Authors: Mitesh Patel, Om Prakash Sondhiya
Abstract: Due to their constant exposure to harsh external conditions, solar panel structural materials are extremely susceptible to air corrosion, thermal stress, and UV radiation-induced deterioration. The mechanical robustness and durability of solar mounting infrastructure are seriously jeopardized by these environmental variables. The invention, extensive testing, and validation of a novel polycarbonate-based UV-protective and rust-preventive coating system designed especially for solar panel structural supports are the main objectives of this work. The coating offers a strong, dual-action defense mechanism against extended solar exposure and moisture-driven oxidation by incorporating sophisticated corrosion-inhibiting nano-agents and specific organic UV absorbers into a durable polycarbonate matrix. Performance was assessed using a thorough, methodical testing strategy that included surface morphology evaluations, neutral salt spray corrosion assays, cross-cut adhesion strength measures, and accelerated weathering experiments. According to experimental results, the coated substrates show remarkable resistance to UV-induced yellowing and gloss retention while retaining their structural integrity and high barrier qualities against dampness and chloride ions. Additionally, a significant improvement in corrosion resistance was proven by electrochemical impedance spectroscopy (EIS) and extended exposure to salt fog, which demonstrated minimal degradation and no rust development over extensive operational cycles. The developed polycarbonate coating system's dependability and industrial potential to greatly increase the service life, lower maintenance costs, and guarantee structural safety of solar panel installations in a variety of harsh climates are highlighted by this methodical validation framework.
