ZnO–polyaniline nanocomposite with core–shell nanostructure was prepared by in situ polymerization
of aniline monomer in the presence of ZnO nanoparticles. Fourier transform infrared spectroscopy, X-ray
diffraction patterns, field emission scanning electron microscopy and transmission electron microscopy
techniques were used to characterize the composition and structure of ZnO–polyaniline nanocomposite.
d.c. electrical conductivity measurement showed that the electrical conductivity of ZnO–polyaniline
nanocomposite pellets is higher than that of pristine polyaniline and ZnO nanoparticles pellets. The addition
of ZnO nanoparticles causes to the increasing of polyaniline electrical conductivity. ZnO–polyaniline
nanocomposite was mixed with polyvinyl chloride (PVC) through a solution mixing method and the
three components PVC/ZnO–polyaniline hybrid material was applied as coating on iron coupon by the
solution casting method. Corrosion protection efficiency of PVC/ZnO–polyaniline hybrid coating on iron
coupons was studied by open circuit potential and Tafel techniques in 3.5% NaCl solution as corrosive
environment. According to the results, PVC/ZnO–polyaniline hybrid nanocomposite coating showed dramatically
increased corrosion protection effect on iron samples compared to that of uncoated iron coupon
and pure polyaniline anticorrosive coating. It was found that ZnO nanoparticles improve the barrier and
electrochemical anticorrosive properties of polyaniline and the addition of polyvinyl chloride increases
the barrier effect of polyaniline coating.