Electropolymerization of PANI coating in nitric acid for corrosion protection of 430 SS

A smooth and adherent polyaniline (PANI) coating was electropolymerized in HNO3 solution by cyclic voltammetry in order to protect the ferritic and economic 430 stainless steel (SS) from corrosion. The corrosion resistance was evaluated in 3.5 wt.% NaCl solution by anodic polarization, potentiodynamic polarization, and electrochemical impedance spectroscopy. The PANI coating shifts the corrosion potential of SS to the passive region and provides a strong and steady corrosion resistance. A low growth rate leads to a compact PANI coating that acts as a good physical barrier. However, the strong corrosion inhibition is mainly attributed to the dense oxide layers formed by the catalytic effect of PANI at the polymer/metal interface. The composition of the oxide layers was analyzed via depth profiling using X-ray photoelectron spectroscopy alternating with sputtering. Compared with layers formed on uncoated SS, the iron and chromium oxide layers under the PANI are thinner and denser, absorbing less oxygen, and providing a stronger corrosion inhibition.