Synthetic polyaniline-boron nitride-aqueous epoxy resin composite coating for improving the corrosion resistance of hot-dip galvanized steel plates

Hydroxy BN, ABA–BN, PANI–BN, ATMP. [Display omitted] •A PANI-BN/EP coating is prepared on the hot-dip galvanized layer surface.•The covalent modification of BN by PANI is achieved through ABA.•The environmental corrosion inhibitor ATMP is selected to dope the PANI.•PANI-BN/EP is not damaged after soaking in 3.5 wt% NaCl solution for 72 h.•PANI-BN/EP can protect the galvanized layer even after it is broken. Polyaniline (PANI) was covalently linked with hexagonal boron nitride (BN) using p-aminobenzoic acid (ABA) to obtain a PANI-BN powder. The PANI-BN/EP coating was applied on hot-dip galvanized steel, which exhibited remarkable corrosion resistance. Electrochemical test results showed that the impedance modulus in the low-frequency region of PANI-BN/EP was maximum after soaking in NaCl solution (3.5 wt.%) for 72 h compared with other coatings. The outstanding corrosion resistance of the PANI-BN/EP coating was primarily attributed to the synergistic effect of BN and PANI.