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<p>Metal corrosion is a persistent global challenge that drives the development of high-performance protective materials. Polymer-based composites, by combining the barrier properties of polymer matrices with the unique advantages of functional fillers, have significantly surpassed traditional coatings and become at the forefront of corrosion prevention strategies. This review systematically summarizes the latest research progress on polymer-based composites in two distinctly different yet crucial corrosive environments: aqueous electrolytes (such as sodium chloride, acidic, and alkaline solutions) and organic electrolytes (such as those used in lithium-ion batteries). The design principles tailored for different environments&#xa0;are delved into. For aqueous environments, the focus is on enhancing barrier effects and integrating intelligent inhibitor-release systems. For organic environments, emphasis is placed on the electrochemical stability of materials under high pressure and compatibility with reactive electrolytes. The article elaborates on the synergistic mechanisms of various polymer matrices (such as epoxy, polyurethane, and polyvinylidene fluoride) with advanced fillers (such as two-dimensional nanosheets, inhibitor carriers, and conductive polymers), revealing a paradigm shift from passive barriers to active/‘smart’ protection, where stimulus-responsive self-healing capabilities are key to achieving long-term protection. In addition, advanced characterization techniques and performance evaluation methods and critically discuss the challenges faced in this field, including filler dispersion, long-term stability, and sustainability, are critically reviewed. Finally, future research directions are outlined, including multi-scale computational modeling, multifunctional integrated coatings, and customized designs for extreme environments. This review aims to provide theoretical guidance and a technical roadmap for designing the next generation of efficient, intelligent anti-corrosion coatings for specific application environments.</p>

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Corrosion protection with polymer composites in aqueous versus organic electrolytes

  • 期刊论文

  • 发表日期：

    2026年1月16日

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  • Xuexue Pan,
  • Yi Zhao,
  • Qian Liu,
  • Jianhui Zhang

摘要

Metal corrosion is a persistent global challenge that drives the development of high-performance protective materials. Polymer-based composites, by combining the barrier properties of polymer matrices with the unique advantages of functional fillers, have significantly surpassed traditional coatings and become at the forefront of corrosion prevention strategies. This review systematically summarizes the latest research progress on polymer-based composites in two distinctly different yet crucial corrosive environments: aqueous electrolytes (such as sodium chloride, acidic, and alkaline solutions) and organic electrolytes (such as those used in lithium-ion batteries). The design principles tailored for different environments are delved into. For aqueous environments, the focus is on enhancing barrier effects and integrating intelligent inhibitor-release systems. For organic environments, emphasis is placed on the electrochemical stability of materials under high pressure and compatibility with reactive electrolytes. The article elaborates on the synergistic mechanisms of various polymer matrices (such as epoxy, polyurethane, and polyvinylidene fluoride) with advanced fillers (such as two-dimensional nanosheets, inhibitor carriers, and conductive polymers), revealing a paradigm shift from passive barriers to active/‘smart’ protection, where stimulus-responsive self-healing capabilities are key to achieving long-term protection. In addition, advanced characterization techniques and performance evaluation methods and critically discuss the challenges faced in this field, including filler dispersion, long-term stability, and sustainability, are critically reviewed. Finally, future research directions are outlined, including multi-scale computational modeling, multifunctional integrated coatings, and customized designs for extreme environments. This review aims to provide theoretical guidance and a technical roadmap for designing the next generation of efficient, intelligent anti-corrosion coatings for specific application environments.