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<p>Epoxy coatings are susceptible to microcrack formation during curing, which compromises their corrosion protection. While aramid fiber (AF) reinforcement helps mitigate cracking, its inert surface impedes interfacial adhesion. To address this limitation, polyaniline-coated aramid fibers (PANI/AF) were synthesized via in situ polymerization of aniline. Unlike traditional AF modifications that solely enhance mechanical properties, the introduced PANI layer enables the PANI/AF filler to simultaneously improve both the mechanical performance and corrosion resistance of epoxy composites. At a loading of 1.0 wt.%, the composite exhibited a 96.4% increase in elastic modulus and maintained a low-frequency impedance of 10<sup>10</sup> Ω·cm<sup>2</sup> after 168&#xa0;h of immersion in 3.5% NaCl—four orders of magnitude higher than that of pure epoxy. PANI serves as an intermediate layer, improving the aramid fiber-epoxy interfacial bonding and coating compactness, while its passivation capability further protects the metal substrate. This dual-functional design effectively blocks corrosive agents and extends the service life of metals.</p>

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Dual-Functional Epoxy Composites Enabled by Polyaniline-Decorated Aramid Fibers: Enhanced Mechanical Properties and Anticorrosion Performance

  • 期刊论文

  • 发表日期：

    2026年3月30日

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  • Xiaofeng Li,
  • Yanru Li,
  • Taihua Zhang,
  • Yanhua Lei,
  • Yan An,
  • Tao Liu

摘要

Epoxy coatings are susceptible to microcrack formation during curing, which compromises their corrosion protection. While aramid fiber (AF) reinforcement helps mitigate cracking, its inert surface impedes interfacial adhesion. To address this limitation, polyaniline-coated aramid fibers (PANI/AF) were synthesized via in situ polymerization of aniline. Unlike traditional AF modifications that solely enhance mechanical properties, the introduced PANI layer enables the PANI/AF filler to simultaneously improve both the mechanical performance and corrosion resistance of epoxy composites. At a loading of 1.0 wt.%, the composite exhibited a 96.4% increase in elastic modulus and maintained a low-frequency impedance of 1010 Ω·cm2 after 168 h of immersion in 3.5% NaCl—four orders of magnitude higher than that of pure epoxy. PANI serves as an intermediate layer, improving the aramid fiber-epoxy interfacial bonding and coating compactness, while its passivation capability further protects the metal substrate. This dual-functional design effectively blocks corrosive agents and extends the service life of metals.