Electric-field aligned ILs functionalized graphene architecture in Cu-enhanced epoxy coatings achieving near-zero wear and corrosion barrier

Graphene-epoxy coatings show promise for protecting marine infrastructure from extreme environments, but their long-term durability and dual wear-corrosion resistance are limited by poor graphene dispersion and random orientation in the matrix. To address this challenge, we developed a highly ordered graphene-enhanced epoxy‑copper composite (DGr-ILs-EP@Cu) via electrophoretic deposition (EPD). Ionic liquids (ILs) enabled one-step exfoliation and functionalization of graphene nanosheets, yielding a stable, positively charged dispersion for EPD. Under an electric field, the graphene nanosheets (DGr) aligned directionally, achieving an ultralow friction coefficient (0.025–0.06) with exceptional stability over 10 h of wear testing. Crucially, copper ions released in situ from the EPD electrode enhanced the coating's wear resistance, approaching near-zero wear rates. The aligned graphene structure also extended the diffusion path of corrosive species, increasing the coating's impedance modulus by 2 orders of magnitude compared to disordered composites. By correlating microstructure (orientation degree) in the EP matrix with performance metrics (friction coefficient, electrical conductivity, and impedance modulus), we demonstrate a multifunctional coating design and new insights specifically optimized for complex environments.