Efficient Anticorrosive Acrylate Water-Borne Paint Based on Polyaniline Nanocomposite Dispersion for Carbon Steel Protection in 3.5% NaCl Solution

Polyaniline (PANI) nanocomposite with Zn and Ni has been prepared by in situ polymerization of aniline monomer in presence of Ni +2 and Zn +2 ions. The prepared nanocomposite (Ncomp) (PANI/Zn/Ni) has been characterized by spectrophotometric analysis via Fourier-transform infrared spectroscopy (FTIR) and ultraviolet–visible absorption spectra (UV–Vis). Morphological studies via scanning electron microscope SEM, particle size distribution PSD, as well as thermo-gravimetric analysis (TGA), have been investigated. Besides, the prepared (Ncomp) of different weight percentages wt% has been incorporated into water-based paint formulations for carbon steel protection. PSD analysis revealed that the particle size of the formed composite is on the nano-scale ranging between 60 and 160 nm. SEM analysis revealed that the Zn and Ni nanoparticles are quite dispersed into the polymer matrix as they appear in the form of bright spots and have been confirmed by energy dispersive X-ray (EDX) analysis. TGA analysis for the Ncomp showed enhanced thermal stability than that of pure PANI. The corrosion inhibition performance of the painted films has been investigated by potentiodynamic polarization and electrochemical impedance spectroscopy as well. The maximum average inhibition efficiency was found to be ranged from 92.8 to 99.4% for the paint of 9% wt% of Ncomp with fair mechanical properties. All measurements have been repeated three times for confirmation. Graphical Abstract