Enhancing the biocorrosion resistance and biocompatibility of Aluminium substrates using Graphene Oxide-PEDOT:PSS Hybrid Coating

Biofilm-associated infections on medical devices remain a major clinical challenge due to antimicrobial resistance, biofouling, and biocorrosion, compromising implant longevity and biocompatibility. Conventional biomedical devices utilizing stainless steel and titanium exhibit limited resistance to biofilm-prone physiological environments, necessitating development of next-generation implant materials. While alumina (Al2O3) is favored for its bio-inertness, it raises concerns like leaching and systemic toxicity. Aluminum alloy 1050 (AA1050) offers intrinsic corrosion resistance via a passive oxide layer under dry conditions but remains prone to microbiologically influenced corrosion (MIC) under humid conditions. In the recent years, graphene family of materials have emerged as promising surface coating for metals and alloys due to their strong barrier properties and antimicrobial efficacy. Most graphene derivatives like GO require relatively higher concentrations to achieve antimicrobial activity, however compromising biocompatibility, limiting in vivo human uses. This study addresses these caveats by exploring GO activity at lower concentrations (50-500 ug/ml) on AA1050 to achieve a balance between antimicrobial efficiency and cytocompatibility. Additionally, poly(3,4-ethylenedioxythiophene):poly(styrenesulfonate) (PEDOT:PSS,1 ug/ml) was integrated with GO to form a hybrid coating on Al (Al_GO/P), to improve GO adhesion, and corrosion resistance. Biological evaluations against Escherichia coli (E. coli), Staphylococcus aureus (S. aureus), and Candida albicans (C. albicans) demonstrated superior antifouling and antimicrobial efficacy of Al_GO/P substrates compared to GO-coated Al (Al_GO) and bare Al surfaces. Corrosion rate, FESEM, ICP-MS, and cytotoxicity analyses further confirmed reduced biocorrosion, minimal ion leaching, along with enhanced biocompatibility of the hybrid coated surfaces. Al_GO/P containing GO at 100 and 250 ug/ml concentration achieved the optimal balance between antimicrobial activity and biocompatibility and can be used as in vivo implant materials. Hence, this technology can be implemented towards surface modification of biomedical devices to mitigate periprosthetic infections as well as support ex vivo applications requiring durable antimicrobial performance.