Iron is one of the most widely used materials in the world, found in everything from buildings and bridges to cars and machines.
But despite its strength, iron has one major weakness—it rusts easily when exposed to air and water. Rust slowly eats away at the metal, leading to damage, expensive repairs, and safety concerns.
Now, scientists from the Hebrew University of Jerusalem have made a major breakthrough. They’ve created a new type of coating that protects iron from rust with 99.6% efficiency.
The discovery, led by Professor Elad Gross from the university’s NanoCenter and Institute of Chemistry, is described in the journal Angewandte Chemie International Edition.
It could lead to longer-lasting buildings, vehicles, and infrastructure, while cutting down on maintenance costs.
The key to this success lies in a two-layer protection system. The first layer is made of special molecules called N-Heterocyclic Carbenes, or NHCs. These molecules form a strong chemical bond directly with the iron surface. This acts as a super-thin “primer” that prepares the metal for the second layer.
On top of that goes a tough polymer coating, which sticks tightly thanks to the NHC primer. This second layer is what physically shields the iron from the elements.
Together, the two layers create a barrier that’s not only strong but also long-lasting—able to resist even salty, corrosive environments like seawater.
To test the coating, researchers placed the treated iron in a harsh saltwater solution, simulating the kind of conditions iron faces in real-world use. The results showed almost no corrosion. In fact, compared to untreated metal, the dual-layer coated iron stayed nearly rust-free, proving the coating’s exceptional durability.
This is a big improvement over traditional coatings, which can wear down, peel off, or allow water to sneak in over time. Many existing products need frequent reapplication and don’t hold up well in extreme environments.
“This is a major step forward,” said Professor Gross. “By designing a special primer that bonds directly to the metal, we’ve created a coating that’s much more stable and effective than anything that’s come before.”
The benefits of this discovery go beyond just stronger metal. For industries like construction, transportation, and manufacturing, the new coating could mean fewer repairs, longer-lasting materials, and less waste. That’s good for the economy—and for the environment.
With further testing and scaling, this technology could become a new standard in rust protection, helping to keep our buildings, vehicles, and machines safer and stronger for years to come.
