Multilayer self-healing coatings based on in-situ LDH films and inhibitor-loaded nanofibers for enhanced corrosion protection of copper

Background Conventional single-layer coatings offer limited durability and lack active self-healing, making them inadequate for protecting copper in aggressive environments. A multilayer strategy combining passive barriers with responsive inhibitor release is therefore essential for enhanced corrosion resistance. Methods A hierarchical self-healing coating was constructed by combining an in-situ grown, silane-modified layered double hydroxides (LDH) film, core–shell PVDF@BTA (PB) nanofibers, and an epoxy (EP) topcoat. The LDH layer extended ion-diffusion pathways and enhanced adhesion, while the nanofibers enabled controlled BTA release upon damage. Interfacial interactions were examined using spectroscopy, SEM/EDS, XRD, FTIR, and molecular dynamics (MD) simulations. Anticorrosion and self-healing performance were evaluated by EIS, OCP, polarization testing, and BTA-release kinetics . Significant Findings The LDHA/PB/EP coating exhibited outstanding long-term corrosion resistance, achieving a high |Z| 0.01 Hz of 4.32 × 10 9 Ω·cm 2 and maintaining stability after 60 days of immersion. Upon mechanical damage, the coating restored up to 90.3% of its original corrosion resistance through synergistic formation of LDHA–BTA and Cu–BTA protective complexes. MD simulations and electrochemical tests confirmed ATES-enhanced BTA adsorption, enabling dense inhibitor films. This multilayer design affords both passive barrier protection and active self-healing, offering a promising strategy for high-performance, intelligent anticorrosion coatings for copper systems.