Conducting polymers represent a promising application prospect in the field of metal corrosion control. In this investigation, poly(o-toluidine) (POT)/nano zirconium dioxide (ZrO2) composite were prepared by in situ polymerization of o-toluidine monomer in the presence of nano ZrO2 particles. Fourier transformation infrared spectroscopy, UV–visible spectroscopy, X-ray diffraction and Scanning electron microscopy were used to characterize the composition and the structure of the composite. POT/nano ZrO2 composite was mixed with epoxy resin (EP) through a solution blending method and the three components POT/nano ZrO2/epoxy composite coating was coated onto the surface of steel coupon, and its corrosion protective efficiency was studied by electrochemical measurements and immersion test in 3.5 % NaCl solution as corrosion environment and also compared with that of POT/epoxy composite coated steel, polyaniline (PANI)/epoxy composite coated steel and pure epoxy coated steel. According to the results, POT/nano ZrO2/epoxy composite coated steel has got higher corrosion resistance than that of POT/epoxy composite coated steel and PANI/epoxy composite coated steel. It was found that POT powders dispersed in the epoxy and polyamide system improved the barrier and electrochemical protection properties of epoxy coating and the addition of nano ZrO2 particles increased the tortuosity of the diffusion pathway of corrosion substances.
