Self-cleaning and anti-corrosion coating properties of pristine D3-co-styrene random copolymer synthesized by anionic and ring-opening polymerization

In industrial and marine areas, corrosion on metal structures causes huge economic and safety failures. Polymeric coating is one of the efficient ways to prevent corrosion on metal structures. In most of the reported literature, polymeric materials with some additive or fillers are used as an anti-corrosion coating. In this report, we have synthesized a 1: 1 random copolymer of hexamethylcyclotrisiloxane (D3) and styrene by anionic and ring-opening polymerization using n-butyl lithium as an initiator. The synthesis is a single-step reaction, and both high and low-molecular-weight polymers are obtained from a one-pot reaction. The low molecular weight polymer has better solubility, while the high molecular weight polymer is sparingly soluble. Both the polymers are thoroughly characterized to understand the structure-property relationship and actual comonomer ratio in the backbone. The low molecular weight polymer can be easily applied to Cu, Al substrates, and glass surfaces by solution processing methods as a coating material. A thin film (approximately 14 μm) of low molecular weight polymer exhibits exceptional chemical and corrosion resistance properties under optimal conditions. The styrene component of this copolymer ensures strong adhesion to metal substrates during prolonged immersion, while the D3 fragment provides the necessary chemical inertness, enhancing the barrier properties. This random copolymer film forms a continuous, thin passive barrier around corrosion-prone metal surfaces, effectively protecting them against harsh chloride, acid, and alkaline environments by restricting the permeation of these ions. Additionally, the low molecular weight polymer is hydrophobic, featuring self-cleaning properties, abrasion resistance, and a hardness rating of 2 H in the pencil hardness test. • A one-pot synthesis by anionic polymerization of D3 and styrene produces two copolymers. • A thin (̴14μm) copolymer coating was applied on Cu and Al substrates to achieve corrosion resistance. • Pristine polymer is hydrophobic, and it has self-cleaning properties. • No filler is added to achieve corrosion resistance properties. • This polymeric coating shows exceptional corrosion resistance properties for Al and Cu.