PEDOT-based conducting polymers boost UV-cured acrylic coatings’ corrosion resistance - European Coatings

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A new study demonstrates how phosphate- and lignin-doped PEDOT polymers enhance the corrosion protection of UV-cured acrylic coatings, offering an efficient and environmentally friendly alternative to conventional systems.

In an effort to develop more sustainable corrosion protection systems, researchers have successfully integrated poly(3,4-ethylenedioxythiophene) (PEDOT) into UV-curable acrylic coatings. The conductive polymer, known for its stability and low toxicity, was doped with various corrosion-inhibiting counter-anions—three alkyl phosphate salts and one cinnamate-based compound. The study, published in Progress in Organic Coatings (Volume 200, March 2025), presents a promising route towards high-efficiency coatings that combine active protection and environmental compatibility.

The PEDOT variants were incorporated into an acrylic formulation at different loadings (20 wt% and 60 wt%) and applied to mild steel substrates. The coatings were then UV cured and subjected to corrosion performance tests under harsh conditions. Notably, coatings with 20 wt% PEDOT additive displayed higher impedance values and better corrosion resistance than those with 60 wt%, indicating that excessive additive concentrations may hinder performance due to aggregate formation.

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The PEDOT-doped coatings showed up to 99 % efficiency in preventing corrosion, as verified through Potentiostatic Electrochemical Impedance Spectroscopy (PEIS), Potentiodynamic Polarisation (PP) and salt spray exposure. They also demonstrated increased resistance to filiform corrosion compared to the control formulation. SEM and EDS analyses confirmed the formation of polymer aggregates, helping to explain the differences in performance depending on additive concentration.

The study highlights the potential of PEDOT-based systems as a viable, less toxic alternative to conventional corrosion inhibitors. Their effectiveness under saline and aggressive environmental conditions makes them strong candidates for protective metal coatings in demanding industrial environments.

Source: Monaci, S. et al. PEDOT conducting polymers as corrosion inhibitors additives for acrylic-UV coatings, Progress in Organic Coatings, Volume 200, March 2025, 109000.

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