Conducting polymers for corrosion protection: What makes the difference between failure and success?

Corrosion-Responsive Self-Healing Coatings

Organic coatings are one of the most popular and powerful strategies for protecting metals against corrosion. They can be applied in different ways, such as by dipping, spraying, electrophoresis, casting, painting, or flow coating. They offer great flexibility of material designs and cost effectiveness. Moreover, self-healing has evolved as a new research topic for protective organic coatings in the last two decades. Responsive materials play a crucial role in this new research field. However, for targeting the development of high-performance self-healing coatings for corrosion protection, it is not sufficient just to focus on smart responsive materials and suitable active agents for self-healing. A better understanding of how coatings can react on different stimuli induced by corrosion, how these stimuli can spread in the coating, and how the released agents can reach the corroding defect is also of high importance. Such knowledge would allow the design of coatings that are optimized for specific applications. Herein, the requirements and possibilities from the corrosion and synthesis perspectives for designing materials for preparing self-healing coatings for corrosion protection are discussed.

Polytriphenylamine and Poly(styrene-co-hydroxystyrene) Blends as High-Performance Anticorrosion Coating for Iron

An electroactive polytriphenylamine (PTPA-C6) is blended with poly(styrene-co-hydroxystyrene) (PS-co-PHS) as coating layers to enhance protection efficiency of PTPA-C6 on iron substrate in 3.5% sodium chloride (NaCl) solution. Experimental results show that incorporation of hydroxyl group to the polystyrene not only increases the miscibility of PTPA-C6 with PS through the hydrogen bond formation, but also enhances the bonding strength between the polymer coating layer and iron substrate. These improvements lead to superior enhancement in anticorrosion performance of PTPA-C6, even after thermal treatment. Protection efficiency (PE) of PTPA-C6 increases from 81.52% of the PTPA-C6 itself to over 94.40% under different conditions (PEmax = 99.19%).

Polymer Nanocomposite-based Coatings for Corrosion Protection

Corrosion of metals induces enormous loss of material performance and increase of cost, which has been a common and intractable issue that needs to be addressed urgently. Coating technology has been acknowledged to be the most economic and efficient approach to retard the metal corrosion. For several decades, polymers have been recognized as an effective anticorrosion coating material in both industries and scientific communities, as they demonstrate good barrier properties, ease of altering properties and massive production. Nanomaterials show distinctively different physical and chemical properties compared with their bulk counterparts, which have been considered as highly promising functional materials in various applications, impacting virtually all the fields of science and technologies. Recently, the introduction of nanomaterials with various properties into polymer matrix to form a polymer nanocomposite has been devoted to improve anticorrosive ability of polymer coatings. In this review article, we highlight the recent advances and synopsis of these high-performance polymer nanocomposites as anticorrosive coating materials. We expect that this work could be helpful for the researchers who are interested in the development of functional nanomaterials and advanced corrosion protection technology.

A Novel Electroactive Imide Oligomer and Its Application in Anticorrosion Coating

A novel aniline tetramer (AT) capped electroactive imide oligomer (EIO) for metal corrosion protection was successfully synthesized in this study. The chemical structure of the EIO was characterized by liquid chromatography-mass spectrometry and Fourier-transform infrared spectroscopy. Furthermore, the redox behavior of EIO was identified using electrochemical cyclic voltammetry studies. An EIO coated on a cold-rolled steel (CRS) electrode was found to possess superior corrosion resistance to polyimide (PI) on a series of electrochemical corrosion measurements in 3.5 wt.% NaCl solution over an extended period (30 days). The mechanism for the advanced corrosion protection of the PI coating on the CRS electrode could be attributed to the redox catalytic capabilities of the AT units present in the EIO. These capabilities may induce the formation of passive metal oxide layers on the CRS electrode. Scanning electron microscopy and X-ray photoelectron spectroscopy were used to analyze the surface condition of the CRS after the corrosion test. EIO- and PI-coated electrodes were identified by a series of electrochemical measurements, including corrosion potential (E_corr), polarization resistance (R_p), and corrosion current (I_corr) measurements, along with electrochemical impedance spectroscopy (EIS).

The Influence of Carbon Nanotubes on the Protective Properties of Polypyrrole Formed at Copper

Protective polypyrrole films doped with dodecylbenzene sulfonate (DBS) were formed at copper, while carbon nanotubes (CNT) were incorporated within the polymer films with the DBS to give PPy-DBSCNT (polypyrrole films doped with DBS and incorporated CNT). The polymer films were deposited from a 0.05 M DBS solution at a pH of 6.0 at a thin polypyrrole film doped with tartrate, which served as a stable pre-layer. Low corrosion currents of 0.12 and 0.05 μA cm⁻² were estimated using Tafel analysis for the PPy-DBS and PPy-DBSCNT films, respectively, while a significant reduction in the concentration of Cu²⁺ ions from the corroding copper was observed for the polymer-modified copper. The corrosion protection properties were attributed to the doping of the polymer by the large and immobile DBS anions and possibly, by the larger anionic micelles that are formed at a DBS concentration of 9.8 mM in the pyrrole-containing solution. These dopants give a negatively charged surface that repels chloride anions. The additional protective properties afforded by the CNTs appear to be related to the morphology of the CNT-modified polypyrrole coatings, while the functionalized CNTs also provide a negatively charged surface.

High Performance Anti-Corrosion Coatings of Poly (Vinyl Butyral) Composites with Poly N-(vinyl)pyrrole and Carbon Black Nanoparticles

Zinc is widely used in battery negative electrodes and steel coatings for automotive industries. The anti-corrosion property of zinc is the most important factor determining the performance and lifetime of the products. In this paper, both size-controlled poly N-(vinyl)pyrrole (PNVPY) nanoparticles and carbon black (CB) nanoparticles were compounded with poly (vinyl butyral) (PVB) binder developing a series of composite coatings covered on the zinc substrates using a spin-coating technique. The morphologies of the surface and cross section of the PNVPY/CB/PVB coatings indicate that the PNVPY and CB nanoparticles are uniformly distributed in the matrix. The corrosion resistance of the composite coatings was tested by electrochemical impedance spectroscopy (EIS) and potentiodynamic polarization in a 3.5% NaCl solution. It is found that the coating with 1.9 wt.% PNVPY and 2.3 wt.% CB nanoparticles shows a remarkably high resistance value (R_c) and corrosion protection efficiency (99.99%). Meanwhile, the immersion results also reveal its superior corrosion resistance. It is considered that the nanoscale dispersion of PNVPY and carbon in PVB matrix and the strong interface action between the nanoparticles and PVB result in the uniform microstructure of the composites which endues the superior corrosion properties of the coatings.

A Solution-Processable, Nanostructured, and Conductive Graphene/Polyaniline Hybrid Coating for Metal-Corrosion Protection and Monitoring

A smart and effective anticorrosive coating consisting of alternating graphene and polyaniline (PANI) layers was developed using top-down solution processing. Graphite was exfoliated using sonication assisted by polyaniline to produce a nanostructured, conductive graphene/polyaniline hybrid (GPn) in large quantities (>0.5 L of 6 wt% solution in a single laboratory-scale process). The GPn was coated on copper and exhibited excellent anticorrosion protection efficiencies of 46.6% and 68.4% under electrochemical polarization in 1 M sulfuric acid and 3.5 wt% sodium chloride solutions, chosen as chemical and seawater models, respectively. Impedance measurements were performed in the two corrosive solutions, with the variation in charge transfer resistance (R ct) over time indicating that the GPn acted as an efficient physical and chemical barrier preventing corrosive species from reaching the copper surface. The GPn-coated copper was composed of many PANI-coated graphene planes stacked parallel to the copper surface. PANI exhibits redox-based conductivity, which was facilitated by the high conductivity of graphene. Additionally, the GPn surface was found to be hydrophobic. These properties combined effectively to protect the copper metal against corrosion. We expect that the GPn can be further applied for developing smart anticorrosive coating layers capable of monitoring the status of metals.

Smart anti-corrosion self-healing zinc metal-based molybdate functionalized-mesoporous-silica (MCM-41) nanocomposite coatings

Smart corrosion-resistant zinc-based composite coatings containing mesoporous silica (MCM-41), impregnated with molybdate are introduced as a metal based self healing material.

Towards the mechanism of electrochemical activity and self-healing of 1 wt% PTSA doped polyaniline in alkyd composite polymer coating: combined AFM-based studies

The mechanisms of electrochemical activity and the self-healing properties of a composite alkyd coating with 1 wt% PTSA doped polyaniline were investigated.

Highly Resolved Nanostructured PEDOT on Large Areas by Nanosphere Lithography and Electrodeposition

Poly(ethylenedioxythiophene) (PEDOT) films were electrodeposited galvanostatically from an EDOT/sodium dodecyl sulfate solution in water, through a carboxylated polystyrene template monolayer self-assembled on ITO, after which the template was dissolved away in tetrahydrofuran. Analysis of the films by scanning electron microscopy and atomic force microscopy reveals large-area PEDOT honeycomb structures. The morphology of these structures was varied electrochemically, as the effective thickness and, surprisingly, the shape of the honeycomb arrangement depend on the polymerization time. Using nanospheres of 1 μm diameter and charge densities between 12 and 30 mC cm(-2) for electrodeposition generates PEDOT hexagons with very thin rectilinear walls 30-35 nm-thick and 800 nm-long, whereas at higher charge densities, circular bowls are created with 60 nm walls separating adjacent bowls; triangular areas as small as 0.02 μm(2) develop at the intersection of three nanospheres. These morphologies are specific to the use of carboxylated PS spheres and a water-based solution with a surfactant in the galvanostatic electrodeposition mode. Using smaller nanospheres, i.e. 500 nm in diameter, makes it possible to reach PEDOT hexagons with rectilinear walls as small as 11-17 nm-thick and 300 nm-long; circular bowls with 25-35 nm walls separating adjacent bowls and triangular areas as small as 0.003 μm(2) can also be generated. The wettabilities of the surfaces depend markedly on the pore depth of the PEDOT nanostructure, with contact angles going from 82° to 130° with increasing pore size. Finally these nanostructured PEDOT electrodes were used in Grätzel-type dye-sensitized solar cells (DSSCs) as Pt-free counter-electrodes, with an increase in the yield from 7.0 (bulk PEDOT) to 8.1%.

Regenerative nano-hybrid coating tailored for autonomous corrosion protection

A novel bilayer coating system for autonomous corrosion-triggered self-healing is demonstrated. The storage of the encapsulated monomer and the catalyst is separated in two different layers. The encapsulated catalyst is stored inside a metallic coating, which ensures its activity even for an extended exposure time. The release from the capsules is triggered by corrosion and the correlated pH increase.

Chemistry-dependent X-ray-induced surface charging

In situ work function measurements during irradiation of solid substrates reveal chemistry-specific surface charging which cannot be detected ex situ.

Redox-responsive self-healing for corrosion protection

Raspberry-shaped redox-responsive capsules for storing corrosion inhibitors are introduced, targeted to solve the drawbacks of conducting-polymer-based coating systems for corrosion protection. These capsules synthesized via the miniemulsion technique have a remarkable release property upon reduction (onset of corrosion) and cease release upon reoxidation (passivation of the defect). The self-healing capability is demonstrated by application of these capsules as part of a composite coating on zinc.

Micro/nano-structured polypyrrole surfaces on oxidizable metals as smart electroswitchable coatings

Polypyrrole (PPy) films were electrodeposited from a pyrrole/sodium salicylate solution in water, through two-dimensional (2-D) polystyrene (PS) templates self-assembled on various oxidizable metals, after which the template was removed by dissolution in tetrahydrofuran (THF). The resulting PPy films were analyzed by scanning electron microscopy and atomic force microscopy. Two-dimensional PPy honeycomb structures are obtained on copper or mild steel by using PS spheres of various sizes. The morphology of these structures was controlled electrochemically, as an increase in the polymerization charge does not disturb the PPy honeycomb arrangement, leading instead to the formation of deeper pores accompanied by a change in their diameter. The hydrophobicity of the reduced micro-structured PPy surface is much greater than that of a bulk PPy film generated on the same metal. Reversible electro-switching of the wettability was obtained with marked variation of the apparent contact angle upon PPy oxido-reduction, and an important effect of film micro-structuration upon the wettability range.

Existence of a lower critical radius for incorporation of silica particles into zinc during electro-codeposition

Recently, it was shown that the surface modification of silica particles with -SH functional groups enables their electro-codeposition with zinc. Here, however, we report that no incorporation into Zn can be observed for such modified particles with diameters of <100 nm, while incorporation is possible for particles with diameters of 225 nm and larger. Furthermore, when silica particles are functionalized with mixtures of -SH and -Cl functional groups, which affect the interface energy at the particle/metal interface differently but have similar interfacial energies for the particle/electrolyte interface, it is found that, for successful incorporation of the particles, a minimum amount of -SH functional groups is needed. An explanation for these observations has been derived based on energetic considerations regarding the interfaces involved in the process.

Novel synthesis of stable polypyrrole nanospheres using ozone

In this study, a novel and exceedingly simple method for the aqueous synthesis of stable, unagglomerated polypyrrole nanospheres was investigated. The method is template- and surfactant-free and uses only pyrrole monomer, water, and ozone. When the monomer concentration, exposure time to ozone, and temperature were varied, it was determined that the temperature was the critical factor controlling the particle size through particle size measurements via dynamic light scattering and transmission electron microscopy (TEM). From the particle size measurements, a particle size distribution with a number-weighted mean diameter of 73 nm and a standard deviation of 18 nm was achieved. The particles were also investigated using ζ-potential measurements, ultraviolet-visible (UV-vis) spectroscopy, Fourier transform infrared (FTIR) spectroscopy, and thermogravimetric analysis in an effort to determine the identity of the nanoparticles as well as the mechanism by which the nanoparticles are formed and stabilized.

Electrochromism and Swelling of Polypyrrole Membranes: An Electrochemical and Ellipsometric Study

The growth of polypyrrole (Ppy) layers on gold electrodes in nearly neutral pH solutions is analysed using “in situ” voltametric and ellipsometric techniques. Different film structures are obtained depending on the potentiodynamic programme and the composition of the electrolyte. More compact dodecylsulphate-(DS) doped Ppy layers were grown at 1.2 V versus RHE than those obtained by applying a higher potential. The more compact layers correspond to the growth of an oxidised Ppy/DS layer that shows low pseudo capacity behaviour. After dipping, the doped Ppy/DS film in KCl solution-significant variations in optical indices and thickness are detected as a function of the applied potential. Higher electrochromism as well as decrease in film thickness after cathodisation is achieved. The optical indices and the thickness of the Ppy layer formed under different applied potential/time programmes are estimated.