Corrosion properties of an organic coating containing polyaniline–ZnO nanocomposites applied on low carbon steel are investigated. Conductive polymers were prepared by in situ chemical oxidative method of aniline in the presence of ZnO nanorods. The synthesised materials were characterised by X-ray diffraction, Fourier transform infrared, scanning electron microscopy, transmission electron microscopy and electrical conductivity. Corrosion behaviour of the epoxy binder blended with polyaniline (PANI)–ZnO nanocomposites was examined in 3·5% NaCl solution at a temperature of 65°C by electrochemical techniques including open circuit potential and electrochemical impedance spectroscopy. It is observed that the epoxy coating containing PANI–2 wt-%ZnO nanocomposite exhibits the highest corrosion resistance, which it can be attributed to the specific morphology of the nanocomposite that derives better barrier properties in paint film and the possibility of formation of passive layer in the presence of PANI at the substrate/coating interface.
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