Corrosion Conditions Research Articles

Failure behavior study of EB-PVD TBCs under CMAS corrosion and thermal shock cycles

Abstract Calcia-magnesia-alumino-silicate (CMAS) erosion has become a major obstacle, limiting the operating temperature and service life of Thermal barrier coatings (TBCs) in aircraft engines. Constructing simulation environments that replicate TBCs’ working conditions and exploring online, non-destructive detection techniques are reliable approaches to studying coatings’ failure, representing both a global research hotspot and a challenge in this field. The paper presents an initial endeavor to establish a simulation experiment for TBCs in aviation-engine within a CMAS environment. Experimental results show that electron beam physical vapor deposition (EB-PVD) Y2O3-stabilized ZrO2 (YSZ), one of the mainstream TBCs technologies, produced 20% surface spallation after 50 thermal-shock cycles under simulated CMAS corrosion conditions. Testing and analysis of the macroscopic and microscopic structures of the failed samples, combined with SEM, EDS, and XRD findings, revealed significant physical and chemical interactions between the ceramic layer and CMAS deposits, as well as phase transformation within the coatings, leading to substantial alterations in mechanical properties and ultimately causing the failure of EB-PVD YSZ.

Moment Curvature and P-M Interaction Analysis of Steel and GFRP Reinforced Concrete Column

This research explores the use of Glass Fiber Reinforced Polymer (GFRP) bars and GFRP circular sections as longitudinal reinforcement in Reinforced Concrete (RC) columns, specifically to mitigate corrosion issues in harsh coastal environments. Twelve concrete specimens were prepared and tested under various loading conditions to evaluate the performance of GFRP as a substitute for conventional steel reinforcement. The experimental findings indicated that GFRP-RC columns displayed slightly lower axial load and bending moment capacities compared to steel-RC columns, though the ductility of both types was found to be similar. The study also highlights the significance of considering the role of GFRP bars in compression, supported by experimental results. This research offers valuable insights into the behavior and performance of both steel and GFRP-reinforced concrete columns, particularly in environments vulnerable to corrosion, with assessments conducted at 28 and 60-day intervals. A comparison of the outcomes from these timeframes reveals the effectiveness of GFRP as a reinforcement option in corrosive conditions

Spatial distribution of corrosion products from a bridge pier

AbstractThis paper studies the spatial distribution of corrosion by-products by a bridge pier within a conductive medium. An electrochemical impedance spectroscopy (EIS) technique was used to investigate an uncoated metallic bridge pier submerged in static distilled water. An equivalent circuit model, derived from EIS results, served as the foundation for the study. Further, the role of diffusion was analysed, considering its significance in characterising the transfer of particles from the pier into the surrounding water. This exploration revealed the complex interaction between the diffusion processes of various corrosion by-products as a function of distance. In addition, by evaluating the spatial distribution of iron (II) corrosion by-products and modelling nanoparticle diffusion, the research examined the impact of diffusion and concentration on corrosion particle transmission. The findings, analysed via Nyquist and Bode plots, demonstrate significant differences between theoretical and empirical diffusion coefficients. Results indicated that under natural corrosion conditions, the primary product of the corrosion reaction, iron (II), disperses into the medium when oxidation occurs. The elevated resistivity due to the presence of iron (II) underscores the diffusion effect, leading to corrosion product precipitation and reaching saturation level. Additionally, the results demonstrated ideal values for the diffusion coefficient, which are crucial for advanced corrosion modelling. The results emphasised the need for empirical data to improve corrosion prediction models and informed maintenance strategies for submerged structures.

Advanced corrosion-resistant materials for enhanced nuclear fuel performance: A conceptual review of innovations in fuel cladding against molten salt degradation

The increasing demand for efficient and sustainable nuclear power has led to the development of advanced corrosion-resistant materials that can significantly enhance nuclear fuel performance. This conceptual review focuses on the innovations in fuel cladding materials designed to resist degradation in molten salt environments, which are crucial for advanced nuclear reactors like molten salt reactors (MSRs). Fuel cladding serves as a critical barrier between the nuclear fuel and the reactor environment, and its ability to withstand extreme temperatures and corrosive conditions is essential for safe and efficient reactor operation. Recent advancements in materials science have introduced novel alloys and coatings that demonstrate superior corrosion resistance in molten salts, which are used as both coolants and fuel solvents in MSRs. These innovations include high-temperature nickel-based alloys, refractory metals, and ceramic coatings, which are engineered to reduce the effects of molten salt corrosion, such as oxidation, pitting, and embrittlement. By enhancing the durability of fuel cladding, these materials contribute to improved fuel performance, longer reactor lifespans, and increased safety. This review explores key developments in corrosion-resistant materials, emphasizing the mechanisms by which these materials mitigate molten salt degradation. Additionally, it highlights the challenges associated with material selection, fabrication, and long-term performance in the highly corrosive environments of advanced nuclear reactors. Ongoing research into these materials offers promising avenues for the future of nuclear energy, particularly in addressing the limitations of current fuel cladding technologies. In conclusion, the use of advanced corrosion-resistant materials represents a significant step toward enhancing the performance and safety of nuclear fuel, ensuring the viability of MSRs and other advanced reactor designs. Continued innovation in this field is essential for the future of nuclear power.

Insight into performance and lifetime of ecofriendly pollution barriers in landfill for emergency: A thermogravimetric analysis for novel polymer materials

The novel polymer barrier wall is an in-situ remediation technology designed to effectively control the migration of pollution and prevent the diffusion of pollutants by blocking, sealing, or altering the direction of groundwater flow. With its advantages of rapid chemical reaction (achieving 95 % strength within 15 min) and portable equipment suitable for narrow and rugged emergency sites, this innovative polymer barrier demonstrates promising prospects for practical application. Hence, ensuring the long-term durability of new materials under corrosive and high-temperature leachate conditions is crucial. In this study, a comprehensive investigation was conducted on the corrosion and thermal aging performance of novel polymer materials. Firstly, the mechanical tensile properties of the polymer materials were examined after immersion in leachates, aiming to elucidate the degradation mechanism underlying these properties. Subsequently, thermogravimetric (TG) analysis was performed on the polymer materials immersed in various leachates. And the thermal stability and oxidation stability of novel materials were investigated using a thermogravimetric analyzer coupled with a Fourier transform infrared spectrometer (TG-FTIR). Based on the results obtained from thermal analysis, the service life of polymer materials under different pollutants was ultimately predicted utilizing the Arrhenius model. The findings indicate that the novel polymer materials exhibit commendable durability and pose little risk of causing secondary pollution.

Exploring pyrolusite β-MnO2 as a robust support for noble metal catalysts in proton exchange membrane water electrolysis

Proton exchange membrane water electrolysis (PEMWE) represents a promising avenue for producing hydrogen sustainably. Nonetheless, its widespread adoption encounters hurdles owing to the sluggishness of the oxygen evolution reaction (OER) and the expensive noble metal catalysts, particularly iridium (Ir). Our investigation addresses these challenges by examining pyrolusite β-MnO2 as a robust substrate for noble metal catalysts, including iridium (Ir) and ruthenium (Ru), within PEMWE systems. We illustrate that nanostructured β-MnO2 effectively supports Ir and Ru catalysts, resulting in significantly improved catalytic activity for acidic OER compared to conventional IrO2 catalysts. The morphology shows nanorod structures with thicknesses ranging of 30–60 nm. The catalytic activity exhibits a lower overpotential of 215 mV and a higher Ir mass activity of 2268.7 A·gIr−1. The catalyst also exhibits lower Tafel slope value (37.82 mV/dec) and higher reaction kinetics. The catalyst also shows durability for the 12h under corrosive acidic OER conditions. The enhancements in performance can be attributed to the distinctive nanostructure of the Mn1-xTixO2 (MTO) support, which facilitates the even distribution of Ir and Ru catalysts. Additionally, the incorporation of titanium in pyrolusite β-MnO2 enhances the electrochemical durability of the MTO support under challenging acidic OER conditions.

Facet Engineering of Cobalt Manganese Oxide for Highly Stable Acidic Oxygen Evolution Reaction

AbstractDeveloping cost‐effective, robust, and durable catalysts for water oxidation in acidic conditions remains a significant challenge for the practical application of proton exchange membrane electrolyzers. Cobalt‐based spinel catalysts, known for their effective oxygen evolution reaction (OER) activity in acidic environments, are promising alternatives to the costly iridium‐based catalysts. However, their application is often limited by poor stability under corrosive acidic conditions and oxidative potential. Here it is demonstrated that doping Co2MnO4 with Ni effectively regulates the structural and electronic properties of the catalysts, enabling stable operation for over 285 h at 100 mA cm−2 in 0.5 m H2SO4. This stability enhancement is primarily due to the increased exposure of the (400) facet, a result supported by theoretical studies. The proton exchange membrane water electrolysis (PEMWE) performance of Ni(5%)Co2MnO4 further demonstrates its potential, achieving 1 A cm−2 at a cell voltage of 2.3 V, with minimal degradation over 100 h at 500 mA cm−2. This study not only provides insights into the design of advanced OER catalysts through the doping of heteroatoms but also offers a pathway to enhance the sustainability and economic viability of acidic OER applications.

Research on mechanical property degradation model of equipment compartment floor under atmospheric corrosion condition

A mechanical property degradation model of material fatigue life varying with stress level and corrosion time was developed in this study. An acidified NaCl solution was used to accelerate the corrosion of stainless-steel samples, and the relationship between laboratory-accelerated corrosion and atmospheric corrosion was established using corrosion thickness loss parameters. Based on the results of a pre-corroded fatigue test, lgN–S–T surface models and a modified version of Miner’s rule for calculating nonlinear mechanical damage accumulation were proposed. Taking a real part of a high-speed train as an example, critical operating mileages considering material fatigue performance degradation under corrosion conditions were calculated, which were consistent with failure mileages of the census results.

ნიადაგით გამოწვეული ელექტროქიმიური კოროზია ტენიან, ნაკლებ მჟავიან, ნეიტრალურ და ტუტოვან გარემოში

The article analyzes the anodic, transient and cathodic processes of a galvanic cell. Electrochemical corrosion caused by soil in a moist, less acidic, neutral and alkaline environment is discussed. The scheme of corrosion of underground pipelines under various conditions of soil aeration is given. The cases of corrosion process control for various soil corrosion conditions are considered: soil corrosion with prevailing cathodic control; corrosion in loose, dry soils (anodic control); corrosion over long stretches (prevailing ohmic control).

Real-time in-situ coatings corrosion monitoring using machine learning-enhanced triboelectric nanogenerator

Current methods for monitoring coating corrosion are limited by their inability to provide real-time data and dependence on external power sources. This study presents a novel in-situ corrosion monitoring system using a solid-liquid triboelectric nanogenerator (TENG) that converts mechanical energy into electrical signals for self-powered sensing. TENG signals and electrochemical impedance spectra were measured on a dopamine-modified lignin-polydimethylsiloxane coating on steel in 1 M NaCl solution under no corrosion, indentation, pitting, and broken conditions, respectively. We extract time-frequency features from the TENG signals to predict the coating’s corrosion condition by applying a customised convolutional neural network (CNN). By extracting time-frequency features from the TENG signals and applying a custom CNN, a prediction accuracy of 99 % for corrosion classification was achieved. Furthermore, the CNN regression model predicted coating impedance values with a high coefficient of determination (R² = 0.98), demonstrating its effectiveness in tracking corrosion progression. The developed TENG also facilitates defect localisation via a matrix electrode beneath the coating. Our approach introduces a promising real-time technology for in-situ corrosion monitoring.

Effect of Zr addition on the corrosion resistance of Ti-Mo alloy in the H2O2-containing inflammatory environment

Reactive oxygen species (ROS), produced by immune cells during inflammatory reaction, are known to promote corrosion of standard biomedical materials such as CP-Ti and Ti-6Al-4V. Electrochemical corrosion in the ROS environment can be further accelerated in the vicinity of fretting regions, where titanium can be polarized towards negative potentials. This study considers both of these aspects and presents corrosion analysis under complex inflammatory conditions for Ti-Mo and Ti-Mo-Zr alloys, which offer exceptional strain-hardening behavior and ductility. Combining electrochemical impedance spectroscopy (EIS) and atomic emission spectroelectrochemistry (AESEC) allowed us to understand the origin of ROS-induced corrosion. At free corrosion conditions, Zr was found to suppress oxide layer growth without any significant effect on the dissolution process. On the other hand, Zr suppressed dissolution rate under cathodic potentials. Although applying cathodic potential resulted in a rapid increase of dissolution rate, cross-section transmission electron microscopy (TEM) analysis did not reveal significant influence of the short cathodic polarization on the oxide film growth during further prolonged exposure at free corrosion conditions.

Modelling and experimental study on pipeline defect characterisations using a pulsed eddy current measurement

ABSTRACT Pipelines are widely used as the main transportation method in petrochemical and metallurgical industries. However, the special nature of the materials transported in pipelines means they are often subjected to high temperature, high pressure and corrosive conditions. This can lead to defects, such as thinning and cracking, resulting in pipeline failure and causing serious economic losses. Therefore, regular non-destructive testing of pipelines is particularly important. This paper uses the non-destructive testing method with pulsed eddy current technology to characterise pipeline thinning and defects. A preliminary study is conducted on the pulsed eddy current detection signal patterns for pipeline crack defects with varying orientations and quantities. A more portable pulsed eddy current detection device with an extended wall thickness detection range is developed. It can achieve measurements with a maximum thickness of 30 mm for detections of pipelines with rectangular defects and thickness-stepped reduced. The experimental results are consistent with modelling results, and the accuracy for pipelines with insulation layer is also investigated. On-site measurements using the PEC system are conducted on equipment sections with pipe thickness within 20 mm in a petrochemical plant. It is confirmed that the developed PEC inspection device can accurately characterises the thickness of pipelines with 0–50 mm cladding.

Understanding the Effect of Corrosion Resistance in Welded AA2198‐T8 Alloy: Microstructural‐Electrochemical Insights

ABSTRACTIn this study, we explore the corrosion resistance of AA2198‐T8 alloy in friction stir‐welded zones, focusing on microstructure changes and resulting corrosion susceptibility. Macrogalvanic coupling effects are observed in weldment under corrosive conditions, particularly in the welding joint (WJ), heat‐affected zones, and base metal (BM). Severe localized corrosion is prevalent in anodic zones, revealing intricate trenching patterns around micrometric particles in cathodic domains. Investigating isolated zones exposes SLC across all welding‐affected regions and BM, underscoring the involvement of microgalvanic cells in corrosion. The novel utilization of a syringe cell as an electrochemical tool proves to be instrumental in delineating the electrochemical characteristics of welding testing zones. Notably, stir zone within WJ emerges as the region depicting the lowest corrosion resistance, a critical finding substantiated by localized electrochemical impedance spectroscopy. These insights into the interplay of electrochemical phenomena and microstructural attributes have implications for advancing corrosion mitigation strategies and alloy engineering in materials science.

Nonlinear ultrasonic test applied to discern factors controlling cracking of cement mortar affected by reinforcement corrosion

Intermodulation ultrasonic testing technique was used to detect corrosion- induced cracking in prismatic mortar samples. Three sets of five specimens were prepared and subjected to accelerated corrosion conditions. The different times of exposure allowed to attain unlike damage conditions in every sample of each set. The onset of damage was monitored through the evolution of the accumulated Intensity Modulation Ratio (R) and crack width measurements. The accumulated values of the Intensity Modulation Ratio were used to study the effect of different testing factors (cover depth, corrosion rate or amplitude of the input pump signal) and increased monotonically clearly discriminating the different damage levels. These observations point to the possibility of stablishing damage thresholds to detect cracking using nonlinear ultrasonic (NLU) techniques.

Anticorrosion and rheological properties of Calyptocarpus vialis extract as a green coating for mild steel in 2MH2SO4

This study assesses the rheological properties and corrosion inhibition efficacy of Calyptocarpus vialis (CV) extract, a wild plant in Asteraceae family. Shear and dynamic rheology studies show that CV extract has shear-thinning behaviour, with viscosity changes occurring at higher shear rates, most likely owing to aggregate formation. These aggregates may develop due to certain solvent characteristics and a jamming tendency is due to the presence of extract phytochemicals. Dynamic rheology confirms its viscoelastic nature. Corrosion inhibition effectiveness was investigated using Mild Steel (MS) in 2 M H2SO4, resulting in an 82.69 % inhibition with an extract concentration of 1 g/L. Adsorption isotherm indicates phytochemical adsorption on MS surface. Contact angles of polished MS (87.30°), with extract (80.10°), and without extract (51.25°) show decrease in wetting and increase in hydrophobicity which indicates that a thin protective layer is formed at MS surface. FE-SEM (Field Emission Scanning Electron Microscopy) images reveal that the CV extract forms a protective barrier on the MS surface, significantly reducing corrosion as compared to the unprotected surface exposed to the mild acid solution. Theoretical calculations, including Density Functional Theory (DFT) simulations, Monte Carlo (MC), and Molecular Dynamics (MD) simulations, support the experimental findings, elucidating phytochemicals adsorption on the MS surface. Further research is required to examine the scalability of CV extracts for industrial applications, as well as their long-term stability and efficacy in various corrosive conditions.

Highly thermally conductive and anti-corrosive silicone grease enabled using unique hexagonal boron nitride nanosheet/alumina microsphere-based hierarchical structure for heat dissipation in a humid environment

Electronic devices operating in the marine environment often face severe corrosion. In addition, highly integrated and powerful devices generate a notable amount of heat, which may lead to a deterioration in performance and reliability. Therefore, it is essential to develop thermal interface materials (TIMs) with high thermal conductivity and outstanding corrosion resistance for efficient and stable heat dissipation. Herein, a novel hierarchical three-dimensional structure comprising hexagonal boron nitride sheet wrapped alumina microsphere/hexagonal boron nitride flakes (Al2O3@BNNS-BNFs) has been fabricated, which can simultaneously improve the thermal conductivity and corrosion resistance of silicone grease (SG). The dispersibility of BNFs in SG is enhanced by the uniform distribution of Al2O3@BNNSs, while the BNNSs attached to the surface of Al2O3 microspheres improves the compatibility of BNFs and Al2O3 microspheres, thereby effectively enhancing the thermal conductivity of SGs. The thermal conductivity of the Al2O3@BNNS-BNFs/SG can reach up to 1.98 W/(m·K) when the content of Al2O3@BNNS-BNFs is 20 wt%, which is ∼13 times that of ordinary SG. Meanwhile, the Al2O3@BNNS-BNFs/SGs also demonstrate excellent electrical insulation (1.50 × 1013 Ω cm) and corrosion resistance compared to some commercial products. Furthermore, subsequent tests indicate that the Al2O3@BNNS-BNFs/SGs can effectively dissipate heat for electronic devices in various humid environments. These unique properties make the Al2O3@BNNS-BNFs/SGs promising as multifunctional TIMs for thermal management in complex environments, especially in humid or corrosive conditions.

Corrosion behavior of novel Ti6422 alloy with equiaxed structure and lamellar structure in HCl solution

This study systematically investigated the electrochemical corrosion and static immersion corrosion behavior of the novel Ti6422 (Ti-6Al-4V-2Mo-2Fe) alloy with equiaxed (EM) and lamellar structure (LM) in HCl solution. The differences in corrosion performance between EM and LM samples were analyzed based on the characteristics of the passive film and substrate microstructure. Results indicated that the LM sample contained higher contents of TiO₂, Al₂O₃, and MoO₃ with higher stability compared with the EM sample, and the thickness of passive film was approximately twice that of the EM sample. Additionally, the donor density of LM sample was lower than EM sample. These findings indicate that the passive film on LM samples is thicker, with fewer defects and higher density. Electrochemical corrosion results revealed that the corrosion current of LM samples was lower and the polarization resistance was higher than these of EM samples, both suggesting superior corrosion resistance of LM samples. Immersion corrosion further confirmed that the LM sample had a lower corrosion rate. The enhanced corrosion resistance in LM samples was primarily due to higher content of corrosion-resistant β phase. Conversely, the numerous micro-galvanic cells between αs precipitates and adjacent β phase in EM samples weakened the corrosion resistance. Overall, these results demonstrated that regulating microstructure through heat treatment is an effective strategy for improving corrosion resistance of titanium alloys.

Effect of Y2O3 content on the corrosion behavior of Cu-10W composites prepared by spark plasma sintering

Cu-W composites with good mechanical properties, electrical properties and corrosion resistance are still rare. In this study, Y2O3 reinforced Cu-10W composites were prepared by spark plasma sintering. The effects of different Y2O3 contents on the corrosion resistance of Cu-10W composites were studied by static immersion corrosion and electrochemical corrosion. The results show that, the incorporation of Y2O3 makes the microstructure of Cu-10W composites dense and grain refinement. The minimum weight loss value can be obtained when Y2O3 content is 2 wt%. Y2O3 can effectively increase the self-corrosion potential and corrosion current density of Cu-10W composites and enhance the electrochemical impedance level. And Y2O3 can increase the resistivity ring radius, which leads to the increase of charge transfer resistance Rct and the decrease of Warburg impedance Zw.

Electrochemical activation of Pt electrode for efficient and stable anion exchange membrane ammonia electrolyzer

Replacing the oxygen evolution reaction in water electrolysis with ammonia oxidation reaction enables low voltage hydrogen production. Pt is a promising catalyst for the ammonia oxidation reaction due to its superior dehydrogenation and low affinity for *N, but Nads poisoning deactivates the Pt surface. This study proposes a method to improve ammonia oxidation performance and stability through electrochemical activation, introducing cathodic corrosion and recovery conditions. The half-cell results showed a peak current density of 74.2 mA cm−2 and retention ratio of 17 %. Adjusting the lower and upper cell voltage in a membrane electrode assembly based single cell optimized surface cleaning and inhibits further poisoning by O/OHads above 0.75 Vcell. Furthermore, incorporation of recovery conditions can enhance the stability of poisoned electrode compared to that in chronoamperometry test. The results of pulsed ammonia electrolysis tests incorporating recovery conditions suggested a novel approach to practical hydrogen production by stabilizing catalysts with a 83 % Faradaic efficiency at 0.1 A cm−2

Microstructures, physical and corrosion behavior of NiCoFeCu high-entropy alloy nanocomposite coatings electro-co-deposited with nano-Si3N4 particles

High-entropy alloys (HEAs) have gained increasing attention over the decades, owing to their distinctive properties. Electrodeposition stands out as a cost-effective and convenient method for producing diverse types of HEAs. However, there's little attention paid to fabricating ceramic-enhanced HEA composites. In this study, NiFeCoCu/Si3N4 HEA nanocomposites were electro-co-deposited in an aqueous solution with varying loadings of Si3N4 nanoparticles and current densities. The morphological, elemental, and phase-structure characteristics were investigated using scanning electron microscopy (SEM), energy dispersive X-ray spectroscopy (EDX), and X-ray diffraction (XRD) techniques. The Vickers-microhardness measurements, reciprocal wear, and electrochemical tests were conducted to evaluate the physical and anti-corrosion performance of the composite coatings. The findings indicate that the incorporation of Si3N4 nanoparticles not only changes the surface morphologies, compositions, and textures of the HEA matrix but also significantly enhances both the wear and anti-corrosion performance in artificial water by refining the microstructures and reducing the defects of the composite coatings. The HEA-3 g/L-Si3N4-40 mA/cm2 and HEA-6 g/L-Si3N4-40 mA/cm2 composite coatings demonstrate the best wear performance and anti-corrosion properties among the samples investigated, respectively. The present study shows a significant improvement in the mechanical and anti-corrosion properties of HEA coatings by incorporation of Si3N4 nanoparticles, which is a very promising approach for the surface protection of engineering materials used in corrosive and frictional-working conditions.