This research introduces an innovative waterborne intumescent epoxy coating (P-S-IEC) reinforced by in-situ polymerized polyaniline-silicon carbide (PANI-SiC) hybrids, which simultaneously achieves the dual functions of flame retardancy and corrosion protection. The PANI-SiC hybrids are chemically grafted, synergistically combining the thermal insulation properties of SiC nanosheets with the passivation and char-forming abilities of PANI. Large-scale combustion tests show that the P-S-IEC coating maintains its structural integrity even after being exposed to a 1200 °C flame for 120 min, with an impressively low backside temperature of 289 °C. This performance significantly surpasses that of control coatings containing either PANI or SiC alone. Electrochemical analysis further reveals its outstanding corrosion resistance: after immersion in a 3.5 % NaCl solution for 20 days, the charge transfer resistance (Rct) remains as high as 7.43 × 10⁷ Ω·cm², and the corrosion current density is only 2.23 × 10⁻⁸ A/cm². The enhanced flame retardancy of the P-S-IEC coating can be attributed to the thermal insulation provided by SiC and the intumescent char expansion of PANI, which together form a stable three-dimensional carbon layer with reduced microporosity. Regarding corrosion protection, the coating benefits from the tortuous path effect of SiC, which hinders ion penetration, and the electrochemical passivation of the steel substrate induced by PANI. This study offers a scalable approach for developing multifunctional coatings that integrate passive shielding and active protection mechanisms. It effectively addresses key challenges in ensuring structural fire safety and long-term corrosion resistance for various industrial applications.
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