Abstract A series of polymer-clay nanocomposite(PCN) materials that consisted of poly(aniline) and layered montmorillonite (MMT) clay were prepared by effectively dispersing the inorganic nanolayers of MMT clay in organic aniline matrix via an emulsion polymerization. Organic aniline monomers were first intercalated into the interlayer regions of organophilic clay hosts and followed by a convertional emulsion polymerization. With CTAB and KPS as surfactant and initiator respectively .The as-synthesized PCN materials were characterized by infrared spectroscopy (FTIR), wide-angle powder X-ray diffraction (XRD), and transmission electron microscopy (TEM). PCN coatings with low clay loading (e.g., 1 wt%) on cold-rolled steel (CRS) at various service temperature, were found much superior in anticorrosion over those of aniline based on a series of electrochemical measurements of corrosion potential, polarization resistance, corrosion current and Impedance spectroscopy in 5.0 wt% aqueous NaCl electrolyte, The electrical conductivity of polyaniline-clay nanocomposite materials doped with different inorganic acid was further studied by four point probe technique.