Conducting polyaniline/nano-zinc phosphate composite as a pigment for corrosion protection of low-carbon steel

Zinc phosphate (Zn3(PO4)2) nanocrystals were synthesized and used for making conducting polyaniline/nano-zinc phosphate composite by chemical oxidative method. The product was characterized by UV–visible absorption spectroscopy. The crystal structure, morphology and thermal stability of the product were studied by X-ray diffraction, scanning electron microscopy, transmission electron microscopy and thermo gravimetric analysis, respectively. The epoxy-based paint containing conducting polyaniline/nano-zinc phosphate composite pigment was applied on low-carbon steel samples. Corrosion protection performance of the painted low-carbon steel samples in 3.5 mass % sodium chloride solution was evaluated using electrochemical technique. Transmission electron microscopic image revealed the formation of core shell structure of the composite. Composite was found to be more thermally stable than the conducting polyaniline. The corrosion rate of conducting polyaniline/nano-zinc phosphate-painted low-carbon steel was found to be 5.1 × 10−4 mm per year, about 34 times lower than that of unpainted low-carbon steel and 10 times lower than that of epoxy nano-zinc phosphate paint-coated steel. The study reveals the possibility of using conducting polyaniline/nano-zinc phosphate as a pigment for corrosion protection.