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Humidity and pollution deposition on the surface of porcelain insulators affect the electrical field distribution and their performance which may lead to partial discharge and decreasing flashover voltage. Thereby one essential aspect of insulator designing is their surface science and surface wettability. To address these challenges, in this study robust omniphobic coatings were designed which can repel water and oil droplets as well as other contaminant particles from the porcelain insulators surface. In this regard, slippery liquid infused porous surface (SLIPS) coatings were applied on the porcelain substrate by infusing perfluorinated liquid lubricants into 200 %-stretched Teflon tape cover or fluoro-silanized porcelain. The surface of the designed transparent coatings repelled water, olive oil, kaolin, sodium chloride microparticles, and ice. The applied coatings exhibited low contact angle hysteresis (Δθ ≤ 5°) and a low sliding angle (α ≤ 7°) for water and olive oil droplets. SLIPS coatings showed good stability to extreme environments like immersion into acid, base, brine solutions, UV radiation and withstood at 4.5 kV inclined plane test without failure after 6 h. So, the modified SLIPS can be used as effective coatings in the porcelain insulators surface engineering.

ZnO–polyaniline nanocomposite with core–shell nanostructure was prepared by in situ polymerization of aniline monomer in the presence of ZnO nanoparticles. Fourier transform infrared spectroscopy, X-ray diffraction patterns, field emission scanning electron microscopy and transmission electron microscopy techniques were used to characterize the composition and structure of ZnO–polyaniline nanocomposite. d.c. electrical conductivity measurement showed that the electrical conductivity of ZnO–polyaniline nanocomposite pellets is higher than that of pristine polyaniline and ZnO nanoparticles pellets. The addition of ZnO nanoparticles causes to the increasing of polyaniline electrical conductivity. ZnO–polyaniline nanocomposite was mixed with polyvinyl chloride (PVC) through a solution mixing method and the three components PVC/ZnO–polyaniline hybrid material was applied as coating on iron coupon by the solution casting method. Corrosion protection efficiency of PVC/ZnO–polyaniline hybrid coating on iron coupons was studied by open circuit potential and Tafel techniques in 3.5% NaCl solution as corrosive environment. According to the results, PVC/ZnO–polyaniline hybrid nanocomposite coating showed dramatically increased corrosion protection effect on iron samples compared to that of uncoated iron coupon and pure polyaniline anticorrosive coating. It was found that ZnO nanoparticles improve the barrier and electrochemical anticorrosive properties of polyaniline and the addition of polyvinyl chloride increases the barrier effect of polyaniline coating.

Conducting polyaniline, zinc and epoxy resin solely have anticorrosive properties by different mechanisms on metallic substrates. In this work the triple hybrid of PANI/epoxy/Zn nanocomposite was prepared as a thin layer coating (70 ± 5 μm) on iron coupons and its anticorrosion performance was investigated in HCl (0.1 M) as corrosive solution. Epoxy resin and zinc nanoparticles were applied as additives in the PANI matrix to improve the mechanical properties of PANI coating and investigate their synergetic effects on the anticorrosion performance of PANI coating. At first PANI/Zn nanocomposite coatings with different Zn contents were prepared and the zinc content optimized so that the coating achieve the best anticorrosion performance. Accordingly the iron coupons coated by PANI/Zn coating having 4 wt% Zn content showed more noble open circuit potential and lower corrosion current values. Then epoxy resin was applied as additive to the optimized formulation of PANI/Zn coating in different weight percents (0–20 wt%) and the anticorrosion performance of the related PANI/epoxy/Zn triple hybrid nanocomposite coatings was evaluated. Results showed that the addition of epoxy resin causes to the decreasing of corrosion current of iron samples coated by PANI/epoxy/Zn nanocomposite. An optimum range of 3–7 wt% was obtained for the epoxy content in the composition of PANI/epoxy/Zn nanocomposite in which the coating exhibits the best anticorrosion performance. Iron metal coupon was elementally analyzed and the PANI/Zn and PANI/epoxy/Zn nanocomposites were characterized using Fourier Transform Infrared spectroscopy, X-ray diffraction patterns and Scanning Electron Microscopy techniques.

Polyaniline/zinc composites and nanocomposites were prepared using solution mixing method. Zinc (Zn) particles with an average particle size of 60 μm and zinc nanoparticles with an average particle size of 35 nm were used as fillers in polyaniline (PANI) matrix. Films and coatings of PANI/Zn composites and nanocomposites were prepared by the solution casting method. Electrical conductivity and anticorrosion properties of PANI/Zn composite and nanocomposite films and coatings with different zinc loadings were evaluated. According to the results, electrical conductivity and anticorrosion performances of both PANI/Zn composites and nanocomposites were increased by increasing the zinc loading. Also results showed that the PANI/Zn nanocomposite films and coatings have better electrical conductivity and corrosion protection effect on iron coupons compared to that of PANI/Zn composite.

Nanocomposite of polyaniline (PANI) with natural clinoptilolite (Clino) was prepared. Formation of nanocomposite and incorporation of polyaniline in the clinoptilolite channels was confirmed and characterized using FTIR spectroscopy studies, X-ray diffraction (XRD) pattern, scanning electron microscopy (SEM) and cyclic voltammetry techniques. The anticorrosive properties of a 20 μm thickness coating of PANI/Clino nanocomposite with various weight ratios (1, 3 and 5%, w/w) of clinoptilolite content on iron coupons was evaluated and compared with pure polyaniline coating. According to the results in acidic environments PANI/Clino nanocomposite has enhanced corrosion protection effect in comparison to pure polyaniline coating. Comparative experiments revealed that PANI/Clino nanocomposite with 3% (w/w) clinoptilolite content has the best protective properties. Further experiments showed that the PANI/Clino nanocomposite has considerably different corrosion protection efficiencies in various corrosive environments.

Nanocomposites of polyaniline (PANI) with organophilic montmorillonite (O-MMT) and hydrophilic montmorillonite (Na-MMT) were prepared. The nanocomposites were characterized using FT-IR, D.C. electrical conductivity measurement and cyclic voltammetry techniques. It was found that PANI/Na-MMT nanocomposite has lower (5.8%) and PANI/O-MMT nanocomposite has higher (29.4%) conductivity compared to pure polyaniline. Cyclic voltammetry experiments showed that both nanocomposites are electroactive. The anticorrosive properties of a 100 μm thickness coating of nanocomposites on iron coupons were evaluated and compared with pure polyaniline coating. According to the results PANI/MMT nanocomposites have enhanced corrosion protection effect in comparison to pure polyaniline coating. Results showed also that the PANI/Na-MMT and PANI/O-MMT nanocomposites have considerably different corrosion protection efficiencies in various corrosive environments.