Kusuma Putri Suwondo, Diah Ayu Fitriani, Siti Amalina Azahra, Agus Nugroho, Putri Sayyida Ashfiya, Muhammad Kozin, Prabowo Puranto, Muhammad Prisla Kamil
Plasma Electrolytic Oxidation (PEO) effectively enhances the corrosion resistance of Al 6061 alloys, but the amphoteric nature of aluminum and its oxides restricts its performance in aggressive environments. A hybrid coating combining PEO and polyaniline (PANI) was developed to address this, leveraging PANI's redox properties and electrical conductivity. The PANI layer was applied to the PEO-treated surface using an ultrasonic-assisted dip-coating technique and examined with XRD and FESEM-EDX, revealing the hybrid coating's essential structural and compositional details. Water contact angle measurements showed a shift from the hydrophilic PEO surface (20.7° ± 1.4°) to the hydrophobic PANI-coated surface (100.4° ± 1.3°), indicating improved barrier characteristics. Electrochemical assessments utilizing potentiodynamic polarization (Tafel) and Electrochemical Impedance Spectroscopy (EIS) were performed under acidic, neutral, and alkaline conditions. Tafel analysis demonstrated a decrease in the corrosion current density (icorr) of as much as two orders of magnitude and enhanced protection efficiencies (Pe) of 98.77 %, 98.66 %, and 86.05 %, respectively. The EIS results indicate substantial increases in the charge transfer resistance RCT for the hybrid coating, showing one to two orders of magnitude enhancements relative to PEO and bare Al at all pH settings. Equivalent Circuit Modeling (ECM) fitting revealed a shift from a basic Randles circuit for uncoated Al to two-time constant models for PEO and PEO/PANI coatings, signifying the influence of the oxide and PANI layers. The result highlights the efficacy of the hybrid coating in improving corrosion resistance under various environmental conditions. © 2025 Elsevier B.V.
Research Center for Advanced Materials, National Research and Innovation Agency (BRIN), Banten, South Tangerang, 15314, Indonesia; School of Chemical Engineering, University of Adelaide, 5005, SA, Australia; Department of Chemistry, Universitas Pendidikan Indonesia, West Java, Bandung, 40154, Indonesia
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