Acrylic–CeO2 nanocomposite coatings for dual protection: enhancing weathering and corrosion resistance on metal and cement substrates

Abstract An acrylic nanocomposite coating functionalized with cerium oxide (CeO 2 ) nanoparticles has been developed that demonstrates significant advantages in protecting both metal and concrete substrates, offering enhanced durability and environmental resistance. The nanocomposite coatings, synthesized via ex situ doping of CeO 2 within an acrylic polymer matrix, exhibit excellent thermal stability, low surface roughness (<2 nm) and a highly crosslinked morphology. Electrochemical impedance spectroscopy and potentiodynamic polarization studies confirm a significant enhancement in corrosion resistance, achieving an impedance of 4.8 MΩ and a corrosion rate as low as 4 × 10 −4 mm yr −1 . Additionally, strong interfacial adhesion between the coating and aluminium substrates further enhanced the coatings' durability. The optimized acrylic‐Ce0.5 formulation demonstrated superior weathering resistance, maintaining a stable water contact angle of 105° after 30 days of accelerated aging, along with corrosion resistance, highlighting its long‐term durability on cement blocks and metal substrates. These high‐performance nanocomposite coatings offer a promising alternative for protective applications in infrastructure, wind turbines and marine environments, ensuring extended service life and reduced maintenance costs. This dual protection with versatility of substrates, combined with the potential for reduced maintenance costs, sets our work apart from existing studies. © 2025 Society of Chemical Industry.