A Review of Recent Advances in Conversion and Self-Assembled Anti-Corrosion Films for Copper and Its Alloys

Copper and its alloys are indispensable for electronics, communications, new energy systems, and aerospace engineering due to their exceptional electrical conductivity and mechanical properties. However, the thin cuprous oxide (Cu₂O) layer that naturally forms on copper and its alloys is prone to failure under elevated temperatures and high humidity, particularly in chloride-rich environments, leading to accelerated localized corrosion. While conventional chromate-based passivation has long been the industrial standard for preventing corrosion, its use has been increasingly restricted by global regulations (such as RoHS and REACH) due to its severe toxicity and health risks. To address the conflict between environmental compliance and protective performance, this review systematically evaluates recent advances in environmentally friendly, chromium-free anti-corrosion coatings in the present review. These alternative coatings are critically analyzed and categorized into four mechanistic groups: (i) inorganic conversion coatings (including molybdate, tungstate, rare earth, and phosphate systems); (ii) organic films formed via chemical or physical adsorption (such as organic inhibitors, thiol-based monolayers, and organosilane self-assembled films); (iii) conversion coatings engineered through covalent bonding, coordination chemistry, and microstructural tailoring; and (iv) multifunctional coatings that integrate self-healing capability with high electrical conductivity. Beyond providing a technical summary, this review explored how the swift progression of electronic information technology, new energy infrastructure, and robotics has imposed more exacting, multifunctional demands on copper components. This review provides a strategic roadmap for future research and prioritizes the creation of protection strategies that operate robustly in multi-physics coupling environments—integrating high conductivity, autonomous self-healing, and long-term chemical stability to ensure the reliability of next-generation infrastructure.