Synergistic <scp> TiO ₂ </scp> – <scp> SiO ₂ </scp> – <scp>ZnO</scp> hybrid nanocoatings for high‐performance corrosion protection: Experimental and theoretical insights

Abstract The corrosion of mild steel in saline environments poses significant challenges in infrastructure, marine, and industrial applications, where long‐term durability and economic efficiency are paramount. This study presents the fabrication of a novel ternary TiO 2 –SiO 2 –ZnO hybrid nanocoating via a scalable sol–gel process, which was applied to mild steel, achieving an inhibition efficiency of 86.2% in a 3.5% NaCl solution. This performance substantially exceeds that of conventional single‐ and binary‐oxide coatings. The synergistic effects of TiO 2 for oxidative stability, SiO 2 for defect sealing and hydrophobicity, and ZnO for chloride‐ion complexation create a dense, multifunctional barrier. Electrochemical impedance spectroscopy (EIS) and potentiodynamic polarization (PDP) analyses reveal enhanced charge transfer resistance and reduced corrosion rates, while Fourier transform infrared spectroscopy (FTIR), scanning electron microscopy (SEM), and dynamic light scattering (DLS) confirm a uniform nanoscale morphology. Complementary COMSOL Multiphysics simulations, validated with a deviation of less than 10% from the experimental data, provide a predictive framework for rational coating design. By integrating experimental insights with computational modelling, this study establishes the TiO 2 –SiO 2 –ZnO hybrid as a robust, eco‐friendly, and industry‐compatible corrosion‐prone coating with broad applicability in marine, industrial, and biomedical sectors.