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.     

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.     

Monolayer and bilayer conducting polymer coatings for corrosion protection of steel in 1 M H2SO4 solution

In this study, monolayer polypyrrole (PPY), polyaniline (PANI), and bilayer PPY/PANI, PANI/PPY coatings were deposited onto steel electrodes by electropolymerization in 0.1 M monomer and 0.3 M oxalic acid solution. Such corrosion parameters of these electrodes, as corrosion potentials, anodic Tafel constants and corrosion current densities were determined by means of current–potential curves as a function of time in 1 M H₂SO₄ solution. These findings were compared to the corrosion parameters of a bare steel electrode in the same acid solution. The monolayer and bilayer polymer coatings were characterized by the Fourier transform infrared (FTIR) spectroscopy and SEM. Bilayer coatings displayed better corrosion inhibition efficiencies than monolayer coatings. Furthermore, the PPY/PANI coatings offered superior corrosion protection than the PANI/PPY coatings.     

Synthesis of nano polyaniline and poly-<Emphasis Type="Italic">o</Emphasis>-anisidine and applications in alkyd paint formulation to enhance the corrosion resistivity of mild steel

Protection of oxidizable metals against corrosion has now being intensively investigated, by applying or developing different methods such as coatings and conversion films; however, all reported methods involve environmentally hazardous materials. Conducting polymers have now been used as corrosion inhibitor coatings that are either chemically or electrochemically deposited on the metal substrate. The application of nanotechnology in the corrosion protection of metals has recently gained momentum. Environmental impact can also be improved by utilizing nanostructure particulates in coatings and eliminating the requirement of toxic solvents. We report here the synthesis of nanoparticles of polyaniline (PANI) and poly-o-anisidine (POA) using emulsion polymerization method in micellar solution of SDS and their anticorrosive property has been experimentally checked. The prepared nanoparticles have been characterized by FTIR and TEM. The nanoparticles of the synthesized polymers were dispersed in alkyd paint formulation for coatings on the metal surface (mild steel). The water absorption in the prepared coatings was also studied. The corrosion rate of polymeric film was determined by weight loss measurement and the surface morphology was examined by SEM. The nano PANI/Alkyd coatings showed considerable protection against corrosion than the POA/alkyd coatings.     

Effect of polyaniline-modified glass fibers on the anticorrosion performance of epoxy coatings

Polyaniline (PANI) and different mass ratios of polyaniline/glass fiber (GB) composites (PANI/GB, PGB) were prepared through in situ oxidative polymerization. The chemical structure of composites was investigated via Fourier transform infrared spectroscopy and X-ray diffraction. Epoxy coatings loaded with different mixtures of PANI and GB were applied on steel substrate and exposed to NaCl solution. The morphological properties and corrosion resistance of the coatings were investigated through environmental scanning electron microscopy, electrochemical impedance spectroscopy, and salt spray tests. Results showed that the addition of PANI, GB, and PGB composites caused an improvement in corrosion resistance. The greatest improvement in corrosion resistance was exhibited by the coatings loaded with mass ratio of 1:1 of PANI/GB. This enhancement was attributed to the corrosion resistance of PANI and penetration resistance of GB. Moreover, the uniform distribution of PGB composites in the epoxy resin is an important parameter affecting corrosion resistance of the coatings.     

聚苯胺涂层对AZ91D镁合金防护性能的研究

在镁合金表面用循环伏安法制备了聚苯胺涂层,并对其防护性能进行了深入研究。考察了制备工艺对涂层性能的影响,如:扫描电位区间、扫描速率、循环圈数等。研究结果表明,聚苯胺涂层制备工艺对其防护性能影响较大。在0.2 M苯胺+0.5 M水杨酸钠溶液中,采用循环电位区间为-0.2~1.8 V,扫速为30 m V/s,连续扫描10圈的工艺参数,有利于得到与镁合金基材结合良好、均匀致密的聚苯胺膜层。红外光谱和扫描电镜测试结果表明,该涂层为均匀片状结构的聚苯胺。     

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.     

Epoxy/polyaniline–ZnO nanorods hybrid nanocomposite coatings: Synthesis,characterization and corrosion protection performance of conducting paints

The objective of this research is the production of an epoxy coating blended with organic–inorganic hybrid nanocomposite as a corrosion inhibiting pigment applied over carbon steel grade ST37. A series of conducting polyaniline (PANI)–ZnO nanocomposites materials has been successfully prepared by an in situ chemical oxidative method of aniline monomers in the presence of ZnO nanorods with camphorsulfonic acid (CSA) and ammonium peroxydisulfate (APS) as surfactant and initiator, respectively. The synthesized polymers were characterized by X-ray diffraction pattern (XRD), Fourier transform infrared (FTIR), scanning electron microscopy (SEM), transmission electron microscopy (TEM), thermal gravimetric analysis (TGA) and electrical conductivity techniques. Synthesized nanocomposites were solved in tetraethylenpentamine (TEPA), and then prepared solution was mixed with epoxy and then was applied as a protective coating on carbon steel plates. The anti-corrosion behavior of the epoxy binder blended with PANI–ZnO nanocomposites were studied in 3.5% NaCl solution at a temperature of 25 °C by electrochemical techniques including electrochemical impedance spectroscopy (EIS) and chronopotentiometry at open circuit potential (OCP). It was observed that the epoxy coating containing conducting PANI–ZnO nanocomposites exhibited higher corrosion resistance and provided better barrier properties in the paint film in comparison with pure epoxy and epoxy/PANI coatings. In the case of conducting coatings, the OCP was shifted to the noble region due to presence of PANI pigments. Additionally, the possibility of formation of a passive film in the presence of PANI was reinforced at the substrate–coating interface. SEM studies taken from surface of the coatings showed that epoxy/PANI–ZnO hybrid nanocomposite coating systems (EPZ) are crack free, uniform and compact. Furthermore, it was found that the presence of ZnO nanorods beside PANI can significantly improve the barrier and corrosion protection performance of the epoxy coating due to the flaky shaped structure of the PANI–ZnO nanocomposites.     

Protection of stainless steel by polyaniline films against corrosion in aqueous environments

Polyaniline (PANI) thin films were electrochemically deposited by cyclic voltammetry on stainless steel electrode previously covered by a thin film of polyvinyl acetate (PVAc). The corrosion resistance of PANI covered stainless steel substrates was estimated by using potentiodynamic polarization curves and its linear polarization resistance (LPR) was measured in 0.5 M H₂SO₄, 0.5 M NaCl and 0.5 M NaOH aqueous solutions at room temperature. The results indicate that the PANI-PVAc films did improve the corrosion resistance of the stainless steel in NaOH, behaving even worst, in the case of PANI film, than the uncoated substrate. In H₂SO₄ both PANI and PANI-PVAc coatings gave good protection for the stainless steel electrode, with a slightly better performance of PANI-PVAc than PANI. In NaCl solution both PANI and PANI-PVAc films provided a good protection against corrosion. The better performance of PANI-PVAc coatings for corrosion protection in basic media may be due to its major chemical stability compared to simple PANI films, which lose their conductivity in high pH solutions. The E _corr (free corrosion potential) value of the coated substrate was in the passive region of the uncoated substrate in acidic environment but in the active region in neutral or basic environment.     

Accelerating effect and mechanism of passivation of polyaniline on ferrous metals

To investigate the corrosion protection mechanism of polyaniline (PANI) films on ferrous metals, this work presents preparation method of a separate protonated PANI film electrode and results of its open-circuit potential (OCP) in 0.5 M NaClO₄ and 0.5 M Na₂SO₄ solutions with different pH and the galvanic interaction between the PANI film electrode and ferrous metals. X-ray photoelectron spectroscopy (XPS) shows the lower pH corresponds to higher protonation level of H⁺ in the film, and a more positive OCP of PANI film. The PANI film accelerated the corrosion of 20A carbon steel slightly with a PANI to steel area ratio less than 25:1, while the PANI films maintained passivity for a ratio above to 25:1 for the 20A steel. For the coupling of 2Cr13 stainless steel/PANI, an equal area PANI film could maintain 2Cr13 in a passive state. The results suggest that corrosion protection of 20A carbon steel and 2Cr13 stainless steel by PANI film in the acid solution is due to passivity protection. The excess oxidative charge stored in the PANI and the equilibrium activity of protonated PANI with the acid environment provide a persistent driving force for carbon steel and 2Cr13 stainless steel passivity.     

Conducting polymer based hybrid nano-composites for enhanced corrosion protective coatings

Hybrid composite coatings containing zinc oxide (ZnO) and polyaniline (PANI) as nano-additives dispersions were prepared with poly(vinyl acetate) (PVAc) as the major matrix. The steel plates dip-coated with these formulations were tested for corrosion protection by immersion in saline water over long periods. The Tafel plots for the determination of open circuit potential (OCP) and corrosion current (I_corr) were recorded. The coatings containing both ZnO and PANI showed improved corrosion resistance as compared to the single component coating. The I_corr values of PVAc–ZnO–PANI are found to be two-order magnitude lower than that of PVAc and PVAc–ZnO coatings. The results are explained on the basis of enhancement in barrier properties due to nano-particulate additives in PVAc–ZnO–PANI film together with the redox behaviour of PANI and protective oxide layer formation near the substrate.     

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     

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.     

Anticorrosion efficiency of organic coatings depending on the pigment volume concentration of polyaniline phosphate

Polyaniline (PANI) was synthesized by reaction in an aqueous solution of ammonium peroxodisulfate and phosphoric acid. PANI was characterized by means of scanning electron microscopy and its physical–chemical properties were determined. Simultaneously with the synthesized PANI epoxy-ester coatings containing 3, 5, 10, 15, 20 and 24 vol.% of PANI as a corrosion inhibitor were formulated. The coatings were tested for their mechanical properties, film hardness and corrosion resistance. The testing of the anticorrosion efficiency of PANI as corrosion inhibitor was based on accelerated corrosion tests: in condensed water, NaCl mist, and condensing water and SO₂. The prepared PANI displayed inhibition effects in corrosion reactions progressing on a steel base under the organic coating. The synthesized PANI provides good anticorrosion efficiency in an epoxy-ester coating. The studied system does not contain any heavy metals harmful to the environment.     

PANI-DBSA/MMA-BA共聚物导电涂料的结构与性能表征

以十二烷基苯磺酸(DBSA)掺杂的聚苯胺(PANI)为导电组分,三氯甲烷为溶剂,采用溶液共混法制备聚苯胺/丙烯酸酯共聚物(AA)导电薄膜。对导电薄膜进行了导电性能测试,扫描电镜(SEM)、红外光谱(FT-IR)及差示扫描量热(DSC)分析。结果表明:导电薄膜的电导率随PANI-DBSA含量的增加而增加,体系的逾渗阈值低于4%(质量分数)。共混体系表现出良好的相容性。     

Poly(o-anisidine) on brass: Synthesis and corrosion behavior

The electrochemical synthesis of poly(o-anisidine) (POA) was achieved on brass (CuZn) electrode by applying two scan rates (50 and 20 mVs⁻¹). The synthesized polymer films were strongly adherent and homogeneous in both cases. Their corrosion performance was investigated by AC impedance spectroscopy (EIS) technique, anodic polarization plots and open circuit potential-time curves, in 3.5% NaCl solution. It was clearly seen that poly(o-anisidine) films provided a significant physical protection for longer exposure time. It was shown that polymer film coated at high scan rate (CuZn/POA-H) exhibited better barrier property against the attack of corrosive agents when compared with polymer film obtained at low scan rate (CuZn/POA-L). It was found out that poly(o-anisidine) film synthesized at high scan rate caused a significant increase in corrosion resistance by its catalytic behavior on formation of protective oxide layers on the surface in longer time.     

A passivation mechanism of doped polyaniline on 410 stainless steel in deaerated H2SO4 solution

To investigate the role of polyaniline (PANI) in the corrosion protection of stainless steel (SS) in oxygen-deficient acidic solution, a separate doped PANI film electrode on a glass substrate was prepared and the test solution (1 M H₂SO₄) was purged with high-purity N₂ until dissolved oxygen level decreased more than two orders of magnitude. In this deaerated 1 M H₂SO₄ solution, the galvanic coupling interaction between the separate PANI film electrode and 410 SS was studied. Results reveal that the separate PANI film can passivate the 410 SS steadily for a long period of time. A variety of experimental methods including potentiodynamic measurement, potentiostatic (current-time) examination and X-ray photoelectron spectroscopy (XPS) are used to explore the mechanism by which the separate PANI film passivated the galvanic coupling SS in the deaerated sulfuric solution. These studies show that passivation is achieved because PANI film provides a large critical current at the early stage of coupling and a persistent passive current by its electrochemical dedoping/re-doping equilibrium activity with the acidic environment at the subsequent stage of coupling.     

Conductivity and anticorrosion performance of polyaniline/zinc composites: Investigation of zinc particle size and distribution effect

Polyaniline/zinc composites and nanocomposites were prepared using solution mixing method. Zinc (Zn) particles with an average particle size of 60 μm and zinc nanoparticles with an average particle size of 35 nm were used as fillers in polyaniline (PANI) matrix. Films and coatings of PANI/Zn composites and nanocomposites were prepared by the solution casting method. Electrical conductivity and anticorrosion properties of PANI/Zn composite and nanocomposite films and coatings with different zinc loadings were evaluated. According to the results, electrical conductivity and anticorrosion performances of both PANI/Zn composites and nanocomposites were increased by increasing the zinc loading. Also results showed that the PANI/Zn nanocomposite films and coatings have better electrical conductivity and corrosion protection effect on iron coupons compared to that of PANI/Zn composite.     

基于聚苯胺改性构建三维MXene复合材料及其电容性能

通过直接电化学法,本文利用MXene表面官能团的诱导能力,在外加电场的作用下,将苯胺单体与MXene共同修饰在不锈钢电极表面,成功制得具有三维结构的MXene/聚苯胺复合电极材料。采用SEM、XRD、XPS、FTIR和Raman光谱对复合电极材料的表面形貌、物相结构和组成进行了表征,并在1mol/L H₂SO₄中详细研究了该电极材料的电容性能。结果表明,得益于MXene的掺杂,MXene/聚苯胺复合电极表现出较好的电子传导能力和优异的电容性能,在10mV/s的扫描速率下电容可达417F/g,当扫描速率增至200mV/s时,其电容保持率为52%,比纯PANI电极高31%。该复合电极材料具有良好的循环稳定性,在1.0A/g的电流密度下循环2000次后电容保持率可维持在83.4%。此项研究工作可为三维MXene复合材料的构建提供设计思路。     

Electropolymerization, characterization and corrosion performance of poly(N-ethylaniline) on copper

Poly(N-ethylaniline) (PNEA) coatings were grown by cyclic voltammetry technique on copper from 0.1 M N-ethylaniline (NEA) in 0.3 M oxalic acid solution. The optimum conditions (e.g. upper potential limit, scan rate and cycle number) effect on corrosion performance of synthesized PNEA films were determined in order to obtain best protection results against corrosion. The electrodeposited coatings were characterized by cyclic voltammetry (CV), Fourier Transform Infrared-Attenuated Total Reflectance (FTIR-ATR) spectroscopy and scanning electron microscopy (SEM). Redox parameters were found after electrochemical tests and results of stability tests of these films impart an electroactive behavior that is composed of both diffusion control and thin film behavior. In addition, corrosion performance of PNEA coatings were investigated in 0.1 M H₂SO₄ by Tafel extrapolation and electrochemical impedance spectroscopy (EIS) techniques.