Polyaniline (PANT) was synthesized by chemical oxidative polymerization of aniline (ANI) in the presence of alumina (Al2O3) particles. The polymerization of ANT occurred preferentially on the surfaces of the particles, resulting core-shell structured alumina-polyaniline (Al(2)O(3)PANI) particles. Morphology examination showed that with decreasing of the weight ratio of Al2O3/ANI in the reactants, the thickness of the PANT layer increased and changed from an even surface morphology to a particulate morphology. UV-vis and Fourier transformed infrared (FTIR) spectra indicated that there is no chemical interaction between the PANT layer and the AI(2)O(3) surfaces. The PANT layer adhered well to the particles and can be used as anticorrosive fillers for polymer coatings. Enhanced corrosion protection performance was achieved for the emeraldine base (EB) form of PANT deposited Al2O3 particles (Al2O3-EB) filled epoxy coating on carbon steel in 3.0 wt % aqueous NaCl solution. The particles demonstrate both excellent corrosion protection performance and lower cost, which will be of great importance in practical applications. (c) 2006 Wiley Periodicals, Inc.