Development of eco-friendly anti-corrosion electrodepositable sol-gel coatings for metal surface protection

The metal industry traditionally used chromium-based materials for anti-corrosion coatings due to their effectiveness and ability to be applied to complex geometries through electrochemical deposition. However, these materials are toxic and carcinogenic, leading to bans in both the EU and US, with companies only using them under expensive derogations.

Eco-friendly alternatives like sol-gel coatings are non-conductive and suitable for flat surfaces but inadequate for complex geometries.

This project investigated the development of electrodepositable sol-gel coatings. The goal was to integrate industrially compatible electrochemical processes with eco-friendly materials. The technology aimed to offer viable, durable solutions for various coating industries, primarily in transport, construction, and home furniture.

The consortium included two Spanish companies in automotive and aerospace (MAIER) and home furniture (MUGAPE), an Irish SME in the coating industry (KASTUS), and an Irish research organization specializing in industrial coatings (CREST). Together, they synergized scientific, technological, and industrial expertise to develop an innovative eco-friendly coating process with global economic, environmental, and health benefits.