionally, surface rebuilding, as a corrosion protection technique, can extend the lifespan of a component or structure by several years, improve its performance and reliability, save money in the long term, improve its appearance, protect against further corrosion and serve as a cost-effective alternative to replacement. It is also less disruptive and more environmentally friendly than replacement. Additionally, surface rebuilding can enhance the performance and reliability of a component or structure by reducing issues such as reduced strength, reduced conductivity, and increased friction caused by corrosion [8].

The use of coatings and surface rebuilding to protect metals from corrosion is an effective and cost-efficient way to reduce the risk of costly repairs and replacements. These methods are also relatively easy to implement and maintain, making them ideal for many applications. In addition, they can help to improve the performance and lifespan of the metal, while reducing the environmental impact of corrosion. Therefore, the goal of this Special Issue is to provide a comprehensive review of the latest developments in advanced corrosion protection through coatings and surface rebuilding, and to highlight the importance of these technologies in ensuring the safe and reliable operation of structures and equipment. For example, this Special Issue will discuss the various types of coatings available for corrosion protection, including organic coatings (e.g., paints, lacquers), inorganic coatings (e.g., ceramics, metallic coatings) [9,10], and composite coatings (e.g., metal–matrix composites) [11,12]. It will also discuss the advantages and limitations of each type of coating, and their potential applications in different industries.

Additionally, this Special Issue will describe the various techniques used for surface rebuilding, such as thermal spraying [13,14,15], laser cladding [16,17], and electroplating [18,19]. It will also likely explore the pros and cons of these techniques and their potential uses in various industries. It will discuss emerging technologies and trends in the field of corrosion protection, such as the use of nano-coatings [20,21] and self-healing coatings [22,23], and the development of advanced surface rebuilding techniques, such as additive manufacturing [24,25]. Furthermore, it will discuss the challenges and limitations of the current corrosion protection technologies and outline future directions for research and development in this area. It will include the development of new materials and coatings, the optimization of existing technologies, and the integration of corrosion protection into the design and manufacturing processes.

Overall, advanced corrosion protection through coatings and surface rebuilding is an important and effective way to protect metals from corrosion. By using these methods, companies can reduce their costs and improve their safety and reliability. As such, it is essential that companies understand the importance of using these methods and take the necessary steps to ensure that their metals are properly protected. This Special Issue of the Coatings journal includes both research articles and review papers that explore the fundamentals and practical applications of advanced corrosion protection through coatings and surface rebuilding. It will discuss the different types of coatings and surface rebuilding techniques that are available, their advantages and limitations, and their potential applications in various industries. It will also explore emerging trends and challenges in the field of corrosion protection and outline future directions for research and development in this area. It will highlight this topic’s potential to address important societal problems.