Corrosion studies on electrochemically deposited PANI and PANI/epoxy coatings on mild steel in acid sulfate solution

The corrosion behavior of mild steel and mild steel covered by electrochemically deposited (a) polyaniline (PANI) film, (b) epoxy coating and (c) PANI/epoxy coating system in 0.1 M sulfuric acid solution were investigated by electrochemical impedance spectroscopy (EIS). Electrochemical deposition of PANI film was performed from aqueous solution of 0.5 M sodium benzoate and 0.1 M aniline at constant current density of 1.5 mA cm⁻². Epoxy coatings on mild steel and mild steel modified by PANI film were deposited at constant voltage. It was shown that thin PANI film had provided good corrosion protection of mild steel in 0.1 M sulfuric acid solution, and could be used for modification of mild steel prior to epoxy coating deposition. The increased corrosion protection of mild steel by PANI/epoxy coating system in the same solution was obtained.     

Performance evaluation of polyaniline pigmented epoxy coating for corrosion protection of steel in concrete environment

Corrosion protection of mild steel reinforcement offered by a newly developed epoxy based coating system containing inherently conducting polyaniline as one of the pigments has been studied. The synthesis of polyaniline and preparation of epoxy based coating system containing this polyaniline are described here. The corrosion resistant property of epoxy polyaniline system, coated on mild steel was evaluated by various techniques such as electrochemical impedance spectroscopy, potential time studies, cathodic disbondment test, anodic polarization study, salt spray test and chemical resistance test. The corrosion resistance of epoxy polyaniline coating system coated on reinforcement bars embedded in concrete was also studied by an accelerated time to cracking study. The formation of polyaniline was characterized using FTIR, UV, GPC, particle size analyzer and fineness studies. Electrochemical impedance studies reveal that the resistance of the coating decreased initially and then increased due to passivating ability of the polyaniline pigment. Based on the results of different techniques, it is found that epoxy coating with polyaniline pigment is effective in corrosion protection of steel in concrete environment.     

Preparation of PANI/epoxy/Zn nanocomposite using Zn nanoparticles and epoxy resin as additives and investigation of its corrosion protection behavior on iron

Conducting polyaniline, zinc and epoxy resin solely have anticorrosive properties by different mechanisms on metallic substrates. In this work the triple hybrid of PANI/epoxy/Zn nanocomposite was prepared as a thin layer coating (70 ± 5 μm) on iron coupons and its anticorrosion performance was investigated in HCl (0.1 M) as corrosive solution. Epoxy resin and zinc nanoparticles were applied as additives in the PANI matrix to improve the mechanical properties of PANI coating and investigate their synergetic effects on the anticorrosion performance of PANI coating. At first PANI/Zn nanocomposite coatings with different Zn contents were prepared and the zinc content optimized so that the coating achieve the best anticorrosion performance. Accordingly the iron coupons coated by PANI/Zn coating having 4 wt% Zn content showed more noble open circuit potential and lower corrosion current values. Then epoxy resin was applied as additive to the optimized formulation of PANI/Zn coating in different weight percents (0–20 wt%) and the anticorrosion performance of the related PANI/epoxy/Zn triple hybrid nanocomposite coatings was evaluated. Results showed that the addition of epoxy resin causes to the decreasing of corrosion current of iron samples coated by PANI/epoxy/Zn nanocomposite. An optimum range of 3–7 wt% was obtained for the epoxy content in the composition of PANI/epoxy/Zn nanocomposite in which the coating exhibits the best anticorrosion performance. Iron metal coupon was elementally analyzed and the PANI/Zn and PANI/epoxy/Zn nanocomposites were characterized using Fourier Transform Infrared spectroscopy, X-ray diffraction patterns and Scanning Electron Microscopy techniques.     

Preparation of Poly(<Emphasis Type="Italic">o</Emphasis>-toluidine)/Nano Zirconium Dioxide (ZrO<Subscript>2</Subscript>)/Epoxy Composite Coating and Its Corrosion Resistance

Conducting polymers represent a promising application prospect in the field of metal corrosion control. In this investigation, poly(o-toluidine) (POT)/nano zirconium dioxide (ZrO₂) composite were prepared by in situ polymerization of o-toluidine monomer in the presence of nano ZrO₂ particles. Fourier transformation infrared spectroscopy, UV–visible spectroscopy, X-ray diffraction and Scanning electron microscopy were used to characterize the composition and the structure of the composite. POT/nano ZrO₂ composite was mixed with epoxy resin (EP) through a solution blending method and the three components POT/nano ZrO₂/epoxy composite coating was coated onto the surface of steel coupon, and its corrosion protective efficiency was studied by electrochemical measurements and immersion test in 3.5 % NaCl solution as corrosion environment and also compared with that of POT/epoxy composite coated steel, polyaniline (PANI)/epoxy composite coated steel and pure epoxy coated steel. According to the results, POT/nano ZrO₂/epoxy composite coated steel has got higher corrosion resistance than that of POT/epoxy composite coated steel and PANI/epoxy composite coated steel. It was found that POT powders dispersed in the epoxy and polyamide system improved the barrier and electrochemical protection properties of epoxy coating and the addition of nano ZrO₂ particles increased the tortuosity of the diffusion pathway of corrosion substances.     

Anticorrosive properties of epoxy resin coatings cured by aniline/p‐phenylenediamine copolymer

Aniline/p‐phenylenediamine copolymer [poly(ANI‐co‐p‐PDA)] was prepared by chemical oxidative polymerization. FTIR and ¹H‐NMR analysis indicate that the poly(ANI‐co‐p‐PDA) is oligomer with end‐capped amino groups, which can cure epoxy resin. The anticorrosion performance of carbon steel (CS) samples coated by epoxy resin coating cured with poly(ANI‐co‐p‐PDA) and epoxy resin coating cured with triethylenetetramine exposed to 5 wt % NaCl and 0.1 mol/L HCl aqueous solution is studied by the potentiodynamic polarization and electrochemical impedance spectroscopy. The results show that the CS coated by epoxy resin coating cured with poly (ANI‐co‐p‐PDA) has more excellent corrosion protection than that of epoxy resin coating cured with triethylenetetramine. Raman spectroscopy analysis indicates that the surface of CS coated by epoxy resin coating cured with poly(ANI‐co‐p‐PDA) forms passive layer, which is composed of α‐Fe₂O₃. © 2009 Wiley Periodicals, Inc. J Appl Polym Sci, 2009     

Styrene butadiene co-polymer based conducting polymer composite as an effective corrosion protective coating

Electroactive conducting polymer composite coatings of polyaniline (PANI) are electrosynthesized on styrene–butadiene rubber (SBR) coated stainless steel electrode by potentiostatic method using aqueous H₂SO₄ as supporting electrolyte. The protective behaviour of these coatings in different corrosion media (3.5% NaCl and 0.5 M HCl) is investigated using Tafel polarization curves, open circuit potential measurements and electrochemical impedance spectroscopy. The results reveal that SBR/PANI composite coating is much better in corrosion protection than simple PANI coating. The corrosion potential of composite films shifts to more noble values indicating that SBR/PANI composite coating act as an effective corrosion protective layer.     

Corrosion behavior of polypyrrole coating doped by dodecylbenzenesulfonate for mild steel in acidic media

This paper describes the electrochemical synthesis of a dodecylbenzenesulfonate doped polypyrrole (PPy-DBS) coating on a passivated mild steel (MS) and investigation of its corrosion protection behaviors. This coating was prepared by cyclic voltammetry technique and characterized by Fourier transform infrared spectroscopy (FT-IR) and field emission scanning electron microscopy (FESEM). The corrosion protection features of the PPy-DBS coated MS were studied in different acid media (0.5?mol L^?1 H₂SO₄ and 0.5?mol L^?1 HCl solutions) using linear potentiodynamic polarization, electrochemical frequency modulation and, electrochemical impedance spectroscopy methods. Electrochemical measurements and FESEM images reveal that the PPy-DBS coating presents effective protection for the MS against corrosive species. This may be ascribed to the barrier effect of the polymer coating and utilization of the dodecylbenzenesulfonate dopant with large size during the electropolymerization process.     

Coatings based on electronic conducting polymers for corrosion protection of metals

In this work, corrosion protection of mild steel by a novel epoxy resin (EP)-based coating system containing polyaniline (PAni) as an anticorrosive agent was studied. The corrosion behavior of mild steel samples coated with an EP/PAni-EB (emeraldine base), EP/PAni-ES (emeraldine salt), EP/SPAN (PAni sulfonated), EP/PAni-fibers, EP/PhoZn (zinc phosphate), EP/ChroZn (zinc chromate) or EP/Charge was investigated in 3.5% NaCl solution. For this purpose, electrochemical impedance spectroscopy measurements were utilized. It was found that the addition of three forms of PAni—undoped, sulfonated and fibers—to the EP resin increased its corrosion protection efficiency.     

Polyaniline‐grafted polyurethane coatings for corrosion protection of mild steel surfaces

We report the superior corrosion‐resistant properties of conducting polyurethane networks of polyaniline (PANI), poly‐m‐aminophenol (PmAP), and poly‐o‐anisidine (PoA) coated on mild steel panels. These networks were prepared by blending conducting polyanilines with isocyanate‐containing prepolyurethanes. Free‐standing polyurethane films were obtained after a moisture cure for several days to ensure complete reaction of the excess isocyanate. The films were electrochemically active with conductivity in the range of 10^?2 to 10^?3 S/cm. The solution blends and formed films were characterized by infrared, ultraviolet, thermogravimetric analysis, and differential scanning calorimetry. Electrochemical corrosion studies of the coated films on mild steel panels showed excellent corrosion protection in the following order: PU‐PANI > PU‐PmAP > PU‐PoA. © 2017 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2018 , 135, 45806.     

Corrosion of mild steel with composite polyaniline coatings using different formulations

The protective abilities of composite coatings based on electrochemically and chemically formed polyaniline powder against the corrosion of mild steel were investigated. A polyaniline powder has been prepared in the form of an emeraldine base and benzoate salt through chemical dedoping and doping. The composite coatings using polyaniline powders, which were obtained through different routes, and base coatings, which were not corrosion-resistant, with different formulations were prepared and applied on mild steel samples. The corrosion was investigated using an electrochemical impedance technique in 3% NaCl, and the atmospheric corrosion was assessed in a humidity chamber. Emeraldine–benzoate salts, which are a chemically synthesized polyaniline, offer the best protection with an optimal polyaniline concentration of approximately 5 wt%. The different corrosion behaviors were assessed relative to the presence of aniline oligomers in the samples after characterization using UV–vis spectrophotometry. Upon comparison between the corrosion behavior in 3% NaCl with commercial primer paint for iron and that with a paint containing 5 wt% PANI, the composite coating has superior anticorrosion characteristics. The mechanism for the protection of mild steel from corrosion through composite polyaniline coatings was also considered.     

Effects of polyaniline content in chlorrub‐based coatings on corrosion protection of steel

Corrosion protection of steel coated with chlorrub resin containing polyaniline has been studied in 3% NaCl by electrochemical impedance spectroscopy (EIS). Polyaniline was prepared by oxidative polymerization of aniline using ammonium persulphate in HCl medium. Using the synthesized polyaniline, paints were prepared using chlorrub resin with 1, 3, and 5% polyaniline. The variation of resistance and capacitance of the coating with time has been found out be EIS. The study has shown that the polyaniline content of 1% is able to offer sufficient protection of steel in neutral media and usage of higher percentage of polyaniline does not have beneficial effect. © 2006 Wiley Periodicals, Inc. J Appl Polym Sci 102: 3994–3999, 2006     

Corrosion protective bi‐layered composites of polyaniline and poly(o‐anisidine) on low carbon steel

Bi‐layered composites of polyaniline (PANI) and poly(o‐anisidine) (POA) were investigated for corrosion protection of low carbon steel (LCS). In this work, homopolymers and bi‐layers of PANI and POA were electropolymerized on LCS from an aqueous salicylate solution by using cyclic voltammetry. These coatings were characterized by cyclic voltammetry, Fourier transform infrared (FTIR) spectroscopy and scanning electron microscopy (SEM). Corrosion tests were carried out in aqueous 3% NaCl solution for LCS coated with PANI, POA, bi‐layered POA/PANI (POA on top of the PANI) or PANI/POA (PANI on top of the POA) composites using open circuit potential (OCP) measurements, potentiodynamic polarization technique, and electrochemical impedance spectroscopy (EIS). The single layer of PANI and POA protected the LCS in 3% NaCl for 8 and 16 h, respectively. The bi‐layered composite coatings provide effective protection to LCS for a longer time than a single layered PANI or POA coating. However, the corrosion protection offered to LCS depends on the deposition order of polymer layers in the composite. The PANI/POA composite provides better protection to LCS against corrosion than POA/PANI coating. © 2008 Wiley Periodicals, Inc. J Appl Polym Sci, 2008     

High performance polyaniline containing coating system for wet surfaces

Application of paint coatings on wet surfaces is rather difficult due to poor adhesion of coatings. For painting of wet surfaces, moisture curable coating systems based on epoxy resin and ketimine are found to be useful. Hence a study has been made on the corrosion protection ability of coating on wet surfaces using epoxy resin, ketimine and polyaniline. Paints with 20–30% PVC were prepared and applied over the wet steel surface and the corrosion protection performance of the coating was found out by salt spray and electrochemical impedance spectroscopic techniques. Coating with 20% PVC is found to offer very high protection since the impedance values are remained at greater than 10⁹ Ω cm² after immersion and salt spray tests.     

Corrosion protection of mild steel by nano-colloidal polyaniline/nanodiamond composite coating in NaCl solution

The polyaniline/nanodiamond (PANI/ND) nanocomposite coating was synthesized on mild steel via electrochemical polymerization using cyclic voltammetry technique. The ultrasonic irradiation was used for effectively dispersing ND particles in electropolymerization solution. The prepared nanocomposite films were found to be nano-colloidal, and very adherent with low porosity. X-ray diffraction and FTIR techniques confirmed the intercalation of the nanoparticles in PANI matrix. The corrosion performance of the coatings was investigated in 3.5% NaCl solution by electrochemical impedance spectroscopy (EIS), polarization, and salt spray methods. The obtained results showed that the presence of ND particles significantly enhanced the corrosion protection performance of the PANI films in corrosive medium. EIS and polarization measurements indicated that the coating resistance and corrosion resistance values for the PANI/ND nanocomposite coating were much higher than that of pure PANI-coated electrode. Also, the results obtained revealed that the protection efficiency of PANI/ND-coated mild steel is achieved about 90% after 3 days. The porosity in PANI/ND nanocomposite coating is almost 18 times lower than that of the PANI coating.     

聚苯胺颗粒对水性环氧树脂涂层防腐性能的影响

以盐酸为掺杂剂、过硫酸铵为氧化剂、咪唑类离子液体为稳定剂,采用化学氧化聚合法合成了导电聚苯胺(PANI)颗粒,将其分散到水性环氧树脂(ER)中制成聚苯胺水性环氧防腐涂层,研究了聚苯胺颗粒对涂层防腐性能和机械性能的影响。结果表明,添加聚苯胺显著提高了水性环氧涂层的阻隔性能,信号频率f=0.01 Hz时,PANI/ER涂层的阻抗(|Z|f=0.01Hz)均高于纯ER涂层。添加5.0wt% PANI时ER涂层阻隔性能最好,浸泡0~168 h时|Z|f=0.01Hz稳定在约8.0×108 Ω?cm2,浸泡168 h后|Z|f=0.01Hz=7.5×108 Ω?cm2,远高于ER和其它PANI/ER体系。中性盐雾实验结果表明,聚苯胺赋予了涂层钝化腐蚀的能力,显著提高了涂层的防腐性能,且其添加量越高,防腐性能越好。弯曲和冲击实验结果表明,涂层的机械性能随聚苯胺含量增加先上升后降低,当聚苯胺添加量不超过5.0wt%时,涂层的机械性能优异,附着力和韧性均较好;PANI添加量增至7.0wt%时,ER涂层的脆性明显变大,机械性能下降。聚苯胺在水性环氧体系中的最宜添加量为5.0wt%,此时涂层的机械性能良好,综合防腐性能最优。     

水性聚苯胺防腐涂料研究

将聚苯胺水性微乳液和环氧树脂共混作为底漆、与环氧树脂面漆复合制成防腐涂料，采用开路电位法评价复合涂层的防腐性能。结果表明，合成聚苯胺水性微乳液所使用的酸介质、聚苯胺乳液的用量和腐蚀介质等对涂层的防腐性能均有影响。以十二烷基苯磺酸(DBSA)为酸性介质合成的聚苯胺水性微乳液，当其用量为50％时，复合涂料的防腐性能最佳，与裸露钢板相比，该复合涂层的平衡开路电位可提高245mV左右。该复合涂料不使用任何有机溶剂，是一种环境友好型绿色涂料。     

Inhibition of nickel coated mild steel corrosion by electrosynthesized polyaniline coatings

Polyaniline (PANI) coatings were electrochemically synthesized on nickel (Ni) coated mild steel (MS) and their corrosion protection properties were investigated. In this work, the Ni layer (∼1 μm thick) was electrodeposited on MS under galvanostatic condition. Thereafter, the PANI coating was deposited over the Ni layer from aqueous salicylate medium by using cyclic voltammetry. These bi-layered composite coatings were characterized by cyclic voltammetry, UV–vis absorption spectroscopy and Fourier transform infrared (FTIR) spectroscopy. The corrosion protection properties of Ni coated MS (Ni/MS) and PANI coated Ni/MS (PANI/Ni/MS) were investigated in aqueous 3% NaCl by using open circuit potential (OCP) measurements, potentiodynamic polarization technique and electrochemical impedance spectroscopy (EIS). It was shown that the top layer of PANI exhibits a lower porosity behavior with respect to Ni coating and reduces the corrosion rate of Ni/MS almost by a factor of 3500 and increases the lifetime of Ni coating.     

Electrochemical polymerization and initial corrosion properties of polyaniline-benzoate film on aluminum

Electrochemical synthesis of polyaniline (PANI) on aluminum electrode from aqueous solution of 0.25 mol dm⁻³ aniline and 0.2 mol dm⁻³ sodium benzoate has been investigated under potentiodynamic and galvanostatic conditions. Initial corrosion behavior of aluminum and PANI coated aluminum electrode exposed to 3% NaCl has been investigated using electrochemical potentiodynamic and impedance spectroscopy technique (EIS). It was shown that PANI coating initially provide corrosion protection of aluminum, decreasing the corrosion current density at least 15 times.     

Anticorrosion epoxy coating enriched with hybrid nanozinc dust and halloysite nanotubes

In this study, the performance of an epoxy coating with hybrid nanozinc dust and halloysite nanotube (HNT) fillers on the corrosion protection of a carbon steel substrate was investigated. The epoxy resin was mixed with a constant amount of nanozinc dust (1%) and different contents of HNTs (0, 0.5, 1, and 1.5%) with a high speed mixer. Fourier transform infrared spectroscopy and thermogravimetric analysis were used to analyze the interactions between the components in the coating material and the thermal stability of the epoxy coating, respectively. Open‐circuit potential, salt spray testing, and microscopy were also used to assess the corrosion resistance of the carbon steel substrate coated with these coating materials. The incorporation of nanozinc in the epoxy coating enhanced the corrosion protection of the carbon steel substrate compared with the pure coating. Furthermore, HNTs further enhanced the corrosion protection. The best protection was achieved when 1% nanozinc and 1% HNT were used. © 2013 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 130: 955‐960, 2013     

Epoxy curing by polyaniline (PANI) – Characterization and self-healing evaluation

Polyaniline (PANI) was synthesized by chemical oxidative polymerization of aniline dissolved in aqueous phosphoric acid. The polymer was characterized by UV–Visible spectroscopy (UV–Vis), thermal gravimetric analysis (TGA) and Fourier transform infrared spectroscopic (FTIR) techniques. Hardener free epoxy coating was formulated with 10% PANI. The curing process of epoxy resin by PANI was analyzed using FTIR and a suitable mechanism of curing was suggested. The corrosion protective performance of conventional polyamide cured epoxy and PANI cured epoxy coating on steel has been assessed in 3% NaCl by electrochemical impedance spectroscopy (EIS). The self-healing property of the PANI cured epoxy coating on steel in 3% NaCl was studied by scanning vibrating electrode technique (SVET).