Advanced Green Coating and Inhibitor Technologies for Corrosion Resistance

Corrosion poses a serious threat to the safety and longevity of materials used in the automotive and aerospace industries. Despite their effectiveness, traditional corrosion prevention methods usually involve hazardous substances that are bad for the environment and human health, such as hexavalent chromium and volatile organic compounds (VOCs). The global emphasis on the attainment of sustainable development goals and the strengthening of environmental regulations has raised the demand for eco-friendly alternatives. This chapter provides an in-depth analysis of environmentally friendly corrosion prevention methods, with a focus on cutting-edge technologies like waterborne coatings, sol–gel and hybrid systems, biodegradable inhibitors, chromate-free conversion coatings (CFCs), and smart functional materials. These innovations aim to minimise their ecological impact while providing high-performance protection. Real-world examples demonstrate successful industrial adoption. The objective of these inventions is to provide high-performance protection with the least possible ecological impact. Case studies from the real world demonstrate successful industrial adoption and show the potential for widespread adoption. The chapter also discusses future prospects involving advanced manufacturing, artificial intelligence, and interdisciplinary collaboration, as well as ongoing challenges in cost, durability, and regulatory standardisation. In conclusion, environmentally friendly corrosion prevention provides a way forward for engineering solutions in vital industries that are safer, cleaner, and more effective.