防腐防污功能一体化的Fe基非晶涂层的设计、制备与性能研究

The hot and humid ocean environments in South China Sea bring about big challenges of heavy corrosion and fouling on engineering instruments on the sea, and have become major concerns to scientists and engineers. Development of advanced protecting coatings with enhanced anti-corrosion and anti-fouling properties becomes one of the most important research issues. The newly developed Fe-based amorphous coatings have shown promising potentials for ocean engineering applications owing to their excellent mechanical properties and corrosion resistance. However, little work has been done on the corrosion behavior of the amorphous coating in hot and humid ocean environment, and almost no studies have been attached on microbe fouling of amorphous coatings one the sea so far. In this project, we will carry out the a set of studies regarding the common concerns of corrosion and fouling problems on engineering materials in hot and humid sea environments. The researches include: 1) Composition design and fabrication of novel anti-corrosion and anti-fouling amorphous coatings; 2) Microstructure characterizations and modifications of the amorphous coatings; 3) Corrosion and fouling behaviors and mechanisms of the amorphous coatings in hot and humid ocean environment; 4) Design, corrosion and fouling properties of patterning amorphous composite coatings. It is believed, on the basis of above researches, we can develop 1-2 novel Fe-based amorphous coatings with excellent anti-corrosion and anti-fouling properties, and comprehensively understand the mechanisms for pitting and fouling of the amorphous coatings in hot and humid environments. It is envisaged that the project could be of great significance not only in the development of new amorphous materials but also in the application of the amorphous coatings in ocean industries.

在高湿热的热带海洋环境下，工程材料的海洋腐蚀和污损是海洋工程构件及装备失效的关键问题，开发高性能防腐防污涂层材料已成为海洋工程领域的一项紧迫任务。近年来发展起来的Fe基非晶涂层因其具有优异的力学和耐蚀性能，在海洋工程领域呈现广泛的应用前景。然而关于非晶涂层在高湿热海洋环境中腐蚀行为的研究相对贫乏，关于非晶涂层的海洋污损的研究更是鲜见报道。本项目将针对高热、高湿海洋环境中材料的腐蚀与污损的问题，以Fe基非晶涂层为对象，开展以下研究：1）防腐防污功能一体化非晶涂层的成分设计与制备；2）防腐防污非晶涂层的结构表征与调控；3）非晶涂层的腐蚀行为与生物污损性能；4）纹理化结构的非晶复合涂层的设计、腐蚀与污损性能。通过以上研究，开发出1-2种兼具优异防腐防污功能的非晶涂层，揭示在高湿热海洋环境下非晶涂层的防腐、防污机制。这一研究对开发新型海洋防护涂层，促进其在我国海洋工程领域的应用具有重要意义。

在高湿热的热带海洋环境下，工程材料的海洋腐蚀和污损是海洋工程构件及装备失效的关键问题，开发高性能防腐防污涂层材料已成为海洋工程领域的一项紧迫任务。在基金委资助下，本项目四年来完成了以下研究内容：Fe基非晶涂层的微生物腐蚀行为与腐蚀机制；杀菌-低表面能双重改性仿生非晶涂层的设计、制备与防腐防污性能；PDMS/非晶复合涂层的研制及其防腐防污性能；低模量水凝胶改性非晶涂层的研制及其防腐防污性能；非晶涂层在我国南海、东海环境下的服役性能考核。获得的重要发现如下：1）发现海洋细菌加剧非晶涂层的腐蚀，从纳米尺度揭示了Fe基非晶涂层的微生物腐蚀机制，即细菌通过胞外电子转移效应吸收能量，导致钝化膜中高价态、可溶性氧化物含量增多，从而局部薄化钝化膜并诱导亚稳态点蚀发生。2）定量调控了非晶涂层的晶化率，并发现了影响Fe基非晶涂层腐蚀性能存在一个临界晶化率（30%），低于该临界晶化率，非晶涂层腐蚀性能不受影响。3）研制出仿鲨鱼皮结构的非晶涂层，具有杀菌离子可控释放与超疏水特性双功能表面，具有协同防污效果和高耐久性。4）研制出PDMS-Cu2O协同改性的非晶基防腐防污涂层，具有高结合力（>2 MPa）、兼具优异的防腐防污性能。5）研制出水凝胶改性的非晶涂层，具有最为优异的海洋防污性能（包括：抗蛋白、贻贝、藻类、海洋细菌粘附以及实海挂片考核），揭示出其防污机制为杀伤-抵抗-伪装三位一体协同防污。6）在三沙市和舟山海域完成了非晶涂层的应用考核，耐蚀性能和防污性能基本达到了服役要求。本项目在ACS Applied Materials & Interfaces, Journal of Materials Chemistry A, Corrosion Science等期刊上发表SCI论文12篇。申请/获授权发明专利5项。非晶涂层研究获3项省部级奖励（包括教育部自然科学奖二等奖1项）。培养中青年教师1名（入选湖北省杰青、湖北省青拔），硕士毕业研究生7名。与武船、哈飞等单位开展了合作，探索了非晶涂层在我国海工装备上应用的可行性。本项目的顺利完成对海洋工程装备高性能防护涂层的研发提供了科学依据与基础数据。