Jerusalem, 12 June, 2025 (TPS-IL) — Scientists at the Hebrew University of Jerusalem have developed a revolutionary coating that protects iron from rust with 99.6% efficiency, a breakthrough that could dramatically reduce maintenance costs and extend the lifespan of iron-based infrastructure worldwide.
Led by Prof. Elad Gross from the university’s NanoCenter and Institute of Chemistry, the research team created a dual-layer system that outperforms current anti-corrosion methods. Iron, while a critical material in construction, transportation and manufacturing, is highly susceptible to rust, which weakens structures and requires costly repairs. Conventional coatings often degrade over time, offering only temporary protection.
The new coating combines a molecular primer with a durable polymer top layer. The first layer, made from N-Heterocyclic Carbene (NHC) molecules, forms a strong chemical bond with the iron surface, acting as a robust foundation. This bond allows the second, polymer-based layer to adhere more effectively, creating a stable barrier that remains intact even under harsh conditions such as prolonged saltwater exposure.
Until now, most anti-rust coatings relied on paints, sealants, or galvanization methods that physically cover iron surfaces but often degrade over time, especially in harsh conditions like saltwater or high humidity. These conventional coatings tend to peel, wear off, or fail to bond tightly with the metal, requiring frequent maintenance and reapplication. The breakthrough introduces a chemically bonded dual-layer system—anchored by N-Heterocyclic Carbene (NHC) molecules, which creates a far more stable and durable barrier.
The findings were published in the peer-reviewed Angewandte Chemie journal.
“The secret is in the chemistry of the primer,” said Gross. “By ensuring a tight bond at the molecular level, we’ve developed a coating that not only resists corrosion but also maintains its integrity over time.”
Lab tests conducted in highly corrosive saltwater environments demonstrated the coating’s superior performance, showing a dramatic reduction in rust formation compared to conventional treatments. The researchers say the improved adhesion and stability make the coating particularly suitable for use in maritime, industrial and outdoor settings where exposure to moisture is unavoidable.
Beyond structural resilience, the coating’s longevity could reduce the frequency of repairs and replacements, offering a more sustainable and cost-effective solution for industries that depend on iron and steel components.
In construction and infrastructure, it can extend the life of bridges, pipelines, and reinforced concrete. The maritime and offshore sectors could use it to protect ships, oil rigs, and underwater equipment from saltwater corrosion. It also has potential in transportation, safeguarding trains, trucks, and other vehicles from rust, especially in harsh climates. Manufacturing and heavy industry could benefit from more durable machinery and storage tanks, while the energy sector may apply it to wind turbines and power plants. Even defense, aerospace, and consumer goods could see longer-lasting equipment, vehicles, and products.
“This innovation could reshape how we approach metal preservation,” said Prof. Gross. “It offers industries a reliable and long-term method to protect critical infrastructure.”
