Corrosion Control Research Articles

Abstract This study presents the first investigation of halogen-substituted aniline-derived Schiff bases (SB1, SB2, SB3) as corrosion inhibitors for mild steel in Nigerian tar sand environments. Key novelty includes introducing inhibition power as a new gravimetric-based performance metric for alkaline conditions where electrochemical methods are limited. Tar sand from Ilubirin was processed with 0.58 M NaOH at 90 °C for 24 h with inhibitors at concentrations of 25–150 ppm. Gravimetric analysis, SEM–EDS, and Langmuir isotherm modelling revealed a significant corrosion rate with effectiveness order SB3 > SB2 > SB1. SB3 achieved 94.4% inhibition efficiency at 150 ppm due to a favourable molecular structure promoting enhanced adsorption. Langmuir analysis confirmed chemisorption (ΔG°ads > − 20 kJ mol −1 ), while microstructural evaluation demonstrated excellent surface protection. This research demonstrates the effectiveness of inhibition power in assessing corrosion inhibitors using gravimetric data due to the limitations of electrochemical measurement in tar sand environments. The study concludes that Schiff-based compounds offer promising solutions for corrosion control in a harsh alkaline tar sand processing environment.

A novel concrete column with synergistic seismic performance improvement and corrosion control

Fe3+ stress in an algal-bacterial system: nitrification inhibition, iron distribution, and microbial tolerance.

This study investigated the control of early-age corrosion in pre-cracked marine-exposed concrete using cement and lime-paste coated steel bars, alongside hydrated lime slurry injection through the cracks. Reinforced concrete prisms were made with water-to-cement and sand-to-aggregate ratios of 0.45 and 0.44, respectively, using slag cement B (SCB) and C (SCC). Specimens were submerged in seawater for 30 days, followed by three wetting-drying cycles. For specimens made with SCB, coated bars (cement or lime-paste) with lime slurry showed around 50% reduction in corrosion depth compared to the uncoated steel bars. Corroded areas were 1.13% and 0.40% for uncoated and coated bars, respectively. SCC showed better corrosion resistance and presence of less chloride (from 0.55% to 0.16% cement mass) around steel bar near cracks compared to SCB. Scanning electron microscopy revealed deposits of ettringite, calcite and brucite along crack paths those facilitate crack healing and thereby reducing macro-cell corrosion progress with time.

Microbiologically influenced corrosion (MIC) caused bysulfate-reducingbacteria (SRB) poses a severe threat to oil and gas transmission pipelines.This study investigated the corrosion behavior of L415 pipeline steelin an SRB environment in the acidic soil of southern Jiangxi, China,by employing weight loss measurements, electrochemical measurements,and surface analysis. The growth curve revealed that the SRB, isolatedand purified from soil samples in the Southern Jiangxi region, exhibitedhigh activity in an acidic soil environment and further adhered tothe surface of the specimen, ultimately leading to MIC of the pipelinesteel. The experimental results showed that by reducing SO42–, SRB could enhance cathodic reactions. The Fe2+ from anodic dissolution reacted with S2– to form FeS, significantly accelerating corrosion. Additionally,the formation of FeS-SRB/Fe galvanic couples, formed on the surfaceof L415 pipeline steel specimens, promoted the localized corrosion.The depth of the pitting corrosion increased with the extended immersiontime. These experimental results would provide theoretical referencesfor the practical application of pipeline engineering in China andthe corrosion control of the SRB environment in southern Jiangxi.

This research aims to explore how two heterocyclic compounds, 2-phenyl imidazole (PI) and furfuryl amine (FA), inhibit the specific degradation processes of aluminum (Al) in a 0.2–0.4 M HCl solution. The study utilizes gravimetric analysis, potentiodynamic polarization (PDP), and electrochemical impedance spectroscopy (EIS) techniques. Surface morphological analysis is conducted using scanning electron microscopy (SEM), energy-dispersive X-ray spectroscopy (EDX), and atomic force microscopy (AFM). The results from gravimetric, PDP and EIS measurements indicate that both PI and FA act as cathodic corrosion inhibitors, with charge transfer and film formation mechanisms playing key roles in the corrosion control process. PDP tests show inhibition efficiencies of 98.07% for PI and 97.68% for FA at an inhibitor concentration of 50 mM and a temperature of 303 K. The effect of temperature, ranging from 303 to 333 K, on the corrosion behavior was also investigated with the addition of both heterocyclic compounds. An increase in the concentrations of PI and FA led to a decrease in the corrosion rate of Al, with a similar trend observed at lower temperatures. The adsorption behavior of PI and FA inhibitors aligns well with Langmuir and Freundlich isotherms. Both compounds show improved activation thermodynamic properties compared to the control. SEM/EDX and AFM analyses confirm that PI and FA form a protective barrier on the Al surface. Molecular dynamics (MD) simulations and DFT calculations provide deeper insights into the corrosion inhibition mechanisms.

The oil and gas industry faces significant challenges in pipeline corrosion management, with high corrosion resistance and electrical conductivity for effective cathodic protection (CP). This study focuses on the mathematical modelling of electrical conductivity in nanoparticle-sized graphene, graphite, and graphene-graphite coated polyvinyl chloride (PVC) and glass reinforced polymer (GRP) substrates, prepared via low-temperature spray pyrolysis (50–60 °C). Single- and double-layer coatings with graphene-graphite blend ratios of 1:0.5 and 1:1 were applied on 50 × 10 × 2 mm substrates to obtain coating thickness of 0 µm, 56.1 µm, 77.2 µm, 80.6 µm, 80.8 µm, 92.6 µm, and 97.9 µm respectively for the PVC samples while the GRP samples have coating thickness of 0 µm, 110.3 µm, 114.0 µm, 109.0 µm, 115.7 µm, 117.3 µm, 124.7 µm. Electrical conductivity was measured using an LCR meter, and polynomial models were developed to correlate conductivity with coating thickness. Cathodic protection simulations assessed the performance of coated composites in a 15 km pipeline, highlighting the impact of non-conductive sections and the efficacy of bypass wire designs. Results showed that single-layer graphene-coated GRP achieved the highest conductivity (1.8 × 10⁻⁶ S/m), while double-layer hybrid coatings (1-0.5D) offered optimal durability. The mathematical models accurately predicted conductivity trends, with GRP exhibiting superior performance compared to PVC due to better graphene integration. CP modelling revealed that non-conductive GRP sections cause localized underprotection, mitigated by optimized bypass designs. These findings demonstrate that graphene-graphite-coated GRP composites, supported by predictive conductivity models and CP simulations, are promising alternatives to steel for pipeline repairs, enhancing corrosion control and longevity in oil and gas applications.

Balancing heat and pulse width in laser texturing of Al-Mg alloy: Superhydrophobicity with wear, icing, and corrosion control

Role of newly synthesized organic and eco-friendly compounds in boosting the electrochemical performance of mild steel for efficient corrosion control: Insights from experiment and multiscale simulations

Intelligent corrosion control through nano-porous coordination framework −based thin films − review of the recent achievements and future Trends

ABSTRACT Corrosion of mild steel in marine environments poses a major challenge for industrial sustainability. This study aims to develop an eco-friendly corrosion protection approach by combining phenolic extracts (PE) from extremophile plants with Zn₂-Al-layered double hydroxides (LDH) to form hybrid inhibitors for S235JR steel in artificial seawater (3.5% NaCl). Three plant extracts were evaluated for their antioxidant potential, and Cynomorium coccineum was identified as the most active candidate. The hybrid material was synthesized via anion-exchange, and structural integrity was confirmed by XRD, FTIR, and SEM analyses, showing that the incorporation of organic compounds did not alter the crystallinity of the LDH matrix. Electrochemical measurements using the Tafel polarization revealed that the hybrid system achieved a corrosion inhibition efficiency of 60%, surpassing LDH alone (38%) and the phenolic extract alone (45%). This improvement confirms a synergistic effect resulting from the combined adsorption and controlled release mechanisms. These findings demonstrate the potential of combining bioactive plant molecules with inorganic carriers as a sustainable and low-cost strategy for corrosion control in marine applications.

Alternative approaches to lead sampling in drinking water: A comparative study of homes with and without lead service lines in two cities.

This work incorporates precorrosion conditioning and conductive deposits (FeS or FeS2) to explore corrosion mechanisms across base metal (BM), weld metal (WM), and heat-affected zone (HAZ) regions under simulated sour conditions (NaCl (3.5 wt %), Na2S2O3 (1000 ppm), CH3COOH (100 ppm), CO2, 60 °C, pH ∼ 4, and 1000 rpm). Electrochemical studies demonstrated various corrosion rates (CR) hierarchies (CS-BM (0.34-0.42 mmpy) < CS-WM (0.38-0.73 mmpy) < CS-HAZ (0.48-1.75 mmpy)), which were exacerbated by FeS or FeS2 deposition. This was ascribed to a variety of potential variations and localized acidification. Also, there were notable changes in the welded CS areas' compositions and microstructures both before and after corrosion testing. By creating protective layers that reduce microgalvanic interactions, the commercial amine-based inhibitor CRW11 (200 ppm) showed remarkable potency by lowering the CRs (<0.1 mmpy) threshold with inhibition efficiency (IE = >80%). Corrosion products (α-Fe2O3, γ-FeOOH, and Fe3O4) were most significant, identified by Raman spectroscopy. 1D artificial pit tests showed varied pit propagation dynamics, especially under FeS-induced heterogeneity, with CS-BM-FeS having the highest pit depth (71.4 ± 11.8 μm), but increased pit density (568.0 mm2) was recorded for CS-HAZ-FeS2. This proves the impact of conductive deposits on the pitting of welded CS regions. These findings corroborated deposit-induced electrochemical heterogeneity with localized attack, which was most significant with FeS2 deposit. Machine learning (ML) models, like random forest (RF), decision tree (DT), and extreme gradient boost (XGBoost), demonstrated excellent IE predictive ability (R2 = 0.99) for welded CS without/with conductive deposits. However, RF and XGBoost are ideal with the least RMSE/MAE (0.2/0.2 and 0.1/0.1) for welded CS without/with FeS and FeS2, respectively. These results provide a practical foundation for pitting and PWC in preconditioned welded CS with conductive deposits, allowing for the best material selection and corrosion control techniques in sour service applications.

Acidizing operations are vital for enhancing oil well productivity, but their success relies on effective corrosion control under high-pressure high-temperature (HPHT) conditions. Although corrosion inhibitors are standard, their performance can be unpredictably altered by interactions with other additives in the acidizing fluid package. This study addresses a key knowledge gap by quantitatively evaluating the synergistic and antagonistic interactions between a baseline corrosion inhibitor and commonly used additives. Experiments were conducted under simulated reservoir conditions (15% HCl, 100 °C, 2000 psi), focusing on three additive classes: surfactants (CTAB, SDS, TX-100), iron control agents (EDTA, NTA, Sodium Gluconate), and anti-sludge agents (DDBSA, DOSS). Corrosion rates were determined via weight loss measurements to develop a comprehensive interaction matrix. The results reveal, for the first time in a comparative framework, that additive effects are highly concentration-dependent. Sodium Gluconate demonstrated strong synergy, enhancing inhibitor performance by 14.86% at 1.8 mL. In contrast, DDBSA, CTAB, SDS, and NTA showed pronounced antagonism, increasing corrosion rates and, in CTAB’s case, causing severe localized pitting. These findings offer practical insights for optimizing acidizing formulations and underscore the importance of evaluating full chemical systems rather than individual components—a necessary paradigm shift for future treatment design.

Current research on foamed lightweight soil primarily focuses on mechanical properties and durability, with few studies addressing its hydraulic characteristics and internal pore structure in road reconstruction applications. However, the material’s high porosity and low bulk density may significantly alter its mechanical properties and durability under prolonged rainwater exposure, highlighting the importance of investigating its hydraulic characteristics and internal foam structure. Based on the analysis of water absorption and bulk density in phosphogypsum-based foamed lightweight soil, this study further discusses the material’s softening coefficient and internal pore structure through systematic data comparison. Experimental results demonstrate that the unconfined compressive strength (UCS) of both dry and water-soaked specimens increases linearly with dry density. Notably, soaked specimens with 0.5 g/cm3 dry density achieve compliant 7-day UCS values while displaying a steeper strength increase compared to dry specimens. A dry density of 0.64 g/cm3 ensures a softening coefficient exceeding 0.75, confirming the material’s suitability for humid environments. The material contains predominantly small pores (90% ≤ 0.2 mm diameter), with improved bubble distribution at the edges and higher upper porosity. Spherical pores (roundness 0.5–1) enhance mechanical properties, while phosphogypsum (optimal 10% dosage) effectively improves both strength and workability but requires corrosion control due to its hydration products.

Sulfate-reducing bacteria: Unraveling biofilm complexity, stress adaptation, and strategies for corrosion control.

Valorizing the potential of tropical plant extracts for corrosion and biofouling control in neutral chloride media

Background/Objectives: Guided bone regeneration (GBR) requires barrier membrane materials that balance biodegradation with mechanical stability. Magnesium (Mg)-based metals have good prospects for use as biodegradable barrier materials due to their elastic modulus, good biocompatibility, and osteogenic properties. In this study, gallium (Ga) was introduced into Mg to enhance the mechanical strength and optimize the degradation behavior of the alloy, addressing the limitations of conventional magnesium alloys in corrosion control and strength retention. Methods: Mg-xGa alloys (x = 1.0–3.0%, wt.%) were evaluated for biocompatibility, degradation, and osteogenic potential. Corrosion rates were calculated via weight loss, Mg2+ release, and pH changes. Osteogenic effects were assessed using rat bone marrow mesenchymal stem cells (rBMSCs) for alkaline phosphatase (ALP) activity, extracellular matrix (ECM) mineralization, and osteogenic-related gene expression. Optimal alloy was fabricated into barrier membranes with different pore sizes (0.85–1.70 mm) for the rabbit mandibular defect to evaluate the porosity effect on new bone formation. Results: Cytocompatibility tests established a biosafety threshold for Ga content below 3 wt.%. Mg-1Ga demonstrated uniform corrosion with a rate of 1.02 mm/year over 28 days. In vitro, Mg-1Ga enhanced ALP activity, ECM mineralization, and osteogenic gene expression. The 1.70 mm pore size group exhibited superior new bone formation and bone mineral density at 4 and 8 weeks. Conclusions: These results highlight Mg-1Ga’s biocompatibility, controlled degradation, and osteogenic properties. Its optimized pore design bridges the gap between collagen membranes’ poor strength and titanium meshes’ non-degradability, offering a promising solution for GBR applications.

The quality of water in households can be affected by plumbing design and materials, water usage patterns, and source water quality characteristics. These factors influence stagnation duration, disinfection residuals, metal release, and microbial activity. In particular, stagnation can degrade water quality and increase lead release from lead service lines. This study employs numerical modeling to assess how combined corrosion control and flushing strategies affect lead levels in household taps with lead service lines under reduced water use. To estimate potential health risks, the U.S. EPA model is used to predict the percentage of children likely to exceed safe blood lead levels. Lead exceedances are assessed based on various regulatory requirements. Results show that exceedances at the kitchen tap range from 3 to 74% of usage time for the 5 µg/L standard, and from 0 to 49% for the 10 µg/L threshold, across different scenarios. Implementing corrosion control treatment in combination with periodic flushing proves effective in lowering lead levels under the studied low-consumption scenarios. Under these conditions, the combined strategy limits lead exceedances above 5 µg/L to only 3% of usage time, with none above 10 µg/L. This demonstrates its value as a practical short-term strategy for households awaiting full pipe replacement. Targeted flushing before peak water use reduces the median time that water remains stagnant in household pipes from 8 to 3 h at the kitchen tap under low-demand conditions. Finally, the risk model indicates that the combined approach can reduce the predicted percentage of children with blood lead levels exceeding 5 μg/dL from 61 to 6% under low water demand.

Water and wastewater pipelines represent significant investments by owners, and disruptions in these pipelines create inconvenience and safety concerns for users. Therefore, long service life is essential for the pipeline materials. Concrete pressure pipe is a widely used material for the conveyance of water and wastewater that has been used for more than 80 years. This article discusses the corrosion protection methods used for concrete pressure pipe to ensure long service life. It will cover both the inherent corrosion control properties of concrete pressure pipe and supplemental corrosion control methods used in extremely aggressive environments.