New approach for processing chitosan as low cost protective hybrid coating for C-steel in acid media.

The novelty of this study is that it the first time blending and formulation of chitosan as a new hybrid (organometallic) protective coatings for achieving synergistic protection for carbon steel alloy during acid pickling. The role of coated silica (by 0.1 wt % stearic acid lubricant) in the improvement of coating performance was highlighted. Variable weight percentage of chitosan and silica in addition to a fixed weight percentage (35 %) of guar gum natural plant resin, 5 × 10(-6) mmol (2-Hydrazinyl-6-methyl (or phenyl) -4, 5-di-H pyrimidinone) as organic corrosion inhibitors were compounding as hot melt in the presence of a low cost surfactant as an emulsifying agent improved compatibility between coating constituents. Guar gum increased coating flow during application and grafted chitosan into high molecular copolymer resin insoluble in acid media. Phosphorous acid improved coating flexibility during application by hot dipping. Hybrid coating decreased corrosion potential of carbon steel and retarded both redox reactions of corrosion acting as adsorbed mixed-type inhibitor. Percentages protection (%P) approached hundred percentage as confirmed from the agreement between impedance and polarization parameters. Guar gum plant resin and slice powder increased gloss of coating. The coated silica filled the pores and increased stiffness of coating. Super hydrophobicity of coating was confirmed by the measured contact angle above 150(o)C indicating good spreading of coating sample as insulating adherent surface film.