Corrosion Behavior Research Articles

Oxidation behavior and corrosion resistance of CoCrFeNi high entropy alloy compared with FeCoNi medium entropy alloy

The entropy-based alloy with excellent oxidation and corrosion resistance is of great significance for practical applications in high-temperature environments. Thus, the difference in anti-oxidation property and corrosion behavior of FeCoNi MEA and CoCrFeNi HEA in a simulated marine environment was studied via a series of measurements. The results reveal that the HEA possesses superior oxidation and corrosion resistance in comparison with the MEA, which can be demonstrated by comparing the oxidation rate and thickness of oxide layer, corrosion current density (icorr) as well as corrosion morphology after polarization. The microstructure and composition of the oxide layer are the primary reasons resulting in the difference of oxidation and corrosion behaviors of the two alloys. The oxide layer with a compact, even and intact structure is produced on the HEA surface, which hinders the diffusion of detrimental ions and oxygen, whereas the loose, porous and cracked oxide layer consisting of inner Fe3O4 and outer CoO exhibits poor protection against corrosion and oxidation of the MEA. For the HEA, the preferential combination of Cr and O elements forms the protective oxide of Cr2O3, effectively enhancing corrosion resistance and inhibiting oxidation. However, the low protective CoO and relatively active Fe3O4 grow on the MEA surface, which cannot provide a good barrier to restrain oxidation and corrosion.

Effect of shot peening on surface characteristics and high-temperature corrosion behaviour of super 13Cr martensitic stainless steel

Super 13Cr, as an economy stainless steel (SS) for oil country tubular goods, needs stable corrosion resistance in high-pressure and high-temperature (HPHT) downhole medium. Severe plastic deformation (SPD) are the surface modification technology to improve mechanical properties, fatigue behavior and corrosion resistance of metals, and shot peening (SP) has been the most widely used SPD process. However, there are quite limited studies about the microsutructure evolution, residual stress, and high-temperature corrosion behavior of SP treated martensitic SS. In this study, super 13Cr martensitic SS was treated by shot peening with various air pressures and nozzle speeds. The surface characteristics and high-temperature corrosion behaviour in 3.17 mol/L K2HPO4 solution was investigated through finite element model analysis, characterization of residual stress and microstructure, as well as electrochemical and stress corrosion cracking (SCC) tests at 160 °C and 10 MPa. The results showed that SP treated super 13Cr could generate high-level compressive residual stress and SPD microstucture, including nano-sized equiaxed grains, gradient lamellar structure and fragmented carbides. Increasing air pressure contributed to achieve uniform nanocrystalline, but tended to generate high dislocation density and surface defects. The improving effect of SP treatment at low air pressure of 0.15 MPa on passivation ability was limited, and high air pressure adversely impacted corrosion resistance. SP treated specimens showed high SCC susceptibility, due to the introduction of more surface defects, high angle grain boundaries, and dislocations.

Influence of Nb/V on the corrosion behavior of high-strength anti-seismic rebar in marine environments

In this study, the immersion test, surface analysis, cross-section analysis, quantitative analysis and electrochemical analysis were used to study the influence of Nb/V on the corrosion behavior of high-strength anti-seismic rebar in marine environments. The corrosion results clarified that the addition of Nb/V improved the corrosion resistance of the rebar, thereby reducing the corrosion rate of the rebar and improving the stability of corrosion layers. Firstly, the addition of Nb/V promoted the transformation of unstable Fe oxyhydroxides to stable Fe oxyhydroxides in the surface corrosion layers of the rebar, thus increasing the α/(β + γ) ratio, corrosion potential and total impedance value. Secondly, the addition of Nb/V induced the formation of Nb oxides and V oxides in the surface corrosion layers of the rebar, and the existence of these oxides repaired the surface defects of corrosion layers, thus enhancing the corrosion resistance performance of surface corrosion layers of the rebar.

Effect of alternating current density on corrosion behaviour of X65 steel in weakly alkaline soil environment without cathodic protection

Effect of alternating current density on corrosion behaviour of X65 steel in weakly alkaline soil environment without cathodic protection

Effects of MgO on the fibre spinnability, mechanical properties and acid resistance of simulated Martian soil

The ultimate goal of Mars exploration is to construct a Mars base. In particular, it is necessary to prepare fibres by using Martian soil as a raw material. High-strength "Martian glass fibres" can be used to reinforce composite materials to meet the requirements of high-strength functional materials in base construction. Owing to the wide variation in MgO content in Martian soil, in this study, the effects of MgO on the structure, strength and acid resistance of "Martian glass and glass fibres" were investigated. The preparation conditions and mechanical properties of simulated Martian soil fibre (SMSF) were studied via DSC, XRD, Raman, NMR, FT-IR and high-temperature rotational viscometry. The corrosion behaviour of MgO-SMSF in H2SO4 solution was subsequently studied via SEM/EDS. The results showed that MgO reduces the spinnability window and prevents the fibres from stretching continuously, and a threshold appears to exist at 10.89 % MgO. The viscosity of the melt decreased significantly, and the crystallization trend increased with MgO above the threshold. The fibre tensile strength showed a nonlinear relationship with a 22.85 % increase in the fibre tensile strength at 9.24 % MgO. SEM/EDS revealed that the surface of the SMSF formed a gel layer, and the mass retention of the MgO-SMSF in the H2SO4 solution reached 90.17 %. The corrosion of SMSF under acidic conditions was controlled by ion diffusion, with Mg+ and Ca+ diffusing to the fibre surface, resulting in nonuniform corrosion. Raman-based statistical structureproperty modelling further explains the impact of MgO-induced structural changes on the tensile strength and elastic modulus, with good agreement between the model predictions and measured values.

Microstructures and Corrosion Behaviors of Non-Equiatomic Al0.32CrFeTi0.73(Ni1.50−xMox)(x = 0, 0.23) High-Entropy Alloy Coatings Prepared by the High-Velocity Oxygen Fuel Method

Microstructures and Corrosion Behaviors of Non-Equiatomic Al0.32CrFeTi0.73(Ni1.50−xMox)(x = 0, 0.23) High-Entropy Alloy Coatings Prepared by the High-Velocity Oxygen Fuel Method

Corrosion behavior and strengthening mechanism of Ni-Cu alloy coating on Nd-Fe-B magnets

Corrosion behavior and strengthening mechanism of Ni-Cu alloy coating on Nd-Fe-B magnets

Insight into patina formed on beryllium-bronze after 29 years of exposure in an industrial environment and DFT research

This research explores the corrosion behavior of beryllium bronze over a period of 29 years in an industrial atmosphere, revealing an average corrosion rate of 0.557 μm·a−1. The skyward patina layer primarily consists of Cu2O, Cu4SO4(OH)6 and CuSO4, while the field-ward patina layer contains Cu2O, CuO, Cu4SO4(OH)6 and CuSO4. Density functional theory (DFT) calculations and XPS analysis show that Be oxidizes preferentially, providing early-stage corrosion protection. DFT and open circuit potential measurements suggest that the patina layer on the field-ward surface is more thermodynamically stable, but cracks serve as pathways for mass transport, accelerating corrosion.

The corrosion behavior of borosilicate glass in the presence of cementitious waste forms.

Borosilicate glasses are widely used for radioactive waste disposal due to their ability to incorporate a variety of contaminants and radionuclides while exhibiting high durability in various disposal scenarios. This research evaluated the dissolution of borosilicate glass using both single-pass-flow-through (ASTM C1662-18) and product consistency test (ASTM C1285-21) methods with different solutions, including a cementitious-contacted water (called grout-contacted, GC, from this point) and solutions with varying levels of dissolved cementitious species such as Si, Ca, Al. The results indicated that the presence of Ca plays a crucial role in suppressing glass corrosion, as evidenced by the slower normalized dissolution rates, which were one order of magnitude lower for boron and two orders of magnitude lower for rhenium, observed in both Ca-amended and GC solutions compared to the pH 12 buffer solution. This effect is attributed to the formation of a dense, low-porosity, and strongly bonded calcium silicate hydrate (CSH) layer on the glass surface, which implies that a glass corrosion process is influenced by ion exchange involving alkali ions Na+, K+, Ca2+, and hydrogen-containing species. A small number of glass particles treated in the GC solution showed minor corrosion pits in the form of shallow craters with an average diameter of approximately 500 μm. This observation is correlated with a significant reduction, 2000 to 3000 times lower, in the cumulative volume of glass pores, indicating that smaller pore voids were "sealed" in the presence of Ca2+ ions, likely attributed to the formation of CSH precipitation or other corrosion products such as calcium carbonate saturated from the grout solution. These findings suggest that the presence of dissolved Ca in the GC solution can slow down the dissolution of borosilicate glass, contrary to the expected trend of higher dissolution rates resulting from exposure to high alkaline and thus higher pH solutions.

Tribological and electrochemical behaviour study of porous TiNiCu alloys manufactured by the powder metallurgy process

ABSTRACT The experimental work aims to study the effect of the Copper (Cu) addition on the tribological and electrochemical behaviour of porous Ti50Ni50-x-Cux alloys. In the first step pure metal powders of titanium (Ti), nickel (Ni), and Cu were ball-milled during 8 h in a planetary ball mill, and then compacted under a 4 ton load to obtain pre-alloyed powders. The final step is sintering at 950°C for 7 h in a tubular furnace under a controlled atmosphere. X-ray diffraction measurements (XRD), scanning electron microscopy (SEM) analyses, microhardness measurements, friction tests and electrochemical were carried out to characterise the tribological and electrochemical performances of the elaborated specimens. DRX results reveal the formation of four major phases: TiNi, Ti2Ni, TiNi3 and TiNi0.8Cu0.2. Potentiodynamic polarisation tests show the positive effect of adding Cu on corrosion resistance, where the 6% Cu sample exhibits the best corrosion behaviour. Tribological results show a decrease in the coefficient of friction and wear rate with the addition of Cu, compared to the initial state, without Cu addition. The minimum coefficient of friction (0.585) was recorded for the 2% Cu sample, while the minimum wear rate (Ws = 1.06. E−4mm3/N/m) was achieved for the 4% Cu sample.

Corrosion behavior of SMSS 13Cr and SS 316L under chloride solution and H2S/CO2 environments

Abstract Corrosion resistant alloys (CRAs) include a range of different stainless steels and nickel alloys that are used in corrosion-aggressive environments encountered in oil and gas operations. Supermartensitic stainless steel (SMSS 13Cr) has been used in the manufacture of steel tubes for use in oil drilling due a more financially viable option to replace the austenitic stainless steel (SS 316L) in the oil and gas market. This present work estimate the effect of the hydrogen sulphide (H2S) on SMSS 13Cr and SS 316L, in saline solution, simulating the operating conditions in the oil and gas industry. Corrosion behavior was monitored using Potentiodynamic-Potentiostatic-Potentiodynamic (PD-PS-PD) technique in order to obtain pitting potential (Ep) or crevice potential (Ecrev)) and repassivation potential (Erp) while the long-term Open Circuit Potential (OCP) technique was applied to estimate the stable corrosion potential (Ecorr*). A Scanning Electron Microscope (SEM) equipped with Energy Dispersive X-ray Spectroscopy (EDS) and Optical Microscopy were used for surface characterization. With all analysis carried out was possible to propose a trend regarding the pitting probability. The pitting increases with increasing H2S concentration on SSSM 13Cr, consequently, large, and deeper pits were observed, making possible to develop into cracks if there are mechanical stresses. On the contrary, the pitting probability for the SS 316L is low (compared with SMSS 13Cr) for all environments reproduced here in this research.

Influence of Single- and Double-Aging Treatments on the Mechanical and Corrosion Resistance of Alloy 625

Nickel–chromium–molybdenum Alloy 625 exhibits an excellent combination of mechanical properties and corrosion resistance. However, the high-temperature plastic deformation process and the heat treatment represent critical aspects for the loss in mechanical strength by grain coarsening. This detrimental behavior is worsened by the absence of phase transformation temperatures. However, the chemical composition permits slow precipitation-hardening response upon single aging. Therefore, when the soft- or solution-annealed condition is associated with insufficient mechanical properties, this potentiality can be exploited to improve the mechanical strength. Since the 𝛾″ precipitation can be accelerated by double-aging treatment, different time–temperature combinations of double aging at 732 °C and 621 °C are investigated. The simultaneous precipitation of intergranular carbides can dramatically affect the corrosion resistance. Such an undesired phenomenon occurs very quickly at 732 °C, but it is obtained only after very long exposure times at 621 °C. For this reason, a performance chart is developed to compare all the tested conditions. In particular, single aging at 621 °C for 72 h and 130 h are associated with an acceptable combination of mechanical and corrosion properties. Double aging permits a conspicuous acceleration of the aging response. For instance, with double aging at 732 °C 3 h and 621 °C 72 h, it is possible to obtain the same mechanical properties of single aging at 621 °C for 260 h. Such acceleration is accompanied by a more critical corrosion behavior, especially because of the primary step. However, even after its optimization, none of the tested conditions were acceptable.

Effect of seawater salinity, pH, and temperature on external corrosion behavior and microhardness of offshore oil and gas pipeline: RSM modelling and optimization

This research aims to investigate the effects of seawater parameters like salinity, pH, and temperature on the external corrosion behaviour and microhardness of offshore oil and gas carbon steel pipes. The immersion tests were performed for 28 days following ASTM G-1 standards, simulating controlled artificial marine environments with varying pH levels, salinities, and temperatures. Besides, Field emission scanning electron microscopy (FESEM) analysis is performed to study the corrosion morphology. Additionally, a Vickers microhardness tester was used for microhardness analysis. The results revealed that an increase in salinity from 33.18 to 61.10 ppt can reduce the corrosion rate by 28%. In contrast, variations in seawater pH have a significant effect on corrosion rate, with a pH decrease from 8.50 to 7 causing a 42.54% increase in corrosion rate. However, the temperature of seawater was found to be the most prominent parameter, resulting in a 76.13% increase in corrosion rate and a 10.99% reduction in the microhardness of offshore pipelines. Moreover, the response surface methodology (RSM) modelling is used to determine the optimal seawater parameters for carbon steel pipes. Furthermore, the desirability factor for these parameters was 0.999, and the experimental validation displays a good agreement with predicted model values, with around 4.65% error for corrosion rate and 1.36% error for microhardness.

Corrosion behavior of Cu-Ni-Fe-Mn-Cr alloy in 3.5 wt.% NaCl solution

Abstract A novel Cu-10Ni-1.7Fe-0.5Mn-0.2Cr alloy was fabricated and exposed to neutral 3.5 wt.% NaCl solution for various days. The corrosion performance, corrosion film, and corrosion mode of the alloy were investigated in detail. The results suggested that the average corrosion rate reduced from 0.082 mm/a for one-day immersion sample to 0.037 mm/a for thirty-day immersion sample. The reduction in corrosion rate was mainly attributed to the progressive thickness and densification of the corrosion film, leading to increasing the resistance of corrosion film with the prolonging exposure time. Low-valent oxides and chlorinated compounds were generated over the one-day immersion sample surface, while high-valent oxides and hydroxide compounds were developed over the thirty-day immersion sample surface. The mature corrosion film typically composed of Cu2O, CuO, Cu2(OH)3Cl, γ-FeOOH, MnO2, and Cr2O3. Eventually, the alloys suffered from the selective corrosion and intergranular corrosion after a long exposure time in NaCl solution.

Early corrosion behavior of low carbon 9Cr-ODS steel in high temperature oxygen-saturated lead-bismuth eutectic

The early corrosion behavior of low carbon 9Cr-ODS steel in 500 °C oxygen-saturated LBE was investigated. The thickness of the oxide film was found to increase with the duration of corrosion. Results from Scanning Electron Microscopy (SEM), Transmission Electron Microscopy (TEM), and the Shanghai Synchrotron Radiation Facility (SSRF) indicate that the oxide layer on 9Cr-ODS steel is multilayered, consisting of a (Fe, Cr)3O4 spinel inner layer, a nanocrystalline transition layer rich in Cr and Mn but poor in Fe, and an Fe3O4 outer layer. The corrosion mechanism of low carbon 9Cr-ODS steel in liquid LBE is discussed.

Experimental Investigation of Corrosion Behavior of Zinc–Aluminum Alloy-Coated High-Strength Steel Wires under Stress Condition

Experimental Investigation of Corrosion Behavior of Zinc–Aluminum Alloy-Coated High-Strength Steel Wires under Stress Condition

High-temperature corrosion testing of titanium beryllides in the presence of water vapor and oxygen

Beryllium-based intermetallics are promising materials for the blankets of future fusion reactors and have potential applications in other areas of the nuclear industry, such as fission reactor reflectors and space technology. Understanding the high-temperature corrosion behavior of these materials in a noble gas medium containing chemically active impurities is essential for evaluating their suitability and guiding their application.This study investigates the high-temperature corrosion of titanium beryllide Be12Ti in the form of plate and grinded samples, produced by JSC “Ulba Metallurgical Plant” (Ust-Kamenogorsk, Kazakhstan). The corrosion tests were conducted under non-isothermal vapor-gas mixture (Ar + D2O or Ar + H2O flowing atmospheres) purging conditions using thermogravimetric (TG) analysis, differential scanning calorimetry (DSC), and mass-spectrometry of the gas phase.As a result of the corrosion tests, new experimental data on thermal effects have been obtained, describing the corrosion processes of Be12Ti samples across a wide range of temperatures and various heating rates in the presence of water vapor in the purge gas. The dependencies of sample mass change under heating conditions have been determined, and the characterization results of the samples before and after high-temperature corrosion tests are presented.Corrosion of titanium beryllides, both for Be12Ti plate and grinded samples, follows similar mechanisms. At around 500 °C, the mass of the samples begins to increase, and hydrogen isotopes are released. The test results indicate that corrosion of titanium beryllides with varying surface inhomogeneities proceeds similarly within the temperature range of 500–900 °C, showing a linear dependence on temperature.The results revealed significant insights into the oxidation mechanisms and the formation of corrosion products, which are crucial for optimizing the material's performance in fusion reactor environments.

Influence of Post-Heat Treatment on Corrosion Behaviour of Additively Manufactured CuSn10 by Laser Powder Bed Fusion

This study investigates the influence of heat treatments on the corrosion behaviour of CuSn10 tin bronze, additively manufactured using Laser Powder Bed Fusion (LPBF). LPBF enables the creation of finely structured, anisotropic microstructures, whose corrosion behaviour is not yet well understood. After production, specimens were heat-treated at 320 °C, 650 °C, and in a two-stage treatment at 800 °C and 400 °C, followed by hardness and microstructure analysis. Corrosion tests were conducted using linear polarisation, salt spray, and immersion tests. The results show that heat treatments at 320 °C and 650 °C have no significant effect on the corrosion rate, while the two-stage treatment shows a slight improvement in corrosion resistance. Differences in microstructure and hardness were observed, with higher treatment temperatures leading to grain growth and tin precipitates. The formation of a passive protective layer was detected after 30 h of OCP measurement. Results from other studies on corrosion behaviour were partially reproducible. Differences could be attributed to varying chemical compositions and manufacturing parameters. These findings contribute to the understanding of the effects of heat treatments on the corrosion resistance of additively manufactured tin bronze and provide important insights for future applications in corrosive environments.

Accelerated microbiologically influenced corrosion of copper by sulfate‐reducing bacterium Desulfovibrio desulfovibrio

AbstractThe corrosion behavior and electrochemical damage mechanisms induced by sulfate‐reducing bacteria (SRB) on copper (Cu) were investigated in this study. Electrochemical impedance spectroscopy revealed that SRB accelerated the corrosion of Cu, albeit with a mitigating effect observed due to the formation of a protective and dense biofilm. However, upon the rupture of this protective film, the corrosion tendency of Cu significantly increased. Surface analysis corroborated these findings, with the predominant corrosion product identified as Cu2S, a result further supported by thermodynamic calculations. The accelerated corrosion of Cu was primarily attributed to the physiological metabolism of SRB, which generates hydrogen sulfide as the principal agent driving corrosion processes.

How Often Should Microbial Contamination Be Detected in Aircraft Fuel Systems? An Experimental Test of Aluminum Alloy Corrosion Induced by Sulfate-Reducing Bacteria

Microbial contamination in aircraft fuel-containing systems poses significant threats to flight safety and operational integrity as a result of microbiologically influenced corrosion (MIC). Regular monitoring for microbial contamination in these fuel systems is essential for mitigating MIC risks. However, the frequency of monitoring remains a challenge due to the complex environmental conditions encountered in fuel systems. To investigate the impact of environmental variables such as water content, oxygen levels, and temperature on the MIC of aluminum alloy in aircraft fuel systems, orthogonal experiments with various combinations of these variables were conducted in the presence of sulfate-reducing bacteria. Among these variables, water content in the fuel oil demonstrated the most substantial influence on the corrosion rate of aluminum alloys, surpassing the effects of oxygen and temperature. Notably, the corrosion rate of aluminum alloys was the highest in an environment characterized by a 1:1 water/oil ratio, 0% oxygen, and a temperature of 35 °C. Within this challenging environment, conducive to accelerated corrosion, changes in the corrosion behavior of aluminum alloys over time were analyzed to identify the time point at which MIC intensified. Observations revealed a marked increase in the depth and width of corrosion pits, as well as in the corrosion weight-loss rate, starting from the 7th day. These findings offer valuable insights for determining the optimal frequency of microbial contamination detection in aircraft fuel systems.