Synthesis and characterization of poly(aniline) and poly(o-anisidine) films in sulphamic acid solution and their anticorrosion properties

Poly(o-anisidine) (POA) and polyaniline (PANI) coatings were synthesized on platinum (Pt) surface and stainless steel (SS) in monomer containing 0.50 M sulphamic acid (SA) solution by means of cyclic voltammetry (CV) technique. Meanwhile, poly(o-anisidine) film was also deposited with a different scan rate on SS electrode. The behaviour of PANI and POA films obtained on stainless steel examined by CV was different from the one obtained for PANI and POA on Pt electrode. The corrosion performances of PANI and POA coatings in 3.5% NaCl solution were investigated with anodic polarization technique and electrochemical impedance spectroscopy (EIS). EIS measurements verified the effect of monomers and that of scan rate on corrosion inhibition of coatings on SS electrode. The results showed that POA film synthesized at low scan rate exhibited an effective anticorrosive property on SS electrode. POA synthesized at low scan rate and PANI coatings provided a remarkable anodic protection to SS substrate for longer exposure time than the one observed for POA coating produced at high scan rate as well as that of bare SS electrode.     

The use of polyindole for mild steel protection

Synthesis of polyindole was achieved on mild steel electrode previously coated with a very thin polypyrrole layer (PPy). Cyclic voltammetry technique was used for both syntheses; oxalic acid solution was used for synthesis of primer PPy coating and polyindole film (PI) was obtained from LiClO₄ containing acetonitrile medium. The corrosion performance of this PPy/PI coating was investigated properly in 3.5% NaCl solution by using anodic polarization and open circuit potential (E_ocp)–time curves and electrochemical impedance spectroscopy (EIS). This coating exhibited excellent barrier efficiency for a long time (about 190 h) and it was also able to provide a certain anodic protection. After 240 h of immersion time in corrosive test solution, the protection efficiency value was determined to be 98.9%.     

Electrochemical synthesis of poly(5-nitroindole) on 316L-stainless steel in LiClO4-acetonitrile solution and its corrosion performance

The preparation of poly(5-nitroindole) (P5NI) coating was achieved on 316L-stainless steel (SS). Poly(5-nitroindole) was deposited via anodic oxidation of the corresponding monomer in acetonitrile (ACN) solution containing LiClO₄. The influence of P5NI coating against SS corrosion was studied in 3.5% NaCl solution by electrochemical impedance spectroscopy (EIS), anodic polarization curves and the open circuit potential–time (E_ocp–t) diagrams. The results obtained suggest that P5NI coating forms a sacrificial layer but the efficiency against corrosion is limited with increasing time.     

Inhibition of steel corrosion by potentiodynamic deposition of poly(N-methyl carbazole)

Poly(N-methyl carbazole) (PNMeCz) coating was deposited on 304 type stainless steel (SS) by electropolymerization of N-methyl carbazole monomer in tetrabutylammonium perchlorate containing acetonitrile solution using cyclic voltammetry. PNMeCz coating was characterized by attenuated total reflectance-Fourier transform infrared spectroscopy, scanning electron microscopy, thickness, conductivity, and contact angle measurements. Corrosion performance of the polymer-coated steel electrodes was investigated in 1 M H₂SO₄ solution using open circuit potential–time (E_ocp–t) curves, potentiodynamic polarization, and electrochemical impedance spectroscopy techniques. PNMeCz coating was found to provide anodic protection to the substrate and significantly reduce the corrosion rate of SS in acidic medium.     

Polypyrrole films on nickel-plated copper

Polypyrrole (PPy) film was synthesized on nickel-plated copper electrodes, from monomer containing 0.2 M ammonium oxalate solution. The thickness of galvanostatically deposited nickel layer was 2 μm, while 0.80 μm thick polymer film was obtained by using cyclic voltammetry technique. The protective behavior of PPy modified nickel coating has been investigated, against copper corrosion in 3.5% NaCl solution. For this aim, ac impedance spectroscopy, the anodic polarization curves and open circuit potential–time (E_ocp–t) diagrams were utilized. It was shown that PPy modified nickel coating could provide important protection to copper for considerable periods, in such aggressive medium. The thin polymer film constituted a physical barrier on top of nickel layer against the attack of corrosive environment for a certain period. Also, it was found that the thin PPy film could increase the protection efficiency and lifetime of nickel coating, by its catalytic behavior on formation of NiO layer.     

Poly(N-ethylaniline) coatings on 304 stainless steel for corrosion protection in aqueous HCl and NaCl solutions

Poly(N-ethylaniline) (PNEA) coatings were grown by potentiodynamic synthesis technique on 304 stainless steel (SS) alloy from 0.1 M of N-ethylaniline (NEA) in 0.3 M oxalic acid solution. Characterization of adhesive and electroactive PNEA coatings was carried out by cyclic voltammetry, FT-IR spectroscopy and scanning electron microscopy (SEM) techniques. The protective properties of PNEA coatings on SS were elucidated using linear anodic potentiodynamic polarization, Tafel and electrochemical impedance spectroscopy (EIS) test techniques, in highly aggressive 0.5 M HCl and 0.5 M NaCl solutions. Linear anodic potentiodynamic polarization test results proved that PNEA coating improved the degree of protection against pitting corrosion in HCl and NaCl solutions. Tafel test results showed that PNEA coating appears to enhancement protection for SS in 0.5 M NaCl and 0.5 M HCl solutions. However, according to long-term EIS results, PNEA coating is better for the protection of SS electrodes during the long immersion period in NaCl compared to that in HCl medium.     

The influence of polyaniline (PANI) coating on corrosion behaviour of zinc–cobalt coated carbon steel electrode

Zinc–cobalt alloy plating (ZnCo) was successfully deposited on carbon steel (CS) applying current of 2 mA with galvanostatic technique. Polyaniline film (PANI) was synthesized with cyclic voltammetry technique from 0.20 M aniline containing 0.20 M sodium tartrate solution on zinc–cobalt plated carbon steel (CS/ZnCo) electrode. PANI film characterized by scanning electron microscopy (SEM), was covered with a dark green-brown homopolymer film of strongly adherent homogeneous characteristic while the other one was plated with a porous light ZnCo one. The corrosion behaviour of zinc–cobalt deposited carbon steel electrodes with and without polyaniline (PANI) film in 3.5% NaCl solution was investigated with AC impedance spectroscopy (EIS) technique and anodic polarization curves. The results showed that PANI coating led to decrease of the permeability of metallic plating. The PANI homopolymer film provided an effective barrier property on zinc–cobalt coating and a remarkable anodic protection to substrate for longer exposure time.     

Pitting of AISI 304 stainless steel in bicarbonate and chloride solutions

Metastable and stable pitting on 304 stainless steel (SS304) in 0.1–0.5 m NaCl aqueous solution (pH ~8) has been investigated using a potentiodynamic, a potentiostatic and a weak anodic current galvanostatic techniques. The addition of bicarbonate (0.025–0.5 m) to the solution had an inhibiting effect, manifested by a shift of the pitting potentials to more positive values, a longer induction time for pitting and reduced pit nucleation. The pit nucleation frequency and growth, in the metastable and stable states, decrease as the NaHCO3/NaCl molar concentration increases and pitting is no longer observed for NaHCO3/NaCl molar ratios higher than 3 (four times larger % wt of NaHCO3). Pitting events never occurred at a potential below –0.1 V, fewer metastable events were observed at higher temperature (50°C) and none were observed in chloride free bicarbonate solutions. The inhibiting behaviour of oxyanions is discussed.     

Electrodeposition of casein coatings on zinc alloy

The electrochemical behavior of zinc in caseinate solution at pH 10 was investigated. Current–potential curves and weight loss measurements by atomic absorption showed that the anodic dissolution rate of the metal is higher than that obtained in NaOH solution (pH 10). Anodic treatment of zinc alloy at constant potential in such solutions induces the growth of a coating which presents, after drying, strong adherence and a good protection effect in aggressive solution (0.2 M NaCl+0.2 M Na₂SO₄). IR and ESCA spectrophotometric analysis showed that the zinc ions mainly participated in the growth of a casein coating, probably in a complexed form.     

INHIBITING EFFECT OF N-CYCLOHEXYL-N′-PHENYL THIOUREA ON THE CORROSION OF 304 SS IN HYDROCHLORIC ACID SOLUTION

The inhibiting action of N-cyclohexyl-N′-phenyl thiourea (CPTU) on the corrosion behavior of 304 SS in 3 M hydrochloric acid solution has been investigated using potentiodynamic polarization technique at four different temperatures. The results obtained reveal that CPTU acts as an efficient anodic inhibitor for the corrosion of 304 SS. Good inhibition efficiency (>92%) was evident in the acidic solution, and it was found to vary with temperature and concentration of the inhibitor. The adsorption of this compound on the 304 SS surface was found to obey the Temkin adsorption isotherm, and the inhibition was governed by physical adsorption mechanism. The thermodynamic parameters of adsorption deduced revealed a strong interaction and spontaneous adsorption of CPTU on the steel surface. Scanning electron microscopic study (SEM) was done to investigate the surface characterization of inhibited and uninhibited 304 SS specimens.     

Electropolymerization of 2-hydroxybenzothiazole (2-OHBT) in water–methanol media: electrochemical behaviour in NaCl (3%) solution

A new insulating thin polymer (<0.1m) formed by the electropolymerization of 2-OHBT is reported. The anodic oxidation of 2-OHBT on copper, iron and platinum in alcohol and alcohol–water solutions are investigated using cyclic polarization and chronoamperometry. Scanning electronic microscopy (SEM) and energy dispersive X-ray spectrometry (EDX) are performed to confirm the presence of the organic layer. Based on the results obtained, a model for the formation mechanism is proposed. The corrosion behaviour of the coated copper is studied in NaCl (3%) solution by impedance spectrometry and anodic polarization. The results of these experiments show a decrease in the dissolution of copper due to the barrier properties of the organic coating.     

Acceleration and quantitative evaluation of degradation for corrosion protective coatings on buried pipeline: Part I. Development of electrochemical test methods

The electrochemical degradation of polyethylene coated onto SS400 was examined in synthetic groundwater. Electrochemical techniques (electrochemical impedance spectroscopy, potentiodynamic and potentiostatic polarization tests) and surface analysis (scanning electron microscopy) were used to accelerate and evaluate the coating degradation. The pulsed potentiostatic polarization test accelerating both the cathodic reduction and anodic oxidation reactions was applied to reproduce the coating degradation mechanisms of cathodic disbondment and oxide lifting. The applied potentials were determined to be ±300 mV_SCE versus open-circuit potential from the analysis of the anodic and cathodic polarization data. Results from the EIS confirmed that coating degradation is accelerated effectively by the pulsed potentiostatic polarization testing.     

Effects of nanocrystallization on the corrosion behavior of 309 stainless steel

Nanocrystallized (NC) 309 stainless steel (309SS) coating has been fabricated on glass substrate by DC magnetron sputtering. The coating, with an average grain size less than 50 nm, had ferritic (bcc) structure rather than the austenitic (fcc) structure of the bulk steel. The electrochemical corrosion behavior of the NC coating and the bulk steel in solutions of 0.25 M Na₂SO₄ + 0.05 M H₂SO₄ and 0.5 M NaCl + 0.05 M H₂SO₄ was investigated by using potentiodynamic polarization, potentiostatic polarization and AC impedance techniques. The results showed that the corrosion behavior of the NC 309SS coating and 309SS bulk steel depended on the composition of the solutions. In the Na₂SO₄ solution there was only a little difference between the corrosion resistance of the passive films on the NC coating and the bulk steel. However, in the solution with chloride ions, the localized corrosion resistance of 309SS was greatly enhanced by nanocrystallization due to the formation of a compact and stable passive film on the NC coating. The electronic structure of the passive film formed on the NC coating and on the bulk steel was analyzed by means of capacitance measurements, and a corrosion mechanism is proposed.     

Zinc deposited polymer coatings for copper protection

Polypyrrole (PPy) and polyaniline (PAni) coatings were electrosynthesized on copper, by using cyclic voltammetry technique. Then, these coatings were modified with the deposition of zinc particles from aqueous zinc sulphate solution. The electrodeposition of zinc was achieved at a constant potential value of −1.20 V, in the amount of ∼0.75 mg/cm². The corrosion performance of zinc modified polymer coatings were investigated in 3.5% NaCl solution; by using the electrochemical impedance spectroscopy (EIS), and anodic polarization curves. The zinc particles improved the barrier property of polymer films, thanks to formation of voluminous zinc corrosion products within the pores of polymer coating. Also, the zinc particles provided cathodic protection to the substrate, where the polymer film played the role of conductance between zinc particles and copper.     

Electrochemical synthesis of poly(3,4-ethylenedioxythiophene) on stainless steel and its corrosion inhibition performance

Poly(3,4-ethylenedioxythiophene) (PEDOT) coatings have been electrochemically prepared on stainless steel (SS) in acetonitrile and aqueous media, respectively, by the cyclic voltammetry technique. The corrosion behavior of the coated SS was evaluated in 3.5 wt% NaCl solution using anodic polarization and electrochemical impedance spectroscopy, which demonstrate that the polymer coatings are able to mitigate the corrosion of the SS substrate in chloride solution. PEDOT works as the electron exchange medium to passivate the SS underneath and reduce the oxygen on the surface. By comparing the performances, it was clear that PEDOT electrodeposited from an aqueous solution can afford better corrosion inhibition capability.     

Evaluation of the corrosion resistance of phosphate coatings obtained by anodic electrochemical treatment

The corrosion resistance of phosphate coating obtained by anodic electrochemical treatment at 4–6 mA/cm² is addressed in this paper. The corrosion performance of these coatings is also compared with the coatings obtained by chemical treatment. The regenerated phosphoric acid under the influence of anodic current causes a large variation in morphological features of the coatings. Immersion and salt spray tests indicate the ability of these coatings to act as a barrier film on mild steel. Polarization and electrochemical impedance spectroscopic (EIS) studies indicate that the corrosion resistance of phosphate coatings obtained by anodic treatment decreases with increase in current density employed for deposition. In spite of their higher coating weight, the corrosion resistance of phosphate coatings obtained by anodic treatment is inferior to those obtained by chemical treatment. The porosity or discontinuities created due to the dissolution of the coating under the influence of anodic current are considered responsible for the inferior corrosion resistance of these coatings. The study concludes that anodic treatment has only a limited scope for preparing phosphate coatings with improved corrosion resistance.     

Fabrication of superhydrophobic and self cleaning PVA-silica fiber coating on 304L SS surfaces by electrospinning

In this work superhydrophobic coating with self cleaning property is fabricated on 304L SS samples directly using a simple one step electrospinning process followed by silane treatment by using polyvinyl alcohol (PVA) and tetraethyl orthosilicate solution. A maximum water contact angle of 169.2° ± 2.1° is obtained at an electrospinning potential of 15 kV for 2 h, with a distance of 18 cm between the collector and needle. The hierarchical nanostructures thus formed on 304L SS composed of poly(vinyl alcohol)-silica microbeads and nanofibers. The surface morphologies are optimized by varying the electrospinning voltage, time, distance between needle and the collector and aging duration of the precursors. Attenuated total reflectance-infrared spectroscopy studies at different stages of preparation confirmed the presence of PVA/SiO₂ composite nanofibers deposited on the 304L SS surface. The reaction of SiO₂ nanofibers with hexamethyl disilazane resulted in the formation of Si O Si bonds that provided water repellent property. The developed SHP surface coating on 304L SS sample showed dynamic bouncing of water droplets and excellent self cleaning performance. The sample retained the SHP behavior in chloride solutions with different ionic strengths and pH.     

Inhibition of the corrosion of stainless steel by poly-N-vinylimidazole and N-vinylimidazole

In this study, we investigated the inhibition of the corrosion of stainless steel (SS) in acidic solution by N-vinylimidazole monomer (NVI) and poly-N-vinylimidazole (PNVI). First, we have synthesized a polymer sample of PNVI from the monomer NVI. A stainless steel electrode was coated with this polymer as a thin film by dipping method. Corrosion rates of SS electrodes coated with PNVI films of different thicknesses were determined and compared with the results of the bare electrode in acidic solution. Corrosion rates of the bare SS electrodes were also compared with the rates in the presence of monomer and polymer, respectively, in the acidic solution. The corrosion currents were obtained by Tafel extrapolation from anodic and cathodic polarization curves. Electrochemical impedance spectroscopy (EIS) measurements were also carried out. Values of percent inhibition, wetted area and porosity were obtained for SS electrodes coated with PNVI films of different thicknesses.     

Corrosion behaviour of epoxy coatings electrodeposited on galvanized steel and steel modified by Zn–Ni alloys

The electrochemical and transport properties and thermal stability of epoxy coatings electrodeposited on hot-dip galvanized steel and steel modified by Zn–Ni alloys were investigated during exposure to 3% NaCl solution. Zn–Ni alloys were electrodeposited on steel by direct and pulse current. From the time dependence of pore resistance, coating capacitance and relative permittivity of epoxy coating, diffusion coefficient of water through epoxy coating, D(H₂O) and thermal stability, it was shown that Zn–Ni sublayers significantly improve the corrosion stability of the protective system based on epoxy coating. Almost unchanged values of pore resistance were obtained over the long period of investigated time for epoxy coatings on steel modified by Zn–Ni alloys, indicating the great stability of these protective systems, due to the existence of the inner oxide phase layer and the outer layer consisting of basic salts.     

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.