In Situ and Laboratory Investigation of the Anti-Corrosion and Anti-Fouling Efficacy of an Innovative Biocide-Free Coating for Naval Steels

This study presents an in situ and laboratory evaluation of an innovative biocide-free nanocomposite coating designed to provide dual anti-corrosion and anti-fouling protection for EH36 naval steel in marine environments. The coating, comprising polyaniline nanorods, titanium dioxide nanoparticles, and Fe3O4-functionalized multiwalled carbon nanotubes embedded in a robust resin matrix, was systematically assessed through electrochemical, microscopic, and field-based methods. Laboratory immersion tests and extended exposures at two Mediterranean sea sites (Thessaloniki and Heraklion) revealed substantial improvements in corrosion resistance and significant suppression of marine biofouling over periods of up to 24 months. Electrochemical measurements demonstrated that coated specimens maintained a corrosion inhibition efficiency exceeding 93% throughout the study, exhibiting markedly lower corrosion current densities and higher charge transfer resistances than uncoated controls. Impedance spectroscopy and equivalent circuit modeling confirmed sustained barrier properties, while digital imaging and qualitative biological assessments showed reduced colonization by both micro- and macrofouling organisms. Comparative analysis with conventional biocidal and alternative eco-friendly coatings underscored the superior durability, environmental compatibility, and anti-fouling efficacy of the developed system. The results highlight the coating’s promise as a sustainable, high-performance solution for long-term protection of naval steels against the combined challenges of corrosion and biofouling in harsh marine settings.