Corrosion Behavior Research Articles

Effect of reinforcement particle size on the corrosion and mechanical properties of spark plasma sintered aluminium matrix composites.

In this study, the effects of different sizes of reinforcing particles on the corrosion behaviour and mechanical properties of aluminium (Al)-based composites produced by spark plasma sintering (SPS) are analysed. In the study, the effects of SPS parameters, including electrical power, applied pressure and sintering temperature, on the consolidation process and microstructure evolution of the composite are closely investigated. The results reveal a nuanced relationship between the sintering conditions and the properties of the particles, which in turn determine the sintering dynamics and the formation of the microstructural features. The evaluation of mechanical properties indicates a remarkable influence of particle size distribution on the hardness of the composites, showing an initial improvement with the introduction of nanoparticles, followed by a slight decrease as the balance between nano- and micron-sized Al2O3 particles shifts. A scanning electron microscopy (SEM) study demonstrates the influence of particle dimensions on the change of grain boundaries and the spatial arrangement of the composite matrix. Electrochemical experiments in a 0.1M NaCl solution show a consistent corrosion potential (Ecorr) across all samples, while the current densities associated with corrosion (icorr) show considerable variation. The presence of nano-sized Al2O3 particles was found to increase corrosion resistance, in contrast to the detrimental effects observed with larger microparticles. In particular, composites with a bimodal distribution of particle sizes showed a 3.5-fold increase in corrosion resistance compared to pure Al. The specific Al-2n8mAl2O3 composite that exhibited active electrochemical properties at elevated potentials without a defined passivation range emphasises the significant role of particle size. This study draws attention to bimodal microstructures as a promising route to achieving uniformity and improved corrosion resistance in Al matrix composites, while pointing to the need for further research to fully elucidate the operative mechanisms.

Effect of air pressure and flow on steels materials in simulated wet fire drives

The corrosion behaviour of N80, 3Cr, and 5Cr steels were investigated under wet fire drive conditions using a high-temperature and high-pressure autoclave, weight-loss method, and scanning electron microscopy analysis. The findings indicated that elevated air pressure (4–6 MPa) and flow rates (0.5–1.5 m/s) significantly exacerbated corrosion, leading to both localised pitting and general corrosion on the steel samples. Predominant components of the corrosion product scales were identified as FeCO3 and Cr2O3. Notably, N80 steel exhibited higher pitting sensitivity compared to 3Cr and 5Cr steel, whereas 5Cr steel demonstrated superior corrosion resistance under the experimental conditions. Consequently, it is recommended to use cost-effective pipes with adequate corrosion resistance, such as various low-alloy pipes with differing chromium (Cr) contents, in oilfield applications. This study underscores the importance of selecting corrosion-resistant pipes as a primary means of corrosion prevention in oil and gas operations. Furthermore, it provides valuable insights into the corrosion performance of diverse steel materials in wet fire drive environments, offering pertinent implications for corrosion mitigation strategies within the industry.

The corrosion analysis of X80 pipeline steel welded joint using wire beam electrode and numerical simulation methods

Purpose The purpose of this study is to characterize the galvanic corrosion behavior of a simulated X80 pipeline steel welded joint (PSWJ) reconstructed by the wire beam electrode (WBE) and numerical simulation methods. Design/methodology/approach The galvanic corrosion of an X80 PSWJ was studied using WBE and numerical simulation methods. The microstructures of the coarse-grained heat affected zone, fine-grained heat affected zone and intercritical heat affected zone were simulated in X80 pipeline steel via Gleeble thermomechanical simulation processing. Findings Comparing the corrosion current density of coupled and isolated weld metal (WM), base metal (BM) and heat-affected zone (HAZ), the coupled WM exhibited a higher corrosion current density than isolated WM; the coupled BM and HAZ exhibited lower corrosion current densities than isolated BM and HAZ. The results exhibited that the maximum anodic galvanic current fitted the Gumbel distribution. Moreover, the numerical simulation results agreed well with the experimental data. Originality/value This study provides insight into corrosion evaluation of heterogeneous welded joints by a combination of experiment and simulation. The method of reconstruction of the welded joint has been proven to be a feasible approach for studying the corrosion behavior of the X80 PSWJ with high spatial resolution.

The effect of tempering time and cooling environment on the corrosion behavior of AA5083‐H111 alloy

AbstractThe tempering process can increase the mechanical properties of the material, such as hardness and impact strength, as well as enhance the corrosion resistance. Therefore, the selection of appropriate tempering time and cooling environment is crucial. This study aims to investigate changes in properties such as hardness, tensile strength, corrosion resistance, and microstructure of AA5083‐H111 alloy after a brief tempering process (30 minutes, 45 minutes and 60 minutes) at 320 °C, followed by cooling in air and water environments. The study found that tempering time and cooling environment significantly affect the mechanical properties and corrosion rate. The results show that samples labeled as S30 and S60 have the highest hardness and impact strength, but the best corrosion resistance is achieved in the S60 sample. This study demonstrates that even after a limited‐term tempering process, the mechanical properties and corrosion resistance of AA5083‐H111 alloy can be improved. This information is crucial data for use in the production and application of alloys. The findings of this study could have important implications for the production and application of AA5083‐H111 alloy in industries such as aerospace, automotive, and marine engineering.

In vitro degradation behavior of grain refined WE43 magnesium alloy for biodegradable temporary implant applications

AbstractIn the present work, grain‐refined WE43 magnesium alloy was produced by friction stir processing to investigate the in vitro degradation behavior targeted for temporary bone implant applications. Friction stir processing resulted in significant grain refinement (from 46±4.2 μm to 16.1±5.4 μm) as observed from microstructural studies. Increased wettability was observed from the contact angle measurements in grain‐refined WE43 alloy. The corrosion behavior of the base alloy and the grain refined alloy assessed by potentiodynamic polarization tests demonstrated the influence of the smaller grain size and decreased intermetallics on enhancing corrosion resistance. Immersion studies carried out in simulated body fluids for one week indicated a quick development of the protective magnesium hydroxide on the surface of grain‐refined WE43 alloy compared with the base alloy. The deposition of the mineral phases from the immersed solution on the surface of the samples was studied by scanning electron microscopy and x‐ray diffraction analysis to assess the effect of microstructure on the biomineralization. Promisingly, grain refined WE43 exhibited relatively excellent mineral deposition which further helped to control the degradation of the alloy. The weight loss measurements of the samples from the immersion tests were also in good agreement with the electrochemical test results. Hence, the results demonstrate the promising role of grain refinement by friction stir processing in tailoring WE43 magnesium alloy with better degradation behavior for temporary bone implant applications.

Corrosion Behavior of 3104 Aluminum Cans When Used as Packaging for Chinese Liquor

Aluminum cans are commonly used for packaging soft drinks and low-alcohol beverages due to their good recyclability. To enhance the economic cycle and expand the packaging of liquors, the feasibility of commercial 3104 aluminum cans for packaging Chinese liquor was studied. The aluminum’s migration into alcoholic solutions was studied using inductively coupled plasma emission spectroscopy (ICP-OES). Electrochemical impedance spectroscopy (EIS) was used to study the corrosion process of epoxy coatings on the aluminum cans. Scanning electron microscopy (SEM), energy dispersive X-ray spectroscopy (EDS), infrared attenuated total reflection (IR-ATR), and X-ray diffraction (XRD) were used to determine the inner coatings and adhering surfaces of the cans and the corrosion process. The results showed that the maximum aluminum migration in Chinese liquor was 4.3572 mg/kg at 60 °C for 30 days. The epoxy coating was corroded enough to decrease the coating impedance and expose the metal substrate after 25 days. Permeation and aging degradation of coatings are the main factors to consider when packaging liquor.

Evaluation of Corrosion Resistance according to Surface treatment of Installed Ammunition Case(ALDC12)

The Remote Control Munition System is a anti-personnel munitions system to replace land mines that are hard to retrieve and can inflict damage on friendly forces and civilians. As operating environments and methods change, quality improvement is necessary to ensure appropriate durability. Therefore, corrosion resistance evaluation was performed according to the surface treatment of ALDC12, the main assembly material. We conduct the potentiodynamic polarization, cyclic corrosion test to perform analysis on corrosion behavior. Additionally, we try to observe the pitting on the surface through SEM analysis. In conclusion, among the three surface treatments, Anodizing surface treatment is judged to be the most suitable for corrosion durability in a field environment.

Investigation of supercritical CO2 corrosion behavior of X80 carbon steel in pipelines: An in situ experimental and DFT study

The electrochemical corrosion behavior of X80 carbon steel was investigated in a supercritical CO2 (sCO2) environment at 60 ℃ and 9 MPa, by in-situ experiments and density functional theory (DFT) calculations, revealing the corrosion mechanism. For in situ electrochemical measurements, two novel CO2-rich and H2O-rich cells were developed to replace the traditional three-electrode cell. Electrochemical impedance spectroscopy revealed distinct differences in the corrosion behavior between CO2-rich and H2O-rich environments during the later stages of testing. In H2O-rich environments, as corrosion time increased, the corrosion product layer gradually changed from porous to dense, eventually forming a protective layer. In CO2-rich environments, corrosion occurs mainly in areas where water condenses to form FeCO3. Simultaneously, microscopic calculations provided evidence for the three-step sCO2 hydrolysis mechanism and the formation of FeCO3 products.

Corrosion Performance of Cu Doped AlCrFeNiMn HEA Synthesized via Arc-Melting

The development of novel corrosion resistant components is essential since malfunction of materials like super alloys during industrial applications might cause financial loss. Arc-melting and casting were used to create AlCrFeCuNi high entropy alloys (HEAs), which were then doped with various atomic percentages of copper (Cu). Investigations were conducted into the effects of Cu on the evolution of microstructural features, corrosion behavior in various solutions, nano hardness, and thermal stability. The alloy samples had a dendritic microstructure with three different phase zones, as seen by scanning electron micrographs, and EDS validated the elements that were included into the alloys. The behavior of the HEAs’ nano hardness and corrosion resistance significantly improved with the addition of Cu. In NaOH and Na2SO4 solutions, 3 at.% Cu samples demonstrated superior resistance to corrosion. With NaCl and H2SO4 solutions, 5 at.% Cu samples displayed greater corrosion resistance. The sample with 1 at.% Cu showed superior corrosion resistance in HCl solution.

Investigation of microstructure, tribological, and corrosion behaviors of TiN@AISI 316 CN processed by rf plasma

In order to enhance the tribological and corrosion properties of AISI 316 substrate, rf plasma carbonitriding was involved to form a carbonitrided layer on AISI 316 base substrate. The deposition of TiN top layer was executed engaging titanium nitride target in argon plasma atmosphere. All the deposition working parameters were reserved to be constant excepting the deposition period that was altered from 4 to 20 min. The effect of TiN top layer thickness on the structure, tribological and electrochemical characteristics of TiN@AISI 316 CN duplex treatment was explored. It was demonstrated, that the duplex coating enhanced the hardness (max: 1740 HV0.025 for TiN (1325nm)@AISI 316 CN sample) and improved the wear and corrosion resistance. Besides, the coefficient of friction is reduced to 0.12–0.2 for TiN@AISI 316 CN duplex treated samples compared with untreated AISI 316 which recorded a value of 0.47.

Thermokinetics driven microstructure and phase evolution in laser-based additive manufacturing of Ti-25wt.%Nb and its performance in physiological solution

A bio-compatible Ti-25 wt% Nb alloy fabricated from a blend of pure elemental powders using laser powder bed fusion additive manufacturing technique. The present work investigated the effects of processing conditions on the evolution of microstructures and its consequential material attributes, such as mechanical properties and corrosion performance. Thermal management strategies comprising laser powers of 200 W and 300 W in complement with a shorter scan length (1 mm) and substrate preheating above β-transus temperature (1123 K) were considered to achieve complete dissolution of niobium particles. The microstructure in the 200 W sample showed thin α′′ martensite needles in β matrix while martensite laths in the 300 W condition appear coarse and were twice the area fraction compared to that in 200 W build. On the other hand, microstructures in the heated substrate sample exhibited the evolution of α and β phases. A multi-scale finite element method based thermo-kinetic model spanning from melt pool scale to the component scale was incorporated to understand the mechanism of the evolution of microstructures during liquid–solid and solid–solid state transformation. Electrochemical performance in the simulated body fluid of the printed alloys was found to be significantly affected by the presence of martensite fractions. Both mechanical and corrosion behaviors were favorably influenced by adoption of the substrate preheating during additive manufacturing due to promotion of diffusional transformation of β to α at the expense of martensitic transformation.

Effect of TiC grain size on corrosion behaviors of Ti-Si-C nanocomposite coatings fabricated by heterogeneous targets high-power impulse magnetron sputtering

Ti-Si-C coatings with different carbon contents were prepared on SS316L substrates by heterogeneous targets high-power impulse magnetron sputtering with a repetitive C and TiSi deposition. Various tests were employed to analyze the microstructure, anti-corrosion properties in a simulated proton exchange membrane fuel cells (PEMFC) environment and interfacial conductivity of the coatings. Results indicated that the Ti-Si-C coating possessed a typical nanocomposite structure of TiC nanocrystals embedded in amorphous carbon matrix. With the increase of the carbon content, the grain size of TiC nanocrystals was reduced gradually. Electrochemical measurements revealed that a proper decrease of TiC grain size led to an enhanced corrosion resistance of the as-deposited coating. The smallest interfacial contact resistance and corrosion rate of the Ti-Si-C coating in the simulated PEMFC solution reached 5.07 mΩ cm2 and 5.93E-07 A/cm2, respectively. This improvement could be attributed to the formation of a dense and continuous passivation layer composed of Ti2O3 and SiO2 on the top surface of the coating.

Bioactivity and corrosion analysis of thermally sprayed hydroxyapatite based coatings

Metallic biomaterials have been used to repair and replace human body parts because of their excellent biocompatibility, strong corrosion resistance, and high mechanical properties. A ceramic biomaterial that is highly suitable for coating on metallic biomaterials is hydroxyapatite. This is because it is biocompatible with synthetic and natural bone tissue. There has been a growing interest in HAp-based coatings using thermal spray techniques to enhance the crystallinity and adhesion quality and produce a dense coating of metallic biomaterials. Thermally sprayed coating material has been studied and reviewed in detail in the bioactivity analysis and electro-corrosion analysis. Furthermore, the bioactivity of HAp coatings is determined by their ability to promote bone formation and osseointegration and a valuable understanding of the mechanisms and current advancements in bioactivity. Additionally, the corrosion behaviour of thermally sprayed HAp coatings under simulated conditions has been reviewed.

The corrosion behavior of AZ91 bulk alloy and thin films

Purpose The purpose of this study is to campare the corrosion behavior of Az91 films and bulk sample, in the objective to provide reference for the corrosion resistance improvement of Mg alloys. Design/methodology/approach AZ91 films with various thickness values are produced by magnetron sputtering technique, and the corrosion behavior was characterized by immersion tests and electrochemical measurements. Findings The AZ91 films exhibited a preferred orientation with basal planes parallel to the surface and increased densification with the increase of thickness, and a superior corrosion resistance for the AZ91 films compared with the bulk sample. Originality/value The preferred (0002) basal planes in AZ91 films benefited the corrosion resistance and the nanoscale AZ91 films facilitated the development of a dense passivation film. Consequently, AZ91 film exhibited a superior corrosion resistance.

Revealing corrosion behavior and mechanism of cold metal transfer-wire arc additive manufactured Mg-10Gd-4Y-2Zn-0.5Zr alloy in 3.5 wt% NaCl

The microstructure and corrosion behavior of wire arc additive manufactured (WAAM) Mg‐10Gd‐4Y‐2Zn‐0.5Zr alloy were comparatively studied to cast alloy. Higher fraction of eutectic (Mg,Zn)3(Gd,Y) phase along the grain boundary, more (Gd,Y)H2, (Gd,Y)2O3 and Zr enriched particles, heterogeneous microstructure composed of melt pool boundary, melt pool zone and heat affected zone were present in WAAM Mg-10Gd-4Y-2Zn-0.5Zr. Localized corrosion was initiated at the interface between the α-Mg and second phase and precipitated particles due to the inner layer differences of oxide films formed on them, resulting in inferior corrosion property and periodic corrosion characteristics of WAAM GWZ1042K alloy in 3.5 wt% NaCl.

A Study on the Structural, Wear, and Corrosion Properties of CoCuFeNiMo High-Entropy Alloy

This study investigates the structural properties, wear resistance and corrosion behavior of a CoCuFeNiMo equiatomic high-entropy alloy. The alloy was prepared using a vacuum arc melting device, and its structural properties were analyzed through X-ray diffraction (XRD) and scanning electron microscopy (SEM). Wear tests were conducted using a pin-on-disc machine against 4140 stainless steel at different loads. Corrosion behavior was evaluated through potentiodynamic polarization and electrochemical impedance spectroscopy (EIS) in a 3.5wt% NaCl solution. The results indicated the presence of a major face-centered cubic (FCC) phase and a minor (µ) phase. The alloy exhibited segregation of Cu, attributed to positive mixing enthalpy. The coefficient of friction exhibited stability under lower loads but fluctuated under higher loads, possibly due to inhomogeneity in the microstructure caused by Cu segregation. Wear rates increased linearly with applied loads, indicating a direct relationship between load and wear properties. The worn surfaces displayed characteristics of mild abrasive wear, with delaminations, ploughing, and abrasive wear tracks. Pitting corrosion was observed, and the corrosion process was explained as the attack of Cl- ions leading to galvanic corrosion between different phases. In the corrosion analysis, the Ecorr value was -0.616V, and the icorr value was found to be 2.22 × 10-5 A/cm2.

Corrosion behavior of laser directed energy deposited SS316L/Inconel718 functionally graded materials

Functionally graded material (FGM) can exhibit a variety of excellent properties by controlling layer-by-layer gradients in composition and microstructure. In this paper, SS316L/Inconel718 FGM was fabricated by laser directed energy deposition (LDED) to investigate the microstructures and corrosion behaviors at the transitional interfaces. The results indicate that the microstructures in gradient regions along the build direction include cellular crystals, dendritic structures, columnar crystals, and equiaxed crystals. With increasing mass fraction of IN718, the precipitates within the FGM matrix transition from metal oxides to Laves phases and MC phases, accompanied by elemental segregation of Nb and Mo at the grain boundaries. The enhanced corrosion resistance is attributed to the increased pitting corrosion resistance elements within the FGM matrix. Additionally, the high content of Cr2O3 and NiO in the passive film enhance the corrosion resistance. The SKP and LEIS test results indicate that the LDED-manufactured SS316L/IN718 FGM exhibits no apparent galvanic coupling corrosion and maintains excellent corrosion resistance transition. This investigation offers a reference for the study of corrosion-resistant composite materials.

In-situ observation and directional growth of Ca2Lu8(SiO4)6O2 in Lu2SiO5 attacked by CMAS at 1500 °C

Excellent resistance to CMAS is one of the key parameters for environmental barrier coating (EBC) operated in gas turbine engines. The interaction between CMAS and EBC was usually investigated by the characterization of reaction products after corrosion. The lack of direct observation of the high-temperature CMAS corrosion processes hinders the understanding of CMAS-induced degradation of EBC. In this work, the interaction between CMAS and an EBC candidate (Lu2SiO5) was investigated by an in-situ observation method, where the melting of CMAS and the growth of reaction products were first observed. It was found that the reaction product Ca2Lu8(SiO4)6O2 tends to precipitate vertically to form a textured structure. In addition, Lu2SiO5 tends to decompose into Lu2Si2O7 and Lu2O3 at 1500 °C, which induces an intergranular infiltration of CMAS and leads to the formation of Ca2Lu8(SiO4)6O2 fringes. Compared with the corrosion behavior at 1300 °C, Lu2SiO5 exhibits fast interaction with CMAS and poor CMAS resistance at 1500 °C. The results provide important guidelines on the design of rare earth silicate EBC.

Effects of microstructure on the corrosion behavior of pearlitic rail steel under simulated salt fog conditions

In this paper, the corrosion resistance and mechanisms of rail specimens with different lamella spacings in a salt spray environment were evaluated and investigated. This investigation was achieved by controlling different cooling rates of pearlitic bodies through heat treatment to obtain various lamella spacings. The results indicated that the corrosion resistance of all the specimens decreased during the salt spray test. The specimens with slow cooling rates (resulting in large pearlitic sheet layer spacings) had poorer corrosion resistance than those with fast cooling rates. Specimens obtained with both fast and slow cooling rates (air cooling at a 0.01°C/s cooling rate) displayed similar corrosion patterns. However, the corrosion stability of the specimen obtained at a cooling rate of 0.03°C/s fluctuated considerably after 144h of salt spray corrosion. This fluctuation was attributed to the transformations of corrosion products within the rust layer. The structural stability of the rust layer was related to the defects present in the material. Large defects increase the instability of the rust layer, thereby increasing the susceptibility to corrosion in a salt spray environment.

Effect of combined microbial and stress corrosion on 7075 aluminum alloy in high salinity environment

The study investigates the impact of the combination of Gram-positive bacteria Bacillus subtilis (B. subtilis) and tensile stress on the surface corrosion of 7075 aluminum alloy (AA7075) in a high-salt solution environment. The change in PH value caused by the growth curve of bacteria was analyzed for corrosion factors. Scanning electron microscopy (SEM) and ultra-depth 3D microscopy (DOF) were used to compare the surface morphology, elements and corrosion of the samples. The presence of a biofilm reduces the corrosion rate by 0.005 ± 0.0004mm/y and the application of a constant load results in an increase in the corrosion rate to 0.26 ± 0.013mm/y. The applied stress leads to the disruption of both the biofilm and oxide film on the metal surface, causing a significant reduction in the impedance isolation effect, and resulting in an expansion of the average diameter and depth of the corrosion pit by 372.21 and 29.5µm, respectively. In electrochemical impedance testing, there is an approximately 7.01×103 Ω increase in impedance value when exposed to B. subtilis environment; conversely, under stress conditions, there is a decrease by 4.02×103 Ω with B. subtilis present. The corrosion current density has increased fourfold to reach 9.15×10-6 (uA/cm2). This suggests that the combination of bacterial and stress can have a complex and detrimental impact on the corrosion behavior of aluminum alloys in high-salt environments.