Self-cleaning performance of superhydrophobic hybrid nanocomposite coatings on Al with excellent corrosion resistance

Protective ceramic-PANI, ceramic-poly(Ani-co-oPD) and ceramic-poly(Ani-co-oPD)-zinc stearate nanocomposite coatings were formed on Al surface by the processes involving anodization, electropolymerisation and electrodeposition under optimum conditions. The prepared nanocomposite coatings were evaluated by ATR-IR and XRD studies. SEM studies performed on nanocomposite coatings reveal that ceramic-poly(Ani-co-oPD)-zinc stearate nanocomposite coating shows a cauliflower-like cluster with crack-free morphology compared to ceramic-PANI and ceramic-poly(Ani-co-oPD) nanocomposite coatings. The mechanical properties of different nanocomposite coatings were measured using Vicker microhardness tester and Taber Abrasion tester. The ceramic-poly(Ani-co-oPD)-zinc stearate nanocomposite has higher mechanical stability. The corrosion resistance of the coatings measured by Tafel polarization and electrochemical impedance spectroscopy, shows that ceramic-poly(Ani-co-oPD)-zinc stearate nanocomposite coated aluminum has higher corrosion resistance than other coatings and bare Al. Wettability studies prove that superhydrophobic nature of ceramic-poly(Ani-co-oPD)-zinc stearate nanocomposite coating with contact angle of 155.8 degrees is responsible for good self-cleaning property and excellent corrosion resistance of aluminum. (C) 2016 Published by Elsevier B.V.