Eco-Friendly Acrylate–Polyaniline Emulsion Coatings for Enhanced Corrosion Protection of Carbon Steel

Morsi, Samir M.M.; Samaan, Georgina N.; Khorshed, Lobna A.; Sobhi, Samia; Abadir, Ehab F.; Hussain, Ahmed I.

doi:10.21608/ejchem.2025.399174.11984

	Eco-Friendly Acrylate–Polyaniline Emulsion Coatings for Enhanced Corrosion Protection of Carbon Steel
Egyptian Journal of Chemistry
Articles in Press, Accepted Manuscript, Available Online from 11 August 2025
Document Type: Original Article
DOI: 10.21608/ejchem.2025.399174.11984
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Authors
Samir M.M. Morsi ¹; Georgina N. Samaan²; Lobna A. Khorshed³; Samia Sobhi⁴; Ehab F. Abadir⁴; Ahmed I. Hussain⁵
¹Polymers and pigments dept. National Research Centre
²Internatia. Formerly at International Trade Agencies and Marketing Corporation (ITAMCO), Egypt.onal Trade Agencies and Marketing Corporation (ITAMCO), Egypt. Passed away
³Physical Chemistry Department-National Research Center
⁴Department of Chemical Engineering, Faculty of Engineering, Cairo University, Egypt.
⁵Polymer and Pigments Department, - National Research Centre, 30 El-Tahrir Street
Abstract
This study presents the development of novel, environmentally friendly, waterborne coating blends based on acrylate emulsion incorporated with emulsified polyaniline (PANI) for the corrosion protection of mild steel. The coatings were prepared by emulsion blending with varying PANI contents (0–1.5 wt%) and evaluated through mechanical, electrochemical, and immersion-based tests. The addition of PANI improved the thermal stability, surface hardness, and corrosion resistance of the coatings due to increased interchain interactions and passivation effects. Electrochemical measurements revealed that the coating with 0.75 wt% PANI (CB0.75) exhibited the best performance, achieving a corrosion inhibition efficiency of 98.76% and the highest polarization resistance (10,157 Ω•cm²), while higher PANI loadings led to structural brittleness and reduced protective efficiency. These results highlight the importance of optimizing conductive polymer content and offer a promising route for scalable, VOC-free anticorrosion coatings for industrial and infrastructure applications.
Keywords
Conductive Polymers; Waterborne Coatings; Mild Steel Protection; Polyaniline Emulsion; Eco-Friendly Materials; Anticorrosion Performance


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