June 11, 2025 – Researchers at the Hebrew University of Jerusalem have developed a highly effective new coating that can protect iron from rusting with 99.6% efficiency. Led by Professor Elad Gross from the NanoCenter and the Institute of Chemistry at Hebrew University, the study introduces an innovative two-layer coating system that significantly improves upon existing methods for preventing corrosion. 

Iron is widely used in industries such as construction, transportation, and manufacturing, but it is highly prone to rust when exposed to air and moisture. Rust weakens the metal, which can lead to structural damage and costly repairs. While protective coatings exist, many tend to degrade over time, offering limited protection. 

This new research presents a solution by combining two protective layers that work together to create a strong and long-lasting barrier. The first layer is an ultra-thin coating made of N-Heterocyclic Carbene (NHC) molecules, which form a tight bond with the iron surface. The primary layer ensures that the second layer—a polymer-based coating—sticks firmly, creating a highly stable and durable protective shield. Thanks to this improved adhesion, the coating remains intact even in harsh conditions, such as prolonged exposure to saltwater. 

Experiments showed that this dual-layer system dramatically reduced corrosion, with tests conducted in a highly corrosive saltwater environment confirming its exceptional effectiveness. By forming a strong chemical bond between the iron and the protective layers, this method offers significantly greater durability than conventional coatings, which often wear down or peel off over time. 

“This discovery offers a major leap forward in protecting iron from corrosion,” said Professor Elad Gross. “By using a specially designed primer, we created a coating that is not only highly effective but also long-lasting. This could reduce maintenance costs, extend the lifespan of iron-based materials, and provide industries with a much more reliable solution.” 

This breakthrough has broad implications for industries that rely on iron and steel, including construction, transportation, and manufacturing. By reducing the need for frequent repairs and replacements, this coating could also support more sustainable and cost-effective material use.  

The research paper titled “Self-Assembled Monolayer of N-Heterocyclic Carbene as a Primer in a Dual-Layer Coating for Corrosion Protection on Iron” is now available in Angewandte Chemie and can be accessed here.

Researchers:
Linoy Amar, Rajarshi Mondal, Omer Blumen, Lihi Rekanati, Iris Berg, Sara Harpaz, Daniel Sharon,* and Elad Gross 

Institution:
Institute of Chemistry and the Center for Nanoscience and Nanotechnology, The Hebrew University of Jerusalem