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Poly(phenylene methylene) (PPM) is a multifunctional polymer featuring hydrophobicity, high thermal stability, fluorescence and thermoplastic processability. Accordingly, smart corrosion resistant PPM-based coatings (blend and copolymer) were prepared and applied by hot pressing on aluminum alloy AA2024. The corrosion protection properties of the coatings and their dependence on coating thickness were evaluated for both strategies employed. The accelerated cyclic electrochemical technique (ACET), based on a combination of electrochemical impedance spectroscopy (EIS), cathodic polarizations and relaxation steps, was used as the main investigating technique. At the coating thickness of about 50 µm, both blend and copolymer PPM showed effective corrosion protection, as reflected by |Z|0.01Hz of about 108 Ω cm2 over all the ACET cycles. In contrast, when the coating thickness was reduced to 30 µm, PPM copolymer showed neatly better corrosion resistance than blended PPM, maintaining |Z|0.01Hz above 108 Ω cm2 with respect to values below 106 Ω cm2 of the latter. Furthermore, the analysis of many electrochemical key features, in combination with the optical investigation of the coating surface under 254 nm UV light, confirms the intrinsic self-healing ability of the coatings made by PPM copolymer, contrary to the reference specimen (i.e., blend PPM).

This work aims to improve the corrosion protection features of poly(phenylene methylene) (PPM) by sidechain engineering inserting methoxy units along the polymer backbone. The influence of side methoxy groups at different concentrations (4.6% mol/mol and 9% mol/mol) on the final polymer properties was investigated by structural and thermal characterization of the resulting copolymers: co-PPM 4.6% and co-PPM 9%, respectively. Then, coatings were processed by hot pressing the polymers powder on aluminum alloy AA2024 and corrosion protection properties were evaluated exposing samples to a 3.5% w/v NaCl aqueous solution. Anodic polarization tests evidenced the enhanced corrosion protection ability (i.e., lower current density) by increasing the percentage of the co-monomer. Coatings made with co-PPM 9% showed the best protection performance with respect to both PPM blend and PPM co-polymers reported so far. Electrochemical response of aluminum alloy coated with co-PPM 9% was monitored over time under two “artificially-aged” conditions, that are: (i) a pristine coating subjected to potentiostatic anodic polarization cycles, and (ii) an artificially damaged coating at resting condition. The first scenario points to accelerating the corrosion process, the second one models damage of the coating potentially occurring either due to natural deterioration or due to any accidental scratching of the polymer layer. In both cases, an intrinsic self-healing phenomenon was indirectly argued by the time evolution of the impedance and of the current density of the coated systems. The degree of restoring to the “factory conditions” by co-polymer coatings after self-healing events is eventually discussed.

Poly(phenylene methylene) (PPM) is a thermally stable, hydrophobic, fluorescent hydrocarbon polymer. Recently, blended PPM has been proposed as a valuable anti-corrosion coating material, and, in particular, rheological additives such as external plasticizers resulted crucial to prevent crack formation. Accordingly, to avoid common problems related to the use of external plasticizers, the development of PPM-related copolymer-based coatings containing n-octyloxy side chains and their anti-corrosion behavior were explored in this study. The aluminum alloy AA2024, widely employed for corrosion studies, was selected as a substrate, covered with a thin layer of a polybenzylsiloxane in order to improve adhesion between the underlying hydrophilic substrate and the top hydrophobic coating. Gratifyingly, coatings with those copolymers were free of bubbles and cracks. The n-octyloxy side-chains may be regarded to adopt the role of a bound plasticizer, as the glass transition temperature of the copolymers decreases with increasing content of alkoxy side-chains. Electrochemical corrosion tests on PPM-substituted coatings exhibited good corrosion protection of the metal surface towards a naturally aerated near-neutrally 3.5% wt.% NaCl neutral solution, providing comparable results to blended PPM formulations, previously reported. Hence, the application of rheological additives can be avoided by use of proper design copolymers.

Poly(phenylene methylene) (PPM) is a thermally stable, hydrophobic, fluorescent hydrocarbon polymer. PPM has been proposed earlier to be useful as a coating material but this polymer was isolated in relevant molar masses only recently, and in large quantities. Accordingly, the preparation of coatings based on PPM and their behavior was explored in this study, with the example of the metal alloy AA2024 as a common substrate for corrosion tests. Coatings free of bubbles and cracks were obtained by hot pressing and application of the following steps: Coating on AA2024 with a layer of polybenzylsiloxane to improve the adhesion between PPM and the metal surface, the addition of polybenzylsiloxane to PPM in order to enhance the viscosity of the molten PPM, and the addition of benzyl butyl phthalate as a plasticizer. Electrochemical corrosion tests showed good protection of the metal surface towards a NaCl solution, thanks to a passive-like behavior in a wide potential window and a very low current density. Remarkably, the PPM coating also exhibited self-healing towards localized attacks, which inhibits the propagation of corrosion.