{"status":"ok","message-type":"work","message-version":"1.0.0","message":{"indexed":{"date-parts":[[2026,8,11]],"date-time":"2026-08-11T11:30:52Z","timestamp":1786447852168,"version":"build-2736575974"},"reference-count":53,"publisher":"MDPI AG","issue":"16","license":[{"start":{"date-parts":[[2026,8,11]],"date-time":"2026-08-11T00:00:00Z","timestamp":1786406400000},"content-version":"vor","delay-in-days":0,"URL":"https:\/\/creativecommons.org\/licenses\/by\/4.0\/"}],"funder":[{"name":"Scientific Research Fund of Zhejiang Guangsha Vocational and Technical University of Construction","award":["2026ZX032"],"award-info":[{"award-number":["2026ZX032"]}]},{"name":"State Key Laboratory of Special Surface Protection Materials and Application Technology","award":["CBGZJJ2023-2-10"],"award-info":[{"award-number":["CBGZJJ2023-2-10"]}]},{"award":["CBGZJJ2023-2-10"],"award-info":[{"award-number":["CBGZJJ2023-2-10"]}],"id":[{"id":"https:\/\/ror.org\/04za79z50","id-type":"ROR","asserted-by":"publisher"}]}],"content-domain":{"domain":[],"crossmark-restriction":false},"short-container-title":["Polymers"],"abstract":"<jats:p>In this study, a two-step electrodeposition strategy was proposed to fabricate an eco-friendly superhydrophobic polyaniline (PANI)\/silane composite coating on mild steel for corrosion protection. The first step consists of creating a pure PANI adherent coating using a cyclic voltammetry technique and the second step consists of realizing superhydrophobic features using electrodeposition in mixed silane monomers at constant potential. The structure and composition characterization results revealed successful modification of the underlying pure PANI layer with superhydrophobic surface silane film. Wettability tests indicated a high contact angle of 155\u00b0 and a low sliding angle of 4.2\u00b0. Electrochemical measurements revealed that the corrosion current density of PANI\/silane-coated mild steel decreased by approximately three orders of magnitude compared to the uncoated sample and the corrosion protection efficiency was as high as 99.6%. Moreover, the prepared PANI\/silane hybrid coating exhibited good chemical stability and strong adhesion after 10 days of corrosion in 3.5 wt.% NaCl solution.<\/jats:p>","DOI":"10.3390\/polym18161962","type":"journal-article","created":{"date-parts":[[2026,8,11]],"date-time":"2026-08-11T10:32:16Z","timestamp":1786444336000},"page":"1962","update-policy":"https:\/\/doi.org\/10.3390\/mdpi_crossmark_policy","source":"Crossref","is-referenced-by-count":0,"title":["Electrochemical Synthesis of Superhydrophobic Polyaniline\/Silane Coating Towards Corrosion Protection of Mild Steel"],"prefix":"10.3390","volume":"18","author":[{"given":"Yu","family":"Chen","sequence":"first","affiliation":[{"name":"School of Intelligent Manufacturing, Zhejiang Guangsha Vocational and Technical University of Construction, Jinhua 322100, China"},{"name":"School of Materials and Energy, Foshan University, Foshan 528000, China"}],"role":[{"vocabulary":"crossref","role":"author"}]},{"given":"Haoyao","family":"Zhou","sequence":"additional","affiliation":[{"name":"School of Materials and Energy, Foshan University, Foshan 528000, China"}],"role":[{"vocabulary":"crossref","role":"author"}]},{"given":"Niteng","family":"Fang","sequence":"additional","affiliation":[{"name":"School of Intelligent Manufacturing, Zhejiang Guangsha Vocational and Technical University of Construction, Jinhua 322100, China"}],"role":[{"vocabulary":"crossref","role":"author"}]}],"member":"1968","published-online":{"date-parts":[[2026,8,11]]},"reference":[{"key":"ref_1","doi-asserted-by":"crossref","first-page":"100789","DOI":"10.1016\/j.nexres.2025.100789","article-title":"Corrosion and protection in lithium-ion and sodium-ion batteries: Principles and applications of graphene and conducting polymers as anticorrosion coatings","volume":"2","author":"Mohammadipour","year":"2025","journal-title":"Next Res."},{"key":"ref_2","doi-asserted-by":"crossref","first-page":"109894","DOI":"10.1016\/j.corsci.2021.109894","article-title":"Corrosion mitigation ability of differently synthesized polypyrrole (PPy-FeCl3 & PPy-APS) conductive polymers modified with Na2MoO4 on mild steel in 3.5% NaCl solution: Comparative study and optimization","volume":"193","author":"Shahryari","year":"2021","journal-title":"Corros. Sci."},{"key":"ref_3","doi-asserted-by":"crossref","unstructured":"Stejskal, J., Jur\u010da, M., Trchov\u00e1, M., Proke\u0161, J., and K\u0159ivka, I. (2024). In-situ coating of iron with a conducting polymer, polypyrrole, as a promise for corrosion protection. Materials, 17.","DOI":"10.3390\/ma17194783"},{"key":"ref_4","doi-asserted-by":"crossref","first-page":"5659","DOI":"10.1039\/D0RA07800J","article-title":"Conducting polymers, a comprehensive review on recent advances in synthesis, properties and applications","volume":"11","author":"Namsheer","year":"2021","journal-title":"RSC Adv."},{"key":"ref_5","doi-asserted-by":"crossref","first-page":"14716","DOI":"10.1007\/s10853-024-10047-2","article-title":"Enhancing corrosion resistance of 316L stainless steel through electrochemical deposition of polyaniline coatings in acidic environments","volume":"59","author":"Fatahiamirdehi","year":"2024","journal-title":"J. Mater. Sci."},{"key":"ref_6","doi-asserted-by":"crossref","first-page":"107492","DOI":"10.1016\/j.surfin.2025.107492","article-title":"Theoretical evaluation of anti-corrosion PANI-composite coating based on protection and interface mechanical features using Molecular dynamics, Monte Carlo, and DFT simulations","volume":"73","author":"Moradi","year":"2025","journal-title":"Surf. Interfaces"},{"key":"ref_7","doi-asserted-by":"crossref","first-page":"278","DOI":"10.1016\/j.jiec.2023.08.040","article-title":"An experimental study and Monte Carlo simulation about the polyaniline coating dopants impact on long-time corrosion resistance of 304 SS","volume":"129","author":"Moradi","year":"2024","journal-title":"J. Ind. Eng. Chem."},{"key":"ref_8","doi-asserted-by":"crossref","first-page":"131564","DOI":"10.1016\/j.matchemphys.2025.131564","article-title":"A novel superior corrosion resistance and spot-weldable polyimide-polyaniline composite coating for low alloy mild steel","volume":"348","author":"Nayak","year":"2026","journal-title":"Mater. Chem. Phys."},{"key":"ref_9","doi-asserted-by":"crossref","first-page":"732","DOI":"10.1016\/j.stam.2006.09.014","article-title":"Electrochemical synthesis of corrosion protective polyaniline coatings on mild steel from aqueous salicylate medium","volume":"7","author":"Pawar","year":"2006","journal-title":"Sci. Technol. Adv. Mater."},{"key":"ref_10","doi-asserted-by":"crossref","first-page":"480","DOI":"10.1016\/j.porgcoat.2011.06.006","article-title":"Comparison study for passivation of stainless steel by coating with polyaniline from two different acids","volume":"72","author":"Ganash","year":"2011","journal-title":"Prog. Org. Coat."},{"key":"ref_11","doi-asserted-by":"crossref","unstructured":"Rangel-Olivares, F.R., Arce-Estrada, E.M., and Cabrera-Sierra, R. (2021). Synthesis and characterization of polyaniline-based polymer nanocomposites as anti-corrosion coatings. Coatings, 11.","DOI":"10.3390\/coatings11060653"},{"key":"ref_12","doi-asserted-by":"crossref","unstructured":"Kamran, M., Shah, A.H.A., Rahman, G., and Bilal, S. (2022). Potential impacts of Prunus domestica based natural gum on physicochemical properties of polyaniline for corrosion inhibition of mild and stainless steel. Polymers, 14.","DOI":"10.3390\/polym14153116"},{"key":"ref_13","doi-asserted-by":"crossref","unstructured":"Li, B., Yang, H., He, J., Yu, S., Xiao, R., Luo, H., Wen, Y., Peng, S., Liao, X., and Yang, D. (2023). Photopolymerization of coating materials for protection against carbon steel corrosion. Materials, 16.","DOI":"10.3390\/ma16052015"},{"key":"ref_14","doi-asserted-by":"crossref","first-page":"1368","DOI":"10.1016\/j.synthmet.2011.05.003","article-title":"Electropolymerization of PANI coating in nitric acid for corrosion protection of 430 SS","volume":"161","author":"Lu","year":"2011","journal-title":"Synth. Met."},{"key":"ref_15","doi-asserted-by":"crossref","first-page":"133909","DOI":"10.1016\/j.colsurfa.2024.133909","article-title":"Electropolymerized conducting polyaniline coating on nickel-aluminum bronze alloy for improved corrosion resistance in marine environment","volume":"691","author":"Amegroud","year":"2024","journal-title":"Colloids Surf. A Physicochem. Eng. Asp."},{"key":"ref_16","doi-asserted-by":"crossref","first-page":"109242","DOI":"10.1016\/j.porgcoat.2025.109242","article-title":"Unraveling the effect of dopants of electropolymerized polyaniline coating on controlling the oxidation of austenitic stainless steel in contaminated phosphoric acid medium","volume":"204","author":"Hajjaoui","year":"2025","journal-title":"Prog. Org. Coat."},{"key":"ref_17","doi-asserted-by":"crossref","first-page":"132693","DOI":"10.1016\/j.surfcoat.2025.132693","article-title":"Fabrication of a sper-hydrophobic sealing silane film with anti-corrosion, wear-resistance and self-cleaning properties via electrodeposition on a micro-arc oxidized aluminum alloy","volume":"516","author":"Wang","year":"2025","journal-title":"Surf. Coat. Technol."},{"key":"ref_18","doi-asserted-by":"crossref","first-page":"126966","DOI":"10.1016\/j.surfcoat.2021.126966","article-title":"Superhydrophobic silane-based surface coatings on metal surface with nanoparticles hybridization to enhance anticorrosion efficiency, wearing resistance and antimicrobial ability","volume":"410","author":"Nie","year":"2021","journal-title":"Surf. Coat. Technol."},{"key":"ref_19","doi-asserted-by":"crossref","first-page":"580","DOI":"10.1007\/s00339-021-04730-3","article-title":"Enhancing the corrosion resistance of aluminum by superhydrophobic silane\/graphene oxide coating","volume":"127","author":"Du","year":"2021","journal-title":"Appl. Phys. A"},{"key":"ref_20","doi-asserted-by":"crossref","first-page":"695","DOI":"10.1007\/s10971-020-05225-y","article-title":"Multivariable analysis of electrodeposited silane based superhydrophobic coatings for corrosion protection of carbon steel","volume":"94","author":"Leoni","year":"2020","journal-title":"J. Sol.-Gel Sci. Technol."},{"key":"ref_21","doi-asserted-by":"crossref","first-page":"2928","DOI":"10.1016\/S1003-6326(24)66586-6","article-title":"Fabrication and anti-corrosion performance of superhydrophobic silane film on sintered NdFeB","volume":"34","author":"Ju","year":"2024","journal-title":"Trans. Nonferrous Met. Soc. China"},{"key":"ref_22","doi-asserted-by":"crossref","first-page":"127455","DOI":"10.1016\/j.cej.2020.127455","article-title":"Superhydrophobic F-SiO2@PDMS composite coatings prepared by a two-step spraying method for the interface erosion mechanism and anti-corrosive applications","volume":"413","author":"Shen","year":"2021","journal-title":"Chem. Eng. J."},{"key":"ref_23","doi-asserted-by":"crossref","first-page":"126569","DOI":"10.1016\/j.matchemphys.2022.126569","article-title":"Development of superhydrophobic and corrosion resistance coatings on carbon steel by hydrothermal treatment and fluoroalkyl silane self-assembly","volume":"290","author":"Fan","year":"2022","journal-title":"Mater. Chem. Phys."},{"key":"ref_24","doi-asserted-by":"crossref","first-page":"105085","DOI":"10.1016\/j.mtcomm.2022.105085","article-title":"Robust superhydrophobic film on aluminum alloy prepared with TiO2\/SiO2-silane composite film for efficient self-cleaning, anti-corrosion and anti-icing","volume":"34","author":"Han","year":"2023","journal-title":"Mater. Today Commun."},{"key":"ref_25","doi-asserted-by":"crossref","first-page":"74","DOI":"10.1007\/s10971-015-3678-4","article-title":"Effects of fluorine atoms on structure and surface properties of PANI and fluorinated PANI\/GPTMS hybrid films","volume":"75","author":"Yu","year":"2015","journal-title":"J. Sol.-Gel Sci. Technol."},{"key":"ref_26","doi-asserted-by":"crossref","first-page":"3001","DOI":"10.1016\/j.corsci.2007.02.008","article-title":"Characterization and corrosion resistance of organically modified silicate-NiZn ferrite\/polyaniline hybrid coatings on aluminum alloys","volume":"49","author":"Wu","year":"2007","journal-title":"Corros. Sci."},{"key":"ref_27","doi-asserted-by":"crossref","first-page":"64","DOI":"10.1007\/s10971-026-07106-2","article-title":"Designing a robust silane\/polyaniline\/Ni tri-layer coating for superior corrosion resistance of AZ91 magnesium alloy","volume":"117","author":"Ali","year":"2026","journal-title":"J. Sol.-Gel Sci. Technol."},{"key":"ref_28","doi-asserted-by":"crossref","first-page":"1","DOI":"10.1016\/j.surfcoat.2017.12.053","article-title":"Corrosion prevention of AA2024-T3 aluminum alloy with a polyaniline\/poly(\u03b3-glycidoxypropyltrimethoxysilane) bi-layer coating: Comparative study with polyaniline mono-layer feature","volume":"337","author":"Mrad","year":"2018","journal-title":"Surf. Coat. Technol."},{"key":"ref_29","doi-asserted-by":"crossref","unstructured":"Zhou, H., Du, X., Yang, Z., and Chen, Y. (2025). One-step in situ electrochemical synthesis of polyaniline\/CeO2 composite coating for enhanced corrosion protection of mild steel. Coatings, 15.","DOI":"10.3390\/coatings15010074"},{"key":"ref_30","unstructured":"(2020). Paints and Varnishes-Cross-Cut Test (Standard No. ISO 2409:2020(E))."},{"key":"ref_31","doi-asserted-by":"crossref","first-page":"2856","DOI":"10.1016\/j.electacta.2008.11.022","article-title":"The improvement of free-radical scavenging capacity of the phosphate medium electrosynthesized polyaniline","volume":"54","author":"Parsa","year":"2009","journal-title":"Electrochim. Acta"},{"key":"ref_32","doi-asserted-by":"crossref","first-page":"277","DOI":"10.1016\/S0079-6700(97)00030-0","article-title":"Polyaniline: A polymer with many interesting intrinsic redox states","volume":"23","author":"Kang","year":"1998","journal-title":"Prog. Polym. Sci."},{"key":"ref_33","doi-asserted-by":"crossref","first-page":"546","DOI":"10.1039\/tf9444000546","article-title":"Wettability of porous surfaces","volume":"40","author":"Cassie","year":"1944","journal-title":"Trans. Faraday Soc."},{"key":"ref_34","doi-asserted-by":"crossref","first-page":"162305","DOI":"10.1016\/j.jallcom.2021.162305","article-title":"Preparation of hydrophobic silane\/graphene oxide composite coating implanted with benzotriazole to improve the anti-corrosion performance of copper","volume":"893","author":"Chen","year":"2022","journal-title":"J. Alloys Compd."},{"key":"ref_35","doi-asserted-by":"crossref","first-page":"2234","DOI":"10.1016\/j.ssi.2008.08.004","article-title":"Comparative XPS surface study of polyaniline thin films","volume":"179","author":"Golczak","year":"2008","journal-title":"Solid State Ion."},{"key":"ref_36","doi-asserted-by":"crossref","first-page":"33","DOI":"10.1016\/j.cej.2017.01.066","article-title":"Adsorption mechanism of phosphate by polyaniline\/TiO2 composite from wastewater","volume":"316","author":"Wang","year":"2017","journal-title":"Chem. Eng. J."},{"key":"ref_37","doi-asserted-by":"crossref","first-page":"146086","DOI":"10.1016\/j.apsusc.2020.146086","article-title":"Enhanced corrosion inhibition of aniline derivatives electropolymerized coatings on copper: Preparation, characterization and mechanism modeling","volume":"514","author":"Ma","year":"2020","journal-title":"Appl. Surf. Sci."},{"key":"ref_38","doi-asserted-by":"crossref","first-page":"105908","DOI":"10.1016\/j.porgcoat.2020.105908","article-title":"One-step electrochemical synthesis of poly(vinyl pyrrolidone) modified polyaniline coating on stainless steel for high corrosion protection performance","volume":"149","author":"Wang","year":"2020","journal-title":"Prog. Org. Coat."},{"key":"ref_39","doi-asserted-by":"crossref","first-page":"1085","DOI":"10.1163\/156856109X432695","article-title":"XPS analysis of silane films on the surface of a dental ceramic","volume":"23","author":"Hooshmand","year":"2009","journal-title":"J. Adhes. Sci. Technol."},{"key":"ref_40","doi-asserted-by":"crossref","first-page":"141230","DOI":"10.1016\/j.molstruc.2024.141230","article-title":"Theoretical and experimental study of the corrosion inhibition of carbon steel in 1 M HCl solution by a new synthesized organic compound derived from carbendazim","volume":"1327","author":"Zgueni","year":"2025","journal-title":"J. Mol. Struct."},{"key":"ref_41","doi-asserted-by":"crossref","first-page":"1114","DOI":"10.1246\/bcsj.20200051","article-title":"Proposal and verification of a novel superhydrophobic-conductive anti-corrosion polyaniline-silica coating","volume":"93","author":"Xu","year":"2020","journal-title":"Bull. Chem. Soc. Jpn."},{"key":"ref_42","doi-asserted-by":"crossref","first-page":"2100983","DOI":"10.1002\/mame.202100983","article-title":"A smart anticorrosive epoxy coating based on environmental-stimuli-responsive copolymer assemblies for controlled release of corrosion inhibitors","volume":"307","author":"Cao","year":"2022","journal-title":"Macromol. Mater. Eng."},{"key":"ref_43","doi-asserted-by":"crossref","first-page":"130241","DOI":"10.1016\/j.surfcoat.2023.130241","article-title":"Smart epoxy coating containing inhibitor-loaded cellulose nanocrystals for corrosion protection of steel","volume":"477","author":"Miri","year":"2024","journal-title":"Surf. Coat. Technol."},{"key":"ref_44","doi-asserted-by":"crossref","first-page":"2738","DOI":"10.1016\/j.corsci.2011.05.008","article-title":"Superhydrophobic fluoropolymer-modified copper surface via surface graft polymerization for corrosion protection","volume":"53","author":"Yuan","year":"2011","journal-title":"Corros. Sci."},{"key":"ref_45","doi-asserted-by":"crossref","first-page":"163","DOI":"10.1016\/j.apsusc.2015.02.012","article-title":"Stability and corrosion resistance of superhydrophobic surface on oxidized aluminum in NaCl aqueous solution","volume":"333","author":"Lv","year":"2015","journal-title":"Appl. Surf. Sci."},{"key":"ref_46","doi-asserted-by":"crossref","first-page":"108144","DOI":"10.1016\/j.corsci.2019.108144","article-title":"A novel combined method for fabrication of stable corrosion resistance superhydrophobic surface on Al alloy","volume":"159","author":"Abbasi","year":"2019","journal-title":"Corros. Sci."},{"key":"ref_47","doi-asserted-by":"crossref","first-page":"129977","DOI":"10.1016\/j.surfcoat.2023.129977","article-title":"The preparation of cerium nitrate and attapulgite based superhydrophobic epoxy coatings for the corrosion protection of Q235 mild steel surface","volume":"473","author":"Butt","year":"2023","journal-title":"Surf. Coat. Technol."},{"key":"ref_48","doi-asserted-by":"crossref","first-page":"139359","DOI":"10.1016\/j.colsurfa.2025.139359","article-title":"Comparative performance of PTFE-based liquid-infused and superhydrophobic coatings on stainless steel under acid-induced corrosive stress","volume":"733","author":"Cui","year":"2026","journal-title":"Colloids Surf. A Physicochem. Eng. Asp."},{"key":"ref_49","doi-asserted-by":"crossref","first-page":"215","DOI":"10.1016\/j.jiec.2023.01.025","article-title":"Sustainable corrosion-resistance superhydrophobic composite coating with strengthened robustness","volume":"121","author":"Qiao","year":"2023","journal-title":"J. Ind. Eng. Chem."},{"key":"ref_50","doi-asserted-by":"crossref","first-page":"53922","DOI":"10.1016\/j.ceramint.2024.10.245","article-title":"Fluorine-free superhydrophobic Ni\/ Mn-TiO2 composite coatings on carbon steel via one-step electrodeposition for enhanced durability and corrosion resistance","volume":"50","author":"Zhou","year":"2024","journal-title":"Ceram. Int."},{"key":"ref_51","doi-asserted-by":"crossref","first-page":"21","DOI":"10.1016\/j.porgcoat.2014.10.012","article-title":"Electrodeposition of bilayered polyrrole on 316L stainless steel for corrosion prevention","volume":"78","author":"Saidman","year":"2015","journal-title":"Prog. Org. Coat."},{"key":"ref_52","doi-asserted-by":"crossref","first-page":"225","DOI":"10.1016\/j.jelechem.2003.09.028","article-title":"Mechanism for protection of iron corrosion by an intrinsically electronic conducting polymer","volume":"572","author":"Nguyen","year":"2004","journal-title":"J. Electroanal. Chem."},{"key":"ref_53","doi-asserted-by":"crossref","unstructured":"Peng, C., Cao, N., Qi, Z., Yan, Y., Wu, R., and Wang, G. (2021). Preparation and corrosion performance of PPY\/silane film on AZ31 magnesium alloy via one-step cyclic voltammetry. Polymers, 13.","DOI":"10.3390\/polym13183148"}],"container-title":["Polymers"],"original-title":[],"language":"en","link":[{"URL":"https:\/\/www.mdpi.com\/2073-4360\/18\/16\/1962\/pdf","content-type":"unspecified","content-version":"vor","intended-application":"similarity-checking"}],"deposited":{"date-parts":[[2026,8,11]],"date-time":"2026-08-11T10:43:56Z","timestamp":1786445036000},"score":1,"resource":{"primary":{"URL":"https:\/\/www.mdpi.com\/2073-4360\/18\/16\/1962"}},"subtitle":[],"short-title":[],"issued":{"date-parts":[[2026,8,11]]},"references-count":53,"journal-issue":{"issue":"16","published-online":{"date-parts":[[2026,8]]}},"alternative-id":["polym18161962"],"URL":"https:\/\/doi.org\/10.3390\/polym18161962","relation":{},"ISSN":["2073-4360"],"issn-type":[{"value":"2073-4360","type":"electronic"}],"subject":[],"published":{"date-parts":[[2026,8,11]]}}}