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Abstract PANI emulsion was blended with pure acrylate (PACE) that based on (poly methyl methacrylate-butyl acrylate) emulsion. PANI emulsion was also blended with styrene acrylate (SACE) that based on Poly (styrene-co-butyl acrylate). To prepare two types of eco-friendly water-base coating formulations with different solid to solid ratios for each one. The blended formulations for PACE/PANI and SACE/PANI showed bimodal size distribution patterns related to the PANI and copolymers particles in both types. The coated films were used to protect the steel substrate against corrosion. The progressively increasing of PANI content led to increase Tg of the films for both types.Coating films of SACE loaded with 0.75% and 1% PANI exhibited the highest corrosion protection resistivity and their efficiencies were 99.37% and 99.06%, respectively. For PACE coating films loaded with 0.75% and 1% PANI exhibited the optimum corrosion resistivity and efficiencies were 98.76% and 98.39%, respectively.However, at higher concentrations of PANI (as loaded with concentration 1% and 1.5%) in both PACE and SACE coatings, the intermolecular forces(cohesion) increased and the adhesion to the steel substrate greatly decreased |