Epoxy-Based Superhydrophobic Coating Reinforced by Functional Polyaniline@Expanded Graphite with Multiple Anticorrosion Mechanisms

The anti-corrosion performance of epoxy coatings in saline solution environments is restricted by their surface hydrophilicity and microporous defects. Herein, we developed a modified epoxy (MEP)-based superhydrophobic anticorrosive coating by fluorinated resin matrix and incorporation of polyaniline@expanded graphite (FPANI@MEG) anticorrosive fillers. The FPANI@MEG fillers were fabricated via in situ polymerization of aniline on the surface of dopamine-modified expanded graphite to construct the micro-nano hierarchical structure required for superhydrophobicity, while providing barrier shielding and active passivation functions. The results showed that the final coating exhibited excellent superhydrophobicity with a water contact angle of 156.5 ± 1.8° and sliding angle of 3.0 ± 0.6°, along with excellent adhesion and adaptability to various complex environments. Meanwhile, the coating maintained superhydrophobicity after 400 cycles of Taber abrasion and 450 g of falling-sand impact, demonstrating hydrophobic robustness. Furthermore, the coating exhibited a low-frequency impedance modulus of 2.30 × 107 Ω·cm2 after immersion in NaCl solution for 15 days. The synergistic combination of air film shielding, physical barrier, and active passivation endowed the coating with good anticorrosion performance. This work may provide a theoretical reference for improving the corrosion protection of epoxy-based superhydrophobic coatings on carbon steel in aggressive saline solution environments.