Advances in polymer nanocomposite coatings for pipeline corrosion mitigation and structural durability Leonard Etonyeaku [1] , Jacob Muthu* [2] , Golam Kabir [1,3]

https://www.academia.edu/3065-9736/2/4/10.20935/AcadNano7993 The corrosion of pipelines remains a critical challenge for not only the oil and gas industry but also other infrastructures where carbon steel is used, which results in significant operational risks, environmental hazards, and financial losses. This condition presents a pressing need for effective and sustainable pipeline corrosion mitigation that ensures public safety, asset protection, and zero environmental tolerance. Polymer nanocomposite coatings offer a promising solution for effective corrosion mitigation, yet optimizing their composition for long-term durability and integrity management poses a complex task. The complexity in the use of polymer nanocomposites results from their nanoscale structure, which requires proper formulation to ensure their effectiveness. Property optimization of the nanocomposite structure is necessary to position the coating material to function effectively. This paper reviews the mechanisms by which PNCs mitigate corrosion, including their barrier formation, electrochemical insulation, and self-healing capabilities. It further examines how nanofillers contribute to property optimization, improving toughness, abrasion resistance, and chemical durability. The role of PNCs in integrity management is also discussed, with emphasis on their performance in complex coupled environments. While laboratory results are promising, industrial scalability, cost, and environmental safety remain key challenges. The paper concludes with recommendations for future research. One takeaway from this review, amongst others, is that real-life systems are rarely linear, and world processes involve multiple interacting variables which require us to understand how inputs affect response outcomes.