Active Corrosion Research Articles

The Effect of Heat Treatment and Build Orientation on the Susceptibility of Laser Powder Bed Fusion Additively Manufactured Alloy 625 to Crevice Corrosion

This study aimed to determine the optimal heat treatment and build orientation to minimize the susceptibility of additively manufactured (AM) Alloy 625 to crevice corrosion. To accomplish this, metal-to-metal and acrylic-to-metal remote crevice assembly (RCA) experiments were performed for as-made (NT) AM, stress-relieved (SR) AM, solution-annealed AM, and solution plus stabilization-annealed AM Alloy 625 in two different build orientations. Current vs. time data from metal-to-metal RCA experiments were analyzed using commercially available statistical analysis software used to perform analysis of variance. While there was a lack of statistical evidence that build orientation affects crevice corrosion susceptibility, there was strong evidence heat treatment affects crevice corrosion susceptibility. Specifically, according to Tukey’s Multiple Comparison, alloys that were heat treated had a statistically significant lower charge passed as compared to the NT specimens. This finding was consistent with measured penetration depth where NT AM specimens had the largest maximum penetration depth. In contrast, acrylic-to-metal RCAs were used to calculate crevice corrosion current density (rate) and repassivation potential. While current densities for the AM materials were comparable, the forward motion of the active crevice corrosion front on the NT and SR specimens was found to be slow, resulting in high damage accumulation locally. Both metal-to-metal and acrylic-to-metal RCA results are discussed within the context of nonhomogenized microstructures associated with AM.

Spatiotemporally resolved corrosion protection of AA2024-T3 by a lithium-based conversion layer

In this work, the corrosion mechanism of AA2024-T3 covered by a lithium-based conversion layer is studied with high spatial and temporal resolution. Although the aluminium alloy surface is protected by a multi-layered conversion layer, areas around intermetallic phases (IMPs) represent weak spots due to an insufficient generation of a protective inner dense layer. For the freshly formed conversion layer, both the top and the inner layer undergo a gradual dissolution upon exposure to relatively dilute NaCl solution within 2 h due to their chemical instability. For the ambiently-aged conversion layer, most corrosion activity around IMPs is related to the S-phase and large constituent phases, due to their active nature and the lower local conversion layer quality, respectively. Moreover, S-phase-related corrosion activity lasts approximately 8 h due to fast dissolution whereas reactions induced by large constituent particles remain active over the entire re-immersion period of 12 h.

Bond Behavior of Glass Fine Aggregate Reinforcement Concrete after Chloride Erosion under Deicing Salt

This paper reports on the bond behavior of glass fine aggregate reinforced concrete (GFARC) under chloride erosion, considering the chloride solution and glass fine aggregate (GFA) exchange rates as variable parameters. The 16 groups of specimens are designed to conduct central pull-out tests after chloride erosion. The experimental results are analyzed, such as the τ–s curve, ultimate bond strength, peak slip, and bond stiffness. The results indicated that the degree of reinforcement corrosion in GFARC is low under the action of chloride corrosion. Compared with natural aggregate-reinforced concrete (NARC), the ultimate bond strength and bond stiffness of GFARC improve under the same chloride corrosion. The ultimate bond strengths of 25% GFARC, 50% GFARC, and 75% GFARC increased by 7%, 7.85%, and 17.31%, respectively, under natural conditions. Under 3.5% chlorine erosion, the GFARC group increased by 4.67%, 4.83%, and 13.53%, respectively. Under 5% chlorine erosion, the GFARC group increased by 5.54%, 6.24%, and 12.64%, respectively. Glass fine can improve the bonding performance between concrete and steel bars, and its effect is related to the replacement rate. The shape and chemical characteristics of glass sand play an important role in this process and became more prominent with the deepening of the effect. Through the analysis of the experimental results, this paper further elaborated on the bonding mechanism of GFARC under the influence of chloride corrosion. The research indicates that the use of GFA has a great advantage in improving the bond performance under chloride erosion.

Suppressing the Shuttle Effect of Aqueous Zinc-Iodine Batteries: Progress and Prospects.

Aqueous zinc-iodine batteries are considered to be one of the most promising devices for future electrical energy storage due to their low cost, high safety, high theoretical specific capacity, and multivalent properties. However, the shuttle effect currently faced by zinc-iodine batteries causes the loss of cathode active material and corrosion of the zinc anodes, limiting the large-scale application of zinc-iodine batteries. In this paper, the electrochemical processes of iodine conversion and the zinc anode, as well as the induced mechanism of the shuttle effect, are introduced from the basic configuration of the aqueous zinc-iodine battery. Then, the inhibition strategy of the shuttle effect is summarized from four aspects: the design of cathode materials, electrolyte regulation, the modification of the separator, and anode protection. Finally, the current status of aqueous zinc-iodine batteries is analyzed and recommendations and perspectives are presented. This review is expected to deepen the understanding of aqueous zinc-iodide batteries and is expected to guide the design of high-performance aqueous zinc-iodide batteries.

Investigation of the Electrochemical Corrosion Property of 2xxx Series Cast Aluminium Alloy in 0.3 M, 0.6 M NaCl, and Seawater Environments

The electrochemical corrosion activities of 2xxx series Al alloys were investigated in NaCl of 0.3 M, and 0.6 M concentrations and seawater environments. Both Tafel polarization and electrochemical impedance spectroscopy (EIS) methods were followed to analyze the corrosion behavior. These results implied that corrosive attack is more aggressive in sodium chloride solution compared to seawater, as additional elements present in seawater are involved in forming various protective layers. Again, a higher concentration of NaCl solution damaged the alloy surface more drastically. The open circuit potential moved towards the nobler direction in the case of seawater environment, and 0.3 M solution for NaCl. The corrosion rate and corrosion current showed higher values in NaCl solution than in seawater. The surface morphologies of the alloys were characterized not only with an optical microscope but with a scanning electron microscope also. The scratch marks from polishing were removed after corrosion. Extensive damage to the surface was found in the NaCl environment, where 0.6 M solution created the most damage, which is evident by both optical and scanning electron micrography. A higher level of pitting corrosion occurred in NaCl than in seawater, identified by SEM images.

Neural network analysis of safe life of the oil and gas industrial structures

Purpose is to study safe life of industrial (metal) structures under long-time operation in the corrosive-active media of oil and gas wells with the help of neural network analysis. Methods. The MATLAB system (MATrix LABoratory) was selected as the tool environment for interface modelling; the system is developed by Math Works Inc. and is a high-level programming language for technical computations. Of the three existing learning paradigms, we used the “with teacher” learning process, as we believed that a neural network had correct answers (network outputs) for each input example. The coefficients were adjusted so that the network gave answers being as close as possible to the known correct answers. Findings. An artificial neural network has helped obtain a generalized diagram of the expected areas of high viscoplastic characteristics of carbon steels used to manufacture metal structures in the oil and gas industry. While applying the trained neural networks, generalized dependences of the corrosion rates of structural steels on the parameters of media with different concentrations of chlorine ions, sulphate ions, hydrogen sulphide, carbon dioxide, carbon dioxide, and oxygen ions were obtained; they were the basis to predict corrosion behaviour of steels. Originality. For the first time, the possibility of applying neural network modelling to predict local corrosion damage of structural pipe steels has been shown in terms of the “steel 20 – oxygen and chloride-containing medium” system. For the first time, the technological possibility has been demonstrated to use neural network analysis for engineering predictive assessment of corrosion activity of binary systems of simulated solutions, which are most often found under industrial conditions of the oil and gas sector of the economy. Practical implications. The proposed technology of using the neural network analysis will make it possible to expand a range of predicted values beyond experimental data, i.e. to predict the value of Vcor in very dilute or concentrated salt solutions within the acidified and neutral pH ranges. It should be noted that the error of the prediction results shown by the neural network will increase along with distancing from the scope of experimental data.

Sonication assisted superior anti-corrosion properties of cathodically deposited novel nickel-graphene oxide-zinc oxide coating

This study details the sonication-assisted synthesis and characterization of a cathodically deposited novel nickel-graphene oxide -zinc oxide (Ni-GO-ZnO) composite coating achieved through electrodeposition and its comparison with anodically deposited GO. This coating was comprehensively characterized using Fourier-transform infrared (FTIR), X-ray diffraction (XRD), Raman spectroscopy, Field emission scanning electron microscopy (FE-SEM) coupled with Energy-dispersive X-ray spectroscopy (EDAX). Subsequently, its corrosion resistance for MS1010 mild steel in 3.5 wt % (NaCl) was evaluated via weight loss, contact angle, electrochemical impedance spectroscopy (EIS), Potentiodynamic polarization, and surface analysis techniques. These observations suggest that graphene oxide-zinc oxide (GO-ZnO) adsorbs nickel onto the MS surface effectively and reduces defects, which helps in blocking active corrosion sites. Tafel plots and EIS revealed that the Ni-GO-ZnO coating exhibited the lowest current density (39.95 µAcm²) and the highest charge transfer resistance (1211 Ωcm²). This was further validated by long-term immersion testing, where the Ni-GO-ZnO coating exhibited significantly less weight loss (1.33 mils/Y) compared to the deposited GO coating (2.2 mils/Y). The mechanism of formation of deposited GO and Ni-GO-ZnO coating on the metallic surface is proposed. The enhanced corrosion resistance of the Ni-GO-ZnO coating is attributed to its ability to 1) form a more compact metallic layer and 2) Minimize the active surface area vulnerable to corrosion attack. 3) Diminishes the presence of holes and cracks for corrosive ion ingress.4) Functionally impedes the ingress of chloride ions, primarily liable for steel degradation. The synergistic effect of the GO-ZnO constituents within the nickel matrix significantly enhances the long-term durability and integrity of the protective layer, a phenomenon hitherto unexplored. The empirical outcomes advocate for the advanced application of GO-ZnO-nickel coatings in safeguarding infrastructural materials against corrosive degradation.

Smart epoxy coating: g-C3N4 nanosheets loaded MOFs for enhanced anti-corrosion and UV resistance

Large lateral size g-C3N4 nanosheets (Graphite-like carbon nitride) were successfully prepared by surface polymerization. NH2-MIL-101 (Amino-functionalized iron-based metal–organic framework) was then modified on the surface of g-C3N4 nanosheets (NH2-MIL-101@g-C3N4) by an in-situ loading method to construct a long-term smart coating with high barrier, activity inhibition, and anti-UV aging. This novel approach marks a significant advancement in the development of smart coatings for long-term corrosion protection. Evaluation of the active corrosion inhibition of NH2-MIL-101@g-C3N4 (MCN) nanoparticles showed that the corrosion inhibition efficiency of MCN nanoparticles on carbon steel reached 79.3 % after 5 h. The addition of MCN nanoparticles to the epoxy coatings (MCN/EP) endowed the coatings with the ability to actively inhibit corrosion. The release of Fe3+ cations and NH2-BDC (2-aminoterephthalic acid) organic ligands from MCN at defects formed a protective film, effectively preventing further corrosion. The MCN/EP coating maintained a high Log|Z|0.01 Hz value (Impedance modulus at a frequency of 0.01 Hz) during the immersion period with excellent barrier properties. Notably, MCN significantly improved the water resistance, water contact angle, tensile properties, and thermomechanical properties of epoxy coatings after ultraviolet (UV) radiation, highlighting a remarkable enhancement in the coating's performance. The anti-corrosion of MCN/EP coating was unaffected by UV radiation, extending service life of the smart coating, with Log|Z|0.01 Hz values two orders of magnitude higher than pure EP after 300 h of UV radiation. This work presented innovative coating design and preparation methods to improve the performance and functionality of anti-corrosion coatings, making significant attempts in the field.

Evaluation of the Corrosion Activity of Reinforcement in Drainage Gallery of Concrete Dam using Half-cell Potential (HCP)

Dams are essential structures for water management, providing various benefits crucial for human survival and economic growth. However, steel corrosion in concrete dams poses a significant threat, leading to structural deterioration and potential collapse. Detecting corrosion in the early stage is critical to prevent catastrophic failures. This study investigates corrosion risk in a concrete dam's drainage gallery using half-cell potential (HCP) measurements, a common method for assessing corrosion activity in reinforced concrete. The electrochemical process of steel corrosion in concrete, influenced by factors like chloride or carbonation exposure and temperature, is discussed. The HCP method is a nondestructive technique for determining the corrosion rate of steel reinforcement in concrete structures. It involves measuring the potential difference between reinforcing steel and reference electrodes; typically, a copper/copper sulphate electrode is used. The potential difference between the two electrodes is then used to calculate the corrosion rate of the reinforcing steel. The HCP method is a reliable and cost-effective way to identify potential corrosion problems before they become severe. The present study used CorMap II® to measure HCP on the upstream face of the dam's drainage galleries. Results indicate predominantly low corrosion risk across tested locations, with minimal uncertainty. However, interpretations must consider environmental factors' influence on measurements. The study's findings offer valuable insights for future corrosion assessments and underline the importance of preventive measures for concrete dam integrity.

Impact of Aqueous Extract Artemisia Herba-Alba Leaves as a Green Inhibitor against Acid Activation of 2024 Aluminum Alloy

This work is part of the development of new bio-sourced corrosion inhibitors from an abundant resource that can replace conventional synthetic inhibitors that are harmful to both human health and the environment. The corrosion inhibition performance of an aqueous extract of Artemisia herba-alba on the corrosion of 2024 aluminum alloy in a 1 M hydrochloric acid solution is investigated by weight loss method, electrochemical (linear polarization, potentiodynamic polarization, and electrochemical impedance spectroscopy) and SEM techniques. The extract shows excellent corrosion-inhibiting properties on aluminium alloy with a maximum inhibition efficiency of 93% at 0.6 g/L. The adsorption of the natural extract obeys the extended Langmuir isotherm equation adsorption model for multicomponent systems. Temperature studies show that the efficiency of the extract decreases with increasing temperature and that the corrosion activation energies increase in the presence of the extract. Liquid chromatography/high resolution mass spectrometry is used to identify the chemical constituents of the natural extract, and the most abundant phytochemicals for each subclass of metabolite are investigated using density functional theory (DFT) calculations. This study paves the way for further development of a plant that is particularly abundant in the desert regions of North Africa and has until now been used mainly for food for livestock and for pharmaceutical applications.

Investigation of Multi-Factor Stress Corrosion Cracking Failure of Safe-End Feedwater Lines of Submarine Power System.

The corrosion process under the complex safe-end feedwater line conditions was investigated via experimental lab testing and numerical simulation. The corrosion of safe-end feedwater lines was controlled through the combination of galvanic corrosion, residual stress, and flow velocity. Firstly, galvanic corrosion occurred once the 20 steel was welded with 316L stainless steel. The pitting corrosion could be observed on the 20 steel side of the weld joint. Secondly, a vortex flow was detected around the welding bump and within the pits. The growth of the pits was accelerated in both the vertical and horizontal directions. Finally, under the residual stress condition, the stress intensity factor (K) at the bottom of the pits was easier to reach than the critical stress intensity factor (KISCC). Then, pitting was transformed into stress corrosion cracking which then propagated along the weld line. Therefore, the critical factor inducing the failure of safe-end feedwater lines was the combined action of galvanic corrosion, residual stress, and flow velocity.

Comparative studies of tetrazole derivatives on the corrosion inhibition of copper and commercial brass in simulated seawater

The corrosion inhibition of copper and its alloys in seawater using organic inhibitors has received much interest. Electrochemical techniques were used to evaluate the effectiveness of 5-Mercapto-1-methyltetrazole (MTAH) and 5-Aminotetrazole (ATAH) as corrosion inhibitors on copper and commercial brass in simulated seawater with 3.5% NaCl. EDS and SEM techniques were used to investigate the sample surfaces. The results showed that ATAH is more effective than MTAH in both samples, with an inhibition rate of 98% for copper and 86% for brass at a concentration of 0.01 M. Surface investigations reveal that the presence of ATAH has significantly protected the copper and brass surfaces compared to MTAH because of its amino group. According to the Langmuir adsorption isotherm, the inhibitors physicochemically adsorb on the sample surface. On the other hand, the Arrhenius plot showed a considerable jump in the corrosion activation energy when the inhibitor was present, proving the inhibitor’s efficiency in preventing corrosion on copper and brass surfaces.

Numerical modelling on coupled behavior of calcium leaching and chloride transport in cement-based materials by considering ion desorption

Concrete structures serving in water environment with rich chloride ions are subjected to the coupling action of calcium leaching and chloride corrosion. In this paper, a transport model of calcium and chloride ions coupled with the calcium solid-liquid equilibrium equation is proposed to simulate the behavior of calcium leaching and chloride penetration in concrete. In the model, the effect of free chloride ions bound by solid calcium and the release of bound chloride ions caused by the dissolution of solid calcium is considered. Secondly, the model is numerically solved by using the finite difference method of Crank-Nicolson scheme. Then, the experimental data of porosity and calcium silicon ratio, chloride concentration are compared to the calculated results to validate the model. Finally, a numerical simulation is conducted to analyze the evolution of ion concentration, solid calcium content and porosity of cement paste slice exposed to deionized water and accelerated dissolution solution. The results show that, the concentration of calcium ion decreases with corrosion time, while that of chloride ion increases. There are concentration gradient distributions of calcium and chloride ions in the slice. The higher the concentration of accelerated dissolution solution, the larger the porosity of cement paste and the higher the concentration of chloride ions in the paste. It indicates that, the calcium leaching accelerates the chloride penetration into concrete. In addition, the dissolution process of solid calcium, i.e. calcium hydroxide first dissolves followed by C-S-H gel, are presented.

Influence of Galvanized Steel on Kombucha Fermentation: Weight Loss Measurements, Scanning Electron Microscopy Analysis, Corrosion Activity, and Phytochemical Study

This study aimed to investigate the influence of galvanized steel coupons on black tea kombucha fermentation. As a secondary objective, the corrosion activity of the fermented medium at different stages of fermentation was investigated. The results revealed significant interactions among microorganisms, the metal, and the fermented medium. On one hand, mass loss measurement, scanning electron microscopy (SEM) analysis, and released zinc and iron ion analysis showed the deterioration of galvanized steel coupons. On the other hand, HPLC-RI analysis showed that the presence of steel coupons improved the kinetics of fermentation. The chemical composition and bioactivity of kombucha were also influenced by the presence of galvanized steel. The results showed the detection of eleven phenolic compounds by HPLC-DAD, including trihydroxyethylrutin, methyl 3,5-dihydroxybenzoate, and ethyl 4-hydroxy-3-cinamate, which were found only in kombucha in the presence of galvanized steel (K+GS). In addition, a total of 53 volatile compounds were detected by GC-MS before and after derivatization, including eleven constituents identified for the first time in K+GS. Concerning antioxidant activity, a higher percentage of inhibition against the DPPH radical was attributed to the ethyl acetate extract found in K+GS (IC50 = 8.6 µg/mL), which could suggest the formation of inhibitors. However, according to the electrochemical findings, the corrosion current density increased threefold during the fermentation process compared to acidified black tea, indicating that corrosion activity was promoted in the kombucha medium and suggesting several competing phenomena between corrosion and inhibition.

Effect of Elements Segregation at α‐Fe/Al2O3 Interface on Microareas Corrosion Activity around Al2O3 Inclusions

Segregation of interface elements is the main factor affecting the corrosion activity of microareas around Al2O3 inclusions rather than galvanic corrosion. In this work, the effects of segregation of Cu, V, Ni, Mo, B, and P elements on the interfacial bonding strength and microareas corrosion activity around Al2O3 inclusions are analyzed in detail using 3D atomic probe and first‐principles calculations. In the results, it is shown that Cu, V, Mo, B, and P elements reduce the stability of the α‐Fe/Al2O3 interface. In addition, the segregation of Cu, V, Mo, B, and P elements at the interface also enhances the adsorption capacity of Cl and ultimately improves the microarea corrosion activity around Al2O3 inclusions. Ni element can enhance the stability of α‐Fe/Al2O3 interface, and the segregation of Ni element at the interface weakens the adsorption capacity of Cl and ultimately reduces the microarea corrosion activity around Al2O3 inclusions.

Synergy of Mo doping and heterostructures in FeCo2S4@Mo-NiCo LDH/NF as durable and corrosion-resistance bifunctional electrocatalyst towards seawater electrolysis at industrial current density

Electrolysis of seawater to produce hydrogen is a replenished way to utilize sustainable hydrogen energy. However, it remains a challenge to develop electrocatalysts with high chloride corrosion resistance and meet the industrial-required low overpotential at large current density. Here, a heterostructure FeCo2S4@Mo-NiCo LDH/NF (FCS@M-NC LDH/NF) catalyst consisting of Mo-doped NiCo LDH nanosheets on FeCo2S4 nanorods grown on nickel foam is demonstrated as a large-current–density electrocatalyst for seawater electrolysis. The hierarchical structure endows FCS@M-NC LDH/NF with abundant active sites and hydrophilic and aerophobic surfaces, which promotes the adsorption of OH− and accelerates gas-release capabilities during water electrolysis. Moreover, the incorporation of high-valence Mo species and the presence of heterostructures contribute to the outstanding corrosion resistance, selectivity, and activity of FCS@M-NC LDH/NF, which only requires 314 mV (HER) and 307 mV (OER) overpotential to achieve a large current density of 1000 mA cm−2 in alkaline electrolysis of seawater. Impressively, it maintains stable operation for 140 h at a current density of 500 mA cm−2 without the production of hypochlorite. Furthermore, density functional theory calculations demonstrate that Mo doping and formation of heterostructures decrease the adsorption energy barrier for intermediate on FCS@M-NC LDH/NF, which promotes electrocatalytic activity. The robust electronic interaction between FCS and M-NC LDH/NF promotes the redistribution of charges on the interface, boosting electrical conductivity and charge transfer in the FCS@M-NC LDH/NF. This study offers a mild way to create a bifunctional electrocatalyst with exceptional corrosion resistance and stability in industrial high-alkaline natural seawater electrolysis.

The formation of pitting under dynamic DC interference: Corrosion product film defects or passive film induction

The cause of pitting under dynamic DC interference is unclear. This paper studies the mechanisms of pitting in simulated solutions under neutral and alkaline conditions using weight loss, electrochemical testing, and microscopic characterization. The results indicate that the metal mainly undergoes active corrosion in the neutral solution, and the formation of millimeter-scale pits is due to local defects in corrosion products. Metals in the alkaline solution undergo passive corrosion, resulting in micro-scale pits. Initially, stable pits form at damaged areas of the passivation film. Then, pits can grow rapidly under self-catalysis, with the growth rate surpassing other surface locations.

Electrochemical investigation and surface interaction of thiophene based Chitosan Schiff base on mild steel surface in 1 M HCl

Environment friendly Chitosan Thiophene carboxaldehyde Schiff base, a biopolymer derivative was synthesized to examine the inhibitive action of mild steel corrosion in 1 M Hydrochloric acid. Chitosan Thiophene carboxaldehyde Schiff base was prepared by the modification of Chitosan with thiophene carboxaldehyde through condensation reaction. The effect of Chitosan Schiff base as corrosion inhibitor was investigated using electrochemical impedance spectroscopy at higher temperature differentials of 313–343 K. Chitosan Schiff base showed enhanced corrosion resistance in all the studied temperature range by the forming protective film on the metal surface. The preliminary information about the complex formation in the solution phase, protective layer formation on the metal surface was investigated by Atomic absorption spectroscopy and Ultraviolet spectroscopic studies. The surface interaction between inhibitor molecules and mild steel surface was examined by Fourier Transform Infrared Spectroscopy, scanning electron microscopy and Contact angle measurements. The adsorption of inhibitor layer on the metal was monitored by cyclic voltammetry studies. Quantum chemical results support the possibility of surface interaction between inhibitor and empty orbitals of metal surface.

Tribocorrosion studies on DLC films with silver nanoparticles for prosthesis applications

Metals and their alloys are very important for orthopedic applications, and the basic requirements for a successful implant are chemical stability, mechanical behavior, and biocompatibility in body fluids and tissues. For prosthesis applications, the corrosion resistance of metals is one of the major prerequisites to avoid impairment of the material properties due to degradation. The combined action of corrosion and wear on the material is called tribocorrosion and DLC (Diamond-Like Carbon) films have been extensively studied to increase prosthesis biocompatibility and to protect from corrosion. Additionally, DLC coatings can prevent the prosthesis to release toxic elements due to plastic deformation and corrosion. This paper is about tribocorrosion studies on DLC and DLC-Ag (DLC containing silver nanoparticles) on Ti-6Al-4V substrates. These films were obtained by PECVD (Plasma Enhanced Chemical Vapor Deposition) using hexane as a precursor. The tribocorrosion behavior of uncoated and coated samples was investigated in the reciprocating mode in Ringer’s lactate solution. From the polarization test results, the protective efficiency of the film was calculated. Silver nanoparticles improved the corrosion resistance of the films. The protective efficiency was 15 and 19% for DLC and DLC-Ag films, respectively.

Electrodeposited graphene/layered double hydroxides micro/nanocontainers for both passive and active corrosion protection

The poor dispersibility of layered double hydroxides (LDHs) is considered to be the main drawback limiting their application in anti-corrosive coatings. In this work, the problem is solved by combining LDHs with graphene (Gr). A facile electrochemically assisted deposition technique (EAT) is developed to prepare Gr/LDH micro/nano-containers. The high-barrier Gr and LDHs synergistically build a ‘labyrinth effect’ to lengthen the diffusion path of corrosive mediums. Moreover, corrosion inhibitors can be released from the interlayer galleries of LDHs and impede corrosion of metal substrate by substituting the aggressive ions. Therefore, the polyvinyl butyral (PVB) coatings doped with Gr/LDH micro/nano-containers pre-loaded with inhibitors 2-Mercaptobenzothiazole (MBT) have both passive and active corrosion protection properties and provide excellent protection to copper substrate.