Superhydrophobic Polyaniline–Siloxane Coatings with Excellent Barrier and Active Corrosion Protection Properties for Mild Steel

Although superhydrophobic surfaces have attracted much attention in research, their high cost, poor durability, and challenging manufacturing processes have prevented their widespread application. Here, we describe a simple method of preparing superhydrophobic polyaniline (PANI) pigments and their application in protective coatings. Doping polyaniline pigments with low surface energy perfluorodecanoic acid (PFDA) allowed them to overcome their intrinsic high surface energy, and the resultant PANI–PFDA pigments showed superhydrophobicity. The superhydrophobic PANI–PFDA pigments with different weight percentages were incorporated into a polydimethylsiloxane (PDMS) coating to prepare the superhydrophobic coating. We endeavored to examine the role that hydrophobicity played in enhancing corrosion resistance and looked into the highest concentration of pigment that the coating could withstand. Additionally, studies were carried out on the coating's adherence to the metal and the stability of hydrophobicity at various pH levels. The results showed that PANI–PFDA pigments improved the hydrophobicity and corrosion resistance in the PDMS coating without compromising its robustness and durability. Electrochemical impedance spectroscopy studies revealed that 40 wt % PANI–PFDA content in the PDMS coating provided the best corrosion protection, and this coating could offer active corrosion protection when an artificial defect was made in the coating.