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ZnO/GO (Graphene Oxide) and SAN (Styrene Acrylonitrile)/PANI (Polyaniline)/FLG (Few Layers Graphene) nanocomposite coatings were produced by solution casting and sol-gel methods, respectively, to enhance corrosion resistance of ferrous based materials. Corrosive seawater and 'produced crude oil water' environments were selected as electrolytes for this study. Impedance and coating capacitance values obtained from Electrochemical Impedance Spectroscopy (EIS) Alternating Current (AC technique) showed enhanced corrosion resistance of nanocomposites coatings in the corrosive environments. Tafel scan Direct Current (DC technique) was used to find the corrosion rate of nanocomposite coating. SAN/PANI/FLG coating reduced the corrosion of bare metal up to 90% in seawater whereas ZnO/GO suppressed the corrosion up to 75% having the impedance value of 100 Ω. In produced water of crude oil, SAN/PANI/FLG reduced the corrosion up to 95% while ZnO/GO suppressed the corrosion up to 10%. Hybrid composites of SAN/PANI/FLG coatings have demonstrated better performances compared to ZnO/GO in the corrosive environments under investigation. This study provides fabrication of state-of-the-art novel anti corrosive nanocomposite coatings for a wide range of industrial applications. Reduced corrosion will result in increased service lifetime, durability and reliability of components and system and will in turn lead to significant cost savings.

Electrochemical Comparison of SAN/PANI/FLG and ZnO/GO Coated Cast Iron Subject to Corrosive Environments