Formation of ultra-thin prussian blue layer on carbon steel that promotes adherence of hybrid polypyrrole based protective coating

Electrodeposition of well-adhering polypyrrole-based hybrid films containing hexacyanoferrate(II,III) anions from neutral solutions of pyrrole and potassium hexacyanoferrate(II) on medium carbon (0.48% C) steel has been described. The resulting polypyrrole coatings that are doped with hexacyanoferrate(II,III) anions show protective properties against pitting corrosion of carbon steel substrates in strongly acidic media containing chlorides (0.1 mol dm−3 HCl + 0.4 mol dm−3 NaCl). Polypyrrole acts as a stable host matrix for inorganic anions. The presence of negatively charged species (hexacyanoferrates) in the polymer backbone tends to block the access of pitting-causing anions (chlorides) to the surface of steel. The Fe(CN)63-/4− anions existing in the vicinity of steel substrate stabilizes its surface by forming an overcoating in the form of sparingly soluble metal hexacyanoferrate, mostly Prussian blue (PB), microstructures. It has been demonstrated that by applying cyclic voltammetry and X-ray photoelectron spectroscopy, the presence of traces of free cyanide anions promotes the formation of PB on carbon steel surface which results in increasing the adherence of polypyrrole-based films to the metallic substrate. Morphology of the protective composite films is also addressed.