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Corrosion protection of electrogalvanised steel by application of non-conducting polyaniline-silica particles

ABSTRACT The authors have demonstrated that incorporation of poly(ethyleneimine) (PEI) coated polyaniline-silica (PANI-SiO2) particles into the zinc coating matrix improves the corrosion resistance of low carbon steel in a 5% NaCl solution compared to the bare zinc coating. The zinc and hybrid coatings were electrodeposited on a steel cathode surface at pH 5.5 when PANI manifests itself as non-conductive emeraldine base. Scanning electron microscopy showed that the hybrid coating consists of particle agglomerates in size 50–100 μm, mixed with smooth formations and smaller needle-like particles. The influence of PEI is suggested to cause the appearance of the smooth formations. The influence of PANI-SiO2 particles on the cathodic deposition and anodic dissolution has been checked with cyclic voltammetry. The protective properties of the coatings were characterised by potentiodynamic polarisation and polarisation resistance studies. X-ray diffraction and X-ray photoelectron spectroscopy were also applied to investigate the metallographic structure and chemical composition of the coatings.