Investigation of corrosion performance of epoxy coating containing polyaniline nanoparticles

An emulsion polymerization of aniline was performed in a solution of dodecylbenzenesulfonic acid emulsifier, benzoyl peroxide oxidant and tartaric acid as dopant. The polyaniline-containing coating was applied over carbon steel panels and the polyaniline content in the coating was 1 %. The influence of reactants concentration on the morphological and anti-corrosive properties of polyaniline was investigated to determine the optimum conditions for the synthesis of polyaniline nanoparticles. The average size of particles determined by X-ray diffraction measurement was 70-104 nm, which is found to be in agreement with the scanning electron microscopy results. Corrosion resistance of coatings was obtained using electrochemical techniques (electrochemical impedance spectroscopy and open circuit potential measurements) in 3.5 % sodium chloride solution. Nyquist diagrams showed two capacitance loops, one at high frequency range followed by a larger one at low frequencies due to coating and charge transfer resistance. The corrosion resistance values were found to decrease due to the corrosion of carbon steel in pinholes of the coating. For longer immersion times, the coating resistance values were found to increase due to the passivation effect of polyaniline. The results showed that epoxy coating with doped polyaniline nanoparticles is able to offer protection in sodium chloride solution.