Abstract
Different epoxy coatings incorporated with different additions of up to 0.78 wt. % polyaniline (PANI) were manufactured. The dispersion of PANI with epoxy was done using both mechanical and sonication processes. The surface of the fabricated coatings was characterized using field emission scanning electron microscopy (FE-SEM). The chemical composition was also confirmed by using Fourier transform infrared (FTIR-ATR). The hardness, scratch resistance, impact strength, load vs. depth using nanoindentation, and thermal degradation for all of the manufactured coatings were evaluated. The corrosion resistance of the PANI modified coatings after different immersion periods of time, namely, 1 h, 7 days, and 21 days in 3.5 wt. % NaCl solutions were reported using electrochemical impedance spectroscopy (EIS) measurements. Measurements proved that these coatings have excellent mechanical properties and provide good corrosion protection, which is superior as compared to conventional epoxy coatings. Results also indicated that PANI can be considered as suitable alternative to replace hazardous inorganic anticorrosive pigments currently used in coating formulations.