Eco-Friendly AMPS-Doped Polyaniline/Urethane-Methacrylate Coating as a Corrosion Protection Coating: Electrochemical, Surface, Theoretical, and Thermodynamic Studies

In this study, 2-acrylamido-2-methylpropanesulfonic acid (AMPS)-doped polyaniline (PANI) fibers were used as polymerizable smart anticorrosive agents to prepare eco-friendly UV-curable anticorrosive coatings. For this purpose, AMPS-doped PANI fibers were synthesized through chemical oxidative interfacial polymerization. The size and chemical structure of the prepared conducting fibers were characterized by scanning electron microscopy, 1H NMR, and Fourier transform infrared (FTIR) analyses. As a binder for the prepared conducting fibers, an ecofriendly fluorinated urethane-methacrylate dispersion was synthesized and fully characterized using FTIR analysis. Subsequently, various amounts of the synthesized fibers were mixed with the fluorinated binder to prepare UV-curable anticorrosive coatings. The physicochemical interactions between the PANI fibers and UV-curable binder were studied thoroughly using differential scanning calorimetry and thermogravimetric analyses and measurement of the gel contents and adhesion strength of the prepared composite coatings. The corrosion resistance performance of the prepared coatings was evaluated using electrochemical impedance spectroscopy analysis, and the obtained results revealed that the presence of 2 wt % of the AMPS-doped PANI fibers significantly enhanced the corrosion resistance of the obtained coating. In addition, the corrosion layers of the coatings were analyzed using X-ray photoelectron spectroscopy, which indicated that the AMPS-doped PANI fibers changed the composition of the corrosion product layer. To expand these attempts, this study also explores the interaction of AMPS-doped PANI fibers with the Fe(100) surface using density functional theory as well as atom in molecule calculations. All of the obtained results proved that the outstanding corrosion protection performance of the prepared composite coatings originated from exceptional chemical interactions between the unsaturated doping agents of the prepared PANI fibers and the UV-cured polymer.