A thin polyaniline (PANI) film was deposited on AA 2024-T3 from aqueous sulphuric acid medium by potentiostatic method. The polymer film was characterized by FTIR, UV-Vis, SEM and XPS techniques. The corrosion behaviour of PANI coated AA 2024-T3 in 1% NaCl solution was studied by potentiodynamic polarization and electrochemical impedance spectroscopy (EIS). The self-healing ability of the PANI film was studied by scanning vibrating electrode technique (SVET). Corrosion protection ability of electro-deposited PANI with epoxy top coat was evaluated using salt spray and EIS studies. These studies demonstrate that the use of sulphate doped polyaniline film as primer coat for AA 2024-T3 shows better corrosion protection than that of epoxy alone. (C) 2015 Elsevier B.V. All rights reserved.