Startseite Corrosion resistive conducting polymeric nanocomposite-based coatings on steel: a mechanistic insight
Artikel
Lizenziert
Nicht lizenziert Erfordert eine Authentifizierung

Corrosion resistive conducting polymeric nanocomposite-based coatings on steel: a mechanistic insight

  • Kuntal Sarkar , Rishi Raj , Tapan K. Rout und Suryasarathi Bose EMAIL logo
Veröffentlicht/Copyright: 15. April 2025
Veröffentlichen auch Sie bei De Gruyter Brill
Manuskript einreichen Informationen für Autor*innen
International Polymer Processing
Aus der Zeitschrift International Polymer Processing Band 40 Heft 2

Abstract

Conducting polymers and polymer-based nanocomposites has occupied significant importance in the scientific field as well as engineering research and applications. Among all different applications, conducting polymers as a corrosion resistive coating on steel have developed a lot of research interest and success for the last four decades. This paper provides an extensive review on the corrosion resistive conducting organic polymer coating systems over steel substrates. It mainly discusses different mechanisms of corrosion provided by different conducting polymer coatings over steel. The corrosion resistance mechanisms of coatings based on polyaniline (PANI) and polypyrrole (PPy) and their nanocomposites, which are considered very promising conducting polymers in different fields, are reviewed here. PANI provides corrosion resistance via different mechanisms. PANI in oxidised form can offer effective anodic corrosion resistance to steel surface due to its higher oxidising ability than in reduced form. It can provide a good extent of barrier protection to steel as well. PPy also can provide both the barrier and anodic protection. The mechanism of intelligent release of doped corrosion inhibitive anions from the conducting polymer coating and its contribution to corrosion protection mechanism of steel is also focused in this article. The limitations of conducting polymer coating are briefly discussed.

Keywords: conducting polymers; polyaniline (PANI); polypyrrole (PPy); steel; corrosion mechanisms
Corresponding author: Suryasarathi Bose, Department of Materials Engineering, Indian Institute of Science, Bangalore-560012, India, E-mail:

Acknowledgement

The authors (S.B. and R.R.) would like to acknowledge IISc, Bangalore and Tata steel ltd., Jamshedpur for their support in this work.

  1. Research ethics: Not applicable.

  2. Informed consent: Not applicable.

  3. Author contributions: K.S. and R.R. have contributed in literature survey, data interpretation, analysis and manuscript writing and T.K.R. and S.B. helped in editing, data analysis and designing the frame work of the manuscript.

  4. Use of Large Language Models, AI and Machine Learning Tools: None declared.

  5. Conflict of interest: The authors state no conflict of interest.

  6. Research funding: The funding for this research was provided by IISc Bangalore and Tata steel ltd., Jamshedpur.

  7. Data availability: Not applicable.

References

Ahmad, N. and Macdiarmid, A.G. (1996). Inhibition of corrosion of steels with the exploitation of conducting polymers. Synth. Met. 78: 103–110, https://doi.org/10.1016/0379-6779(96)80109-3.Suche in Google Scholar

Ates, M. (2016). A review on conducting polymer coatings for corrosion protection. J. Adhes. Sci. Technol. 30: 1510–1536, https://doi.org/10.1080/01694243.2016.1150662.Suche in Google Scholar

Bandi, P., M.K.V., Kausley, S., and Rai, B. (2020). Development of superhydrophobic and corrosion resistant coatings on mild steel—a greener approach. Mater. Today Commun. 25: 101625, https://doi.org/10.1016/j.mtcomm.2020.101625.Suche in Google Scholar

Bastos, A.C., Simões, A.M., González, S., González-García, Y., and Souto, R.M. (2005). Application of the scanning electrochemical microscope to the examination of organic coatings on metallic substrates. Prog. Org. Coat. 53: 177–182, https://doi.org/10.1016/j.porgcoat.2005.02.005.Suche in Google Scholar

Chen, Z., Cai, Y., Lu, Y., Cao, Q., Lv, P., Zhang, Y., and Liu, W. (2022). Preparation and performance study of carboxy-functionalized graphene oxide composite polyaniline modified water-based epoxy zinc-rich coatings. Coatings 12: 824, https://doi.org/10.3390/coatings12060824.Suche in Google Scholar

Cook, A., Gabriel, A., and Laycock, N. (2004). On the mechanism of corrosion protection of mild steel with polyaniline. J. Electrochem. Soc. 151: B529, https://doi.org/10.1149/1.1782077.Suche in Google Scholar

De Souza, S. (2007). Smart coating based on polyaniline acrylic blend for corrosion protection of different metals. Surf. Coat. Technol. 201: 7574–7581, https://doi.org/10.1016/j.surfcoat.2007.02.027.Suche in Google Scholar

Deberry, D.W. (1985). Modification of the electrochemical and corrosion behavior of stainless steels with an electroactive coating. J. Electrochem. Soc. 132: 1022–1026, https://doi.org/10.1149/1.2114008.Suche in Google Scholar

Deshpande, P.P., Vathare, S.S., Vagge, S.T., Tomšík, E., and Stejskal, J. (2013). Conducting polyaniline/multi-wall carbon nanotubes composite paints on low carbon steel for corrosion protection: electrochemical investigations. Chem. Pap. 67: 1072–1078, https://doi.org/10.2478/s11696-012-0273-9.Suche in Google Scholar

Djara, R., Holade, Y., Merzouki, A., Masquelez, N., Cot, D., Rebiere, B., Petit, E., Huguet, P., Canaff, C., Morisset, S., et al.. (2020). Insights from the physicochemical and electrochemical screening of the potentiality of the chemically synthesized polyaniline. J. Electrochem. Soc. 167: 066503, https://doi.org/10.1149/1945-7111/ab7d40.Suche in Google Scholar

Dominis, A.J., Spinks, G.M., and Wallace, G.G. (2003). Comparison of polyaniline primers prepared with different dopants for corrosion protection of steel. Prog. Org. Coat. 48: 43–49, https://doi.org/10.1016/S0300-9440(03)00111-5.Suche in Google Scholar

Esfandiari, K., Banihashemi, M., and Soleimani, P. (2020). Influence of impressed current cathodic protection systems on chemical characteristics of underground water. Water Environ. Res. 92: 2105–2111, https://doi.org/10.1002/wer.1371.Suche in Google Scholar PubMed

Fang, J., Xu, K., Zhu, L., Zhou, Z., and Tang, H. (2007). A study on mechanism of corrosion protection of polyaniline coating and its failure. Corros. Sci. 49: 4232–4242, https://doi.org/10.1016/j.corsci.2007.05.017.Suche in Google Scholar

Fazli-Shokouhi, S., Nasirpouri, F., and Khatamian, M. (2021). Epoxy-matrix polyaniline/p-phenylenediamine-functionalised graphene oxide coatings with dual anti-corrosion and anti-fouling performance. RSC Adv. 11: 11627–11641, https://doi.org/10.1039/d0ra10665h.Suche in Google Scholar PubMed PubMed Central

Fedrizzi, L., Rodriguez, F.J., Rossi, S., Deflorian, F., and Maggio, R.di (2001). The use of electrochemical techniques to study the corrosion behaviour of organic coatings on steel pretreated with sol-gel zirconia films. Electrochim. Acta 46: 3715–3724, https://doi.org/10.1016/S0013-4686(01)00653-3.Suche in Google Scholar

Fuente, D.de La, Díaz, I., Alcántara, J., Chico, B., Simancas, J., Llorente, I., García-Delgado, A., Jiménez, J.A., Adeva, P., and Morcillo, M. (2016). Corrosion mechanisms of mild steel in chloride-rich atmospheres. Mater. Corros. 67: 227–238, https://doi.org/10.1002/maco.201508488.Suche in Google Scholar

Garcia, B., Lamzoudi, A., Pillier, F., Nguyen, H., Le, T., and Deslouis, C. (2002). Oxide/polypyrrole composite films for corrosion protection of iron. J. Electrochem. Soc. 149: B560–B566, https://doi.org/10.1149/1.1517581.Suche in Google Scholar

Grundmeier, G., Schmidt, W., and Stratmann, M. (2000). Corrosion protection by organic coatings: electrochemical mechanism and novel methods of investigation. Electrochim. Acta 45: 2515–2533, https://doi.org/10.1016/S0013-4686(00)00348-0.Suche in Google Scholar

Hasanov, R. and Bilgiç, S. (2009). Monolayer and bilayer conducting polymer coatings for corrosion protection of steel in 1 M H2SO4 solution. Prog. Org. Coat. 64: 435–445, https://doi.org/10.1016/j.porgcoat.2008.08.004.Suche in Google Scholar

Hayatgheib, Y., Ramezanzadeh, B., Kardar, P., and Mahdavian, M. (2018). A comparative study on fabrication of a highly effective corrosion protective system based on graphene oxide-polyaniline nanofibers/epoxy composite. Corros. Sci. 133: 358–373, https://doi.org/10.1016/j.corsci.2018.01.046.Suche in Google Scholar

Ionita, M. and Pruna, A. (2011). Polypyrrole/carbon nanotube composites: molecular modeling and experimental investigation as anti-corrosive coating. Prog. Org. Coat. 72: 647–652, https://doi.org/10.1016/j.porgcoat.2011.07.007.Suche in Google Scholar

Jalali, H., Eslami-Farsani, R., and Ramezanzadeh, B. (2023). Molybdate-doped sulfonated-polyaniline (SPni.Mo) grafted CNT nano-particles for fabrication of a dual-functional epoxy composite coating with durable corrosion resistance function. Colloids and Surf. A: Physicochem. Eng. Asp. 677: 132433, https://doi.org/10.1016/j.colsurfa.2023.132433.Suche in Google Scholar

Jiang, L., Syed, J.A., Lu, H., and Meng, X. (2019). In-situ electrodeposition of conductive polypyrrole-graphene oxide composite coating for corrosion protection of 304SS bipolar plates. J. Alloys Compd. 770: 35–47, https://doi.org/10.1016/j.jallcom.2018.07.277.Suche in Google Scholar

Kendig, M., Hon, M., and Warren, L. (2003). “Smart” corrosion inhibiting coatings. Prog. Org. Coat. 47: 183–189, https://doi.org/10.1016/S0300-9440(03)00137-1.Suche in Google Scholar

Kinlen, P.J., Menon, V., and Ding, Y. (1999). A mechanistic investigation of polyaniline corrosion protection using the scanning reference electrode technique. J. Electrochem. Soc. 146: 3690–3695, https://doi.org/10.1149/1.1392535.Suche in Google Scholar

Kinlen, P.J., Ding, Y., and Silverman, D.C. (2002). Corrosion protection of mild steel using sulfonic and phosphonic acid-doped polyanilines. Corrosion 58: 490–497, https://doi.org/10.5006/1.3277639.Suche in Google Scholar

Krishna, J.B.M., Saha, A., Okram, G.S., Soni, A., Purakayastha, S., and Ghosh, B. (2009). Electrical properties of polyaniline doped with metal ions. J. Phys. D: Appl. Phys. 42: 095404, https://doi.org/10.1088/0022-3727/42/9/095404.Suche in Google Scholar

Lacroix, J.-C., Camalet, J.-L., Aeiyach, S., Chane-Ching, K.I., Petitjean, J., Chauveau, E., and Lacaze, P.-C. (2000). Aniline electropolymerization on mild steel and zinc in a two-step process. J. Electroanal. Chem. 481: 76–81, https://doi.org/10.1016/S0022-0728(99)00490-8.Suche in Google Scholar

MacDiarmid, Alan G. (2001). Synthetic metals: a novel role for organic polymers (nobel lecture). Angew. Chem., Int. Ed. 40: 2581–2590, https://doi.org/10.1002/1521-3773(20010716)40:14<2581:AID-ANIE2581>3.0.CO;2-2.10.1002/1521-3773(20010716)40:14<2581::AID-ANIE2581>3.0.CO;2-2Suche in Google Scholar

Mengoli, G., Munari, M.T., Bianco, P., and Musiani, M.M. (1981). Anodic synthesis of polyaniline coatings onto Fe sheets. J. Appl. Polym. Sci. 26: 4247–4257, https://doi.org/10.1002/app.1981.070261224.Suche in Google Scholar

Michalik, A. and Rohwerder, M. (2009). Conducting Polymers for corrosion protection: a critical view. De Gruyter, Berlin, Germany.Suche in Google Scholar

Mondal, J., Marandi, M., Kozlova, J., Merisalu, M., Niilisk, A., and Sammelselg, V. (2014). Protection and functionalizing of stainless steel surface by graphene oxide-polypyrrole composite coating. J. Chem. Chem. Eng. 8: 786–793.Suche in Google Scholar

Nayak, S.R., Mohana, K.N.S., Hegde, M.B., Rajitha, K., Madhusudhana, A.M., and Naik, S.R. (2021). Functionalized multi-walled carbon nanotube/polyindole incorporated epoxy: an effective anti-corrosion coating material for mild steel. J. Alloys Compd. 856: 158057, https://doi.org/10.1016/j.jallcom.2020.158057.Suche in Google Scholar

Nguyen, H., Le, T., Garcia, B., Deslouis, C., and Xuan, Q. Le (2001). Corrosion protection and conducting polymers: polypyrrole films on iron. Electrochim. Acta 46: 4259–4272, https://doi.org/10.1016/S0013-4686(01)00699-5.Suche in Google Scholar

Ocón, P., Cristobal, A.B., Herrasti, P., and Fatas, E. (2005). Corrosion performance of conducting polymer coatings applied on mild steel. Corros. Sci. 47: 649–662, https://doi.org/10.1016/j.corsci.2004.07.005.Suche in Google Scholar

Ohtsuka, T. (2012). Corrosion protection of steels by conducting polymer coating. Int. J. Corros. 1–7, https://doi.org/10.1155/2012/915090.Suche in Google Scholar

Paliwoda-Porebska, G., Stratmann, M., Rohwerder, M., Potje-Kamloth, K., Lu, Y., Pich, A.Z., and Adler, H.J. (2005). On the development of polypyrrole coatings with self-healing properties for iron corrosion protection. Corros. Sci. 47: 3216–3233, https://doi.org/10.1016/j.corsci.2005.05.057.Suche in Google Scholar

Rammelt, U., Duc, L.M., and Plieth, W. (2005). Improvement of protection performance of polypyrrole by dopant anions. J. Appl. Electrochem. 35: 1225–1230, https://doi.org/10.1007/s10800-005-9033-7.Suche in Google Scholar

Rashidi, M., Mottaghitalab, V., and Haghi, A.K. (2010). Nanotextiles-based sensing devices to acquire biomechanical signals. Part II. J. Balkan Tribol. Assoc. 16: 267–278.Suche in Google Scholar

Rohwerder, M. (2009). Conducting polymers for corrosion protection: a review. Int. J. Mater. Res. 100: 1331–1342, https://doi.org/10.3139/146.110205.Suche in Google Scholar

Rohwerder, M. and Michalik, A. (2007). Conducting polymers for corrosion protection: what makes the difference between failure and success? Electrochim. Acta 53: 1300–1313, https://doi.org/10.1016/j.electacta.2007.05.026.Suche in Google Scholar

Rui, M. and Zhu, A. (2021). The synthesis and corrosion protection mechanisms of PANI/CNT nanocomposite doped with organic phosphoric acid. Prog. Org. Coat. 153: 106134, https://doi.org/10.1016/j.porgcoat.2021.106134.Suche in Google Scholar

Sangaj, N.S. and Malshe, V.C. (2004). Permeability of polymers in protective organic coatings. Prog. Org. Coat. 50: 28–39, https://doi.org/10.1016/j.porgcoat.2003.09.015.Suche in Google Scholar

Sarkar, K., Mondal, A., Chakraborty, A., Sanbui, M., Rani, N., and Dutta, M. (2018). Investigation of microstructure and corrosion behaviour of prior nickel deposited galvanised steels. Surf. Coat. Technol. 348: 64–72, https://doi.org/10.1016/j.surfcoat.2018.05.036.Suche in Google Scholar

Sathiyanarayanan, S., Jeyaram, R., Muthukrishnan, S., and Venkatachari, G. (2009). Corrosion protection mechanism of polyaniline blended organic coating on steel. J. Electrochem. Soc. 156: C127, https://doi.org/10.1149/1.3073874.Suche in Google Scholar

Sathiyanarayanan, S., Muthkrishnan, S., and Venkatachari, G. (2006). Corrosion protection of steel by polyaniline blended coating. Electrochim. Acta 51: 6313–6319, https://doi.org/10.1016/j.electacta.2006.04.015.Suche in Google Scholar

Shi, X., Nguyen, T.A., Suo, Z., Liu, Y., and Avci, R. (2009). Effect of nanoparticles on the anticorrosion and mechanical properties of epoxy coating. Surf. Coat. Technol. 204: 237–245, https://doi.org/10.1016/j.surfcoat.2009.06.048.Suche in Google Scholar

Shirakawa, H. (2001). Nobel Lecture: the discovery of polyacetylene film—the dawning of an era of conducting polymers. Rev. Mod. Phys. 73: 713–718, https://doi.org/10.1103/RevModPhys.73.713.Suche in Google Scholar

Shirakawa, H., McDiarmid, A., and Heeger, A. (2003). Twenty-five years of conducting polymers. Chem. Commun.: 1–4, https://doi.org/10.1039/B210718J.Suche in Google Scholar

Silva, J.E.P.da, Torresi, S.I.C.de, and Torresi, R.M. (2005). Polyaniline acrylic coatings for corrosion inhibition: the role played by counter-ions. Corros. Sci. 47: 811–822, https://doi.org/10.1016/j.corsci.2004.07.014.Suche in Google Scholar

Sinko, J. (2001). Challenges of chromate inhibitor pigments replacement in organic coatings. Prog. Org. Coat. 42: 267–282, https://doi.org/10.1016/S0300-9440(01)00202-8.Suche in Google Scholar

Sørensen, P.A., Kiil, S., Dam-Johansen, K., and Weinell, C.E. (2009). Anticorrosive coatings: a review. J. Coat. Technol. Res. 6: 135–176, https://doi.org/10.1007/s11998-008-9144-2.Suche in Google Scholar

Souto, L.F.C. and Soares, B.G. (2020). Polyaniline/carbon nanotube hybrids modified with ionic liquids as anticorrosive additive in epoxy coatings. Prog. Org. Coat. 143: 105598, https://doi.org/10.1016/j.porgcoat.2020.105598.Suche in Google Scholar

Spinks, G.M., Dominis, A.J., Wallace, G.G., and Tallman, D.E. (2002). Electroactive conducting polymers for corrosion control: Part 2. Ferrous metals. J. Solid-State Electrochem. 6: 85–100, https://doi.org/10.1007/s100080100211.Suche in Google Scholar

Wrssling, B. (1994). Passivation of metals by coating with polyaniline: corrosion potential shift and morphological changes. Adv. Mater. 6: 226–228, https://doi.org/10.1002/adma.19940060309.Suche in Google Scholar

Xu, H. and Zhang, Y. (2019). A review on conducting polymers and nanopolymer composite coatings for steel corrosion protection. Coatings 9: 807, https://doi.org/10.3390/coatings9120807.Suche in Google Scholar

Yang, S., Zhu, S., and Hong, R. (2020). Graphene oxide/polyaniline nanocomposites used in anticorrosive coatings for environmental protection. Coatings 10: 1–11, https://doi.org/10.3390/coatings10121215.Suche in Google Scholar

Zhang, J. and Zhu, A. (2021). Study on the synthesis of PANI/CNT nanocomposite and its anticorrosion mechanism in waterborne coatings. Prog. Org. Coat. 159: 106447, https://doi.org/10.1016/j.porgcoat.2021.106447.Suche in Google Scholar

Zhu, Q., Li, E., Liu, X., Song, W., Li, Y., Wang, X., and Liu, C. (2020). Epoxy coating with in-situ synthesis of polypyrrole functionalized graphene oxide for enhanced anticorrosive performance. Prog. Org. Coat. 140: 105488, https://doi.org/10.1016/j.porgcoat.2019.105488.Suche in Google Scholar

Zhu, Q., Huang, Y., Li, Y., Zhou, M., Xu, S., Liu, X., Liu, C., Yuan, B., and Guo, Z. (2021). Aluminum dihydric tripolyphosphate/polypyrrole-functionalized graphene oxide waterborne epoxy composite coatings for impermeability and corrosion protection performance of metals. Adv. Compos. Hybrid Mater. 4: 780–792, https://doi.org/10.1007/s42114-021-00265-6.Suche in Google Scholar

Zoshki, A., Rahmani, M.B., Masdarolomoor, F., and Pilehrood, S.H. (2017). Room temperature gas sensing properties of polyaniline/ZnO nanocomposite thin films. J. Nanoelectron. Optoelectron. 12: 465–471, https://doi.org/10.1166/jno.2017.2031.Suche in Google Scholar
Received: 2024-08-09
Accepted: 2025-01-21
Published Online: 2025-04-15
Published in Print: 2025-05-26

© 2025 Walter de Gruyter GmbH, Berlin/Boston

Artikel in diesem Heft

  1. Frontmatter
  2. Review Article
  3. Corrosion resistive conducting polymeric nanocomposite-based coatings on steel: a mechanistic insight
  4. Research Articles
  5. Effect of compatibilizer type on the properties of thermoplastic elastomers based on recycled polyethylene at high ground tire rubber content
  6. Analyzing the effects of solid fraction and heat treatment on the mechanical properties of 3D printed polymer lattices
  7. Effect of polyvinyl acetate on the properties of biodegradable thermoplastic starch/polyethylene glycol blends
  8. A color masterbatch assistance system for optimizing product color by masterbatch addition in injection molding of post-industrial recyclates
  9. Enhancing 3D printing with composite filaments incorporating electronic waste: a study on flexural and compression strength
  10. Development of enhanced co-continuous PVDF/PET nanocomposites via synergistic effects of graphite particle size, hybrid systems, and reduced graphene oxide
  11. Integration of nanographene and action of fiber sequences on functional behaviour of composite laminates
  12. Effect of chain branching on the rheological properties of HDPE/LLDPE and HDPE/LDPE blends under shear and elongational flows and evaluation of die swell and flow instabilities
  13. Effect of graphene nanoplatelets (GnPs) on low velocity impact properties of hybrid kevlar/basalt fiber reinforced epoxy based composites
  14. Sustainability in rotational molding: a study on recycling and the influence of additives
https://doi.org/10.1515/ipp-2024-0101
Schlagwörter für diesen Artikel
conducting polymers; polyaniline (PANI); polypyrrole (PPy); steel; corrosion mechanisms

Artikel in diesem Heft

  1. Frontmatter
  2. Review Article
  3. Corrosion resistive conducting polymeric nanocomposite-based coatings on steel: a mechanistic insight
  4. Research Articles
  5. Effect of compatibilizer type on the properties of thermoplastic elastomers based on recycled polyethylene at high ground tire rubber content
  6. Analyzing the effects of solid fraction and heat treatment on the mechanical properties of 3D printed polymer lattices
  7. Effect of polyvinyl acetate on the properties of biodegradable thermoplastic starch/polyethylene glycol blends
  8. A color masterbatch assistance system for optimizing product color by masterbatch addition in injection molding of post-industrial recyclates
  9. Enhancing 3D printing with composite filaments incorporating electronic waste: a study on flexural and compression strength
  10. Development of enhanced co-continuous PVDF/PET nanocomposites via synergistic effects of graphite particle size, hybrid systems, and reduced graphene oxide
  11. Integration of nanographene and action of fiber sequences on functional behaviour of composite laminates
  12. Effect of chain branching on the rheological properties of HDPE/LLDPE and HDPE/LDPE blends under shear and elongational flows and evaluation of die swell and flow instabilities
  13. Effect of graphene nanoplatelets (GnPs) on low velocity impact properties of hybrid kevlar/basalt fiber reinforced epoxy based composites
  14. Sustainability in rotational molding: a study on recycling and the influence of additives
Jetzt anmelden und 20% sparen
Institutioneller Zugang
Wie funktioniert Authentifizierung?
Haben Sie eine Idee, wie wir unsere Website verbessern können?
Bitte schreiben Sie uns.
© 2025 De Gruyter Brill
Heruntergeladen am 11.10.2025 von https://www.degruyterbrill.com/document/doi/10.1515/ipp-2024-0101/html
Button zum nach oben scrollen