Synthesis and characterization of superhydrophobic ceria doped cardanol polyurea nanocomposite coatings with robust anti-corrosive and antibacterial properties

Abstract

This study reports the synthesis and characterization of superhydrophobic ceria (1–5 %) -doped cardanol polyurea nanocomposite (CP@CeO₂) coatings with exceptional anti-corrosive and antibacterial properties. The coatings were fabricated by incorporating ceria nanoparticles into a cardanol-based polyurea matrix, resulting in a unique nanomaterial with improved thermal stability, mechanical resistance, and hydrophobicity. Fourier-transform infrared spectroscopy (FTIR) confirmed the successful formation of the nanomaterials. Field emission scanning electron microscopy (FE-SEM) and high-resolution transmission electron microscopy (HR-TEM) analyses revealed a uniform distribution of ceria nanoparticles (12 nm to 20 nm) within the polyurea matrix. Atomic force microscope (AFM) shows an approximate roughness of 63.96 nm from the observed root mean square (RMS) value, Skewness value, and Kurtosis value. The coating's contact angle value of 150–155° demonstrates a superhydrophobic surface due to the synergetic nanoparticles distribution, surface composition, and roughness. The coatings exhibited remarkable mechanical properties, including excellent crosshatch adhesion (100 %), bending resistance (passes 1/8 in.), scratch hardness (3.2 kg), pencil hardness (6H), and impact resistance (150 lb./in.). The anti-corrosive stability of the coating was evaluated using electrochemical impedance spectroscopy (EIS), which showed a long-lasting efficiency of 96 % over 18 days. Furthermore, the coatings displayed antimicrobial properties against Gram-positive bacteria, Bacillus subtilis, making them suitable for various industrial applications requiring corrosion protection and antimicrobial resistance.

This work highlights the potential of ceria-doped cardanol polyurea nanocomposite coatings as a novel material for diverse applications where both corrosion protection and antimicrobial properties are essential.