The effect of polyaniline phosphate on mechanical and corrosive properties of protective organic coatings containing high amounts of zinc metal particles

•Zinc metal content reduction in the organic coating material.•Use of PANI-H3PO4 pigment in the organic coating formulations.•Use of Mg3(Si4O10)(OH)2/PANI-H3PO4 pigment in the organic coating formulations.•Mechanical resistance of the organic coating increases with increasing PVC.•Anticorrosive efficiency of the organic coating increases with increasing PVC.

The objective of this paper is to reduce the zinc metal content in organic coatings while preserving their high anticorrosive efficiency. The two goals can be achieved by using conductive polymers as components of the protective coating. Polyaniline phosphate (PANI-H3PO4) was investigated as the conductive polymer and was also used in surface treatment of steatite talc Mg3(Si4O10)(OH)2. Both PANI-H3PO4 and Mg3(Si4O10)(OH)2/PANI-H3PO4 were specified using physico-chemical parameters. An epoxy ester resin was used as binder for the organic coatings investigated. Organic coatings were prepared by combining zinc metal with PANI-H3PO4 or Mg3(Si4O10)(OH)2/PANI-H3PO4. The mechanical resistance of the prepared films was evaluated using the results of mechanical tests. The anticorrosive efficiency of the prepared films was evaluated using the results of direct corrosion tests.