Recent developments in polymer-based composite anticorrosion coatings: materials, mechanisms and applications

Corrosion of metallic materials presents a critical threat to the longevity and performance of industrial infrastructure, prompting the evolution of polymer-based composite anticorrosion coatings.Recent advancements in this field have focused on integrating functional nanofillerssuch as graphene oxide, metal oxides, clay minerals, and conducting polymers -into polymer matrices to enhance mechanical durability, chemical stability, and barrier efficiency.This review highlights the latest strategies in the design, synthesis, and application of advanced composite coatings, including multilayered architectures, self-healing systems, and stimuli-responsive (smart) materials.Emphasis is placed on the correlation between microstructure and anticorrosion performance, with discussion of synthesis routes like in-situ polymerization, solgel processing, and electrophoretic deposition.Furthermore, the mechanisms of protectionranging from passive barrier formation to active inhibition through encapsulated agents -are critically evaluated using electrochemical and surface analysis techniques.While laboratory results demonstrate significant improvements in corrosion resistance, challenges related to large-scale processing, environmental impact, and long-term durability remain.The review outlines emerging directions for future development, including green materials, multifunctional systems, and industrial scalability of smart, adaptive coating technologies.