Synergistic Insights Into Polysiloxane Coatings: Experimental and Theoretical Evaluations of Corrosion Resistance on XC38 Surface

ABSTRACT Cold plasma (CP) is a modern, environmentally friendly technique used to protect metals from corrosion. It alters the metal surface without heat, improves coating adhesion, and forms protective layers. CP also enhances the performance of green inhibitors and is suitable for delicate or complex surfaces. This study investigates the influence of Plasma‐Assisted Chemical Vapor Deposition (PACVD) parameters on the morphology and performance of protective coatings. Through systematic optimization, deposits with notable polarization resistances (13812 Ω cm 2 ) and low corrosion current densities (7.55 × 10 −7 µA cm −2 ) were achieved. Theoretical analysis revealed the stability of polysiloxane and the reactivity of the Fe 35 cluster. Coating thickness, substrate adhesion, and porosity emerged as critical factors in corrosion prevention. Nitrogen pre‐treatment enhanced adhesion, and a firm, partly covalent link between Fe 35 and polysiloxane oxygen highlighted the coating's superior anti‐corrosion defense. This research contributes to the fields of corrosion prevention and materials science, bridging empirical optimization with molecular‐level understanding.