Corrosive Environment Research Articles

“Dual-armor” strategy to prepare multifunctional carbonyl iron particle with corrosion resistance, self-healing and high microwave absorbing performances

As a common and high microwave absorbing material, the application fields of carbonyl iron particle (CIP) are limited because of its poor corrosion resistance when working in harsh environments such as ocean, rainforest, or other high-humidity, high-salt places. Therefore, it is necessary to design a multifunctional CIP with good corrosion resistance and self-healing properties for ensuring its stable microwave absorbing performance. Herein, a “dual-armor” strategy is proposed to prepare multifunctional CIP (Composite particle), which is assembled with CIP coated by polyaniline (PANI/CIP) and Fe-DSe-M. Fe-DSe-M is Fe3+ responsive microcapsule whose shell contains -Se-Se-bonds and is magnetically adsorbed on the surface of PANI/CIP. PANI/CIP and Fe-DSe-M jointly undertake the function of microwave absorbing, anti-corrosion and self-healing. It is worth to note that the microwave absorbing performance of CIP after multi-functionalization has been greatly improved, and the minimum reflection loss value after accelerated corrosion is only reduced by 5.46 dB, which is much lower than PANI/CIP. These excellent properties of functional Composite particle benefit from PANI protective layer, Fe3+ responsive self-healing Fe-DSe-M and their synergistic effect. Our work provides a new approach to fabricate multifunctional microwave absorbing particle, which has a potential application in the corrosive environment.

Organization оf Electrochemical Protection оf Steel Underground Pipelines Against Corrosionin the Gas Distribution Industry of the Republic of Belarus

Steel underground gas pipelines occupy a significant share of the total length of gas distribution pipelines, and therefore their maintenance in proper condition is a constant and very urgent task. Due to its global nature, the main influencing factor affecting the technical condition of any steel underground pipelines, including gas pipelines, is corrosion, primarily soil corrosion. To protect against it on pipeline networks, along with insulating coatings, electrochemical protection (ECP) is applied, that is, following the definition of STO [Standard of Organization] 17330282.27.060.001–2008, protection of metal against corrosion in an electrolytic environment, carried out by establishing a protective potential on it or eliminating the anodic potential shift from the stationary potential. In the gas distribution industry of the country, methods and means of electrochemical protection have been applied since the beginning of gasification and the construction of the first gas pipelines. All gas supplying organizations of the State Production Association for Fuel and Gasification “Beltopgaz” (six regional and Minsk city), which operate gas distribution facilities, have specialized corrosion protection services. These services provide maintenance of available ECP equipment, conduct electrical measurements on gas pipelines and corrosion studies of soils, and have certified laboratories. This paper is devoted to the analysis of domestic experience in organizing electrochemical protection of steel underground gas distribution pipelines, searching for promising directions for its improvement and increasing efficiency through the implementation of a unified industry technical policy, automation and telemechanization of ECP equipment in the general context of digital transformation, optimization of the timing and volume of maintenance.

Versatile GO/ANFs Aerogel for Highly Efficient Solar-Powered Water Purification in Wide Environments.

Solar-driven interfacial evaporation is a very promising choice for producing clean water. Despite the considerable investigation of pure NaCl brine purification, solar-driven complex water purification, such as real-world seawater desalination as well as domestic and industrial wastewater treatment, has rarely been investigated, mainly due to its compositions being much more complicated than NaCl brine. Herein, we developed a graphene oxide/aramid nanofiber (GO/ANFs) aerogel by a freeze-drying process. The GO/ANFs aerogel combined opened porous microchannels, superhydrophilicity, anti-oil-fouling capacity, enhanced broad-spectrum light absorption (more than 92%), and good solar/heat management. These integrated properties enabled the GO/ANFs aerogel to be an advanced solar interfacial evaporator for efficient freshwater production with the characteristics of localized heat conversion, quick water transport, and salt crystallization inhibition, and the rate of steam production rate was as high as 2.25 kg m-2 h-1 upon exposure to 1 solar irradiation. Importantly, the high-water-vapor generation rate was maintained even under complicated conditions, including real-world seawater, dye water, emulsions, and corrosive liquid environments. Considering its promising adaptability to a wide range of environments, this work hopes to inspire the development of brine desalination, wastewater purification, clean water production, and solar energy utilization.

Study on the repair behavior of passive film of iron-based amorphous coatings by eco-friendly phosphate inhibitors

The passivation ability of the coating can be improved by adjusting the elements proportion in the Iron-based Amorphous Coating and the spraying process, but the process is complicated and costly. In this study, it was found for the first time that Iron-based Amorphous Coatings can quickly form passive films in phosphate atmosphere, which simplifies the coating strengthening process. Electrochemical measurements, XPS, AFM, FTIR, and SEM-EDS were used to investigate the inhibition mechanism of eco-friendly phosphates on the dynamic dissolution of passive film of Fe-based amorphous coating. When the coating was soaked in 3.5 wt% NaCl + 0.1 M solution, the iron phosphate compound on the coating surface promoted the repair and growth of the passive film, and the film thickness increased by more than 32.9 %. The increase of Fe2+/Fe3+ and (O2-+H2O)/OH- in the passive film means that more insoluble Fe-Cr compound growth significantly reduces the donor density (Nd) in the passive film and inhibits the degradation rate of the passive film in the corrosive environment.

Amelioration of protective organic layer using acenaphthene-based inhibitor responsible for excellent anti-corrosion performance: Experimental and computational perspectives

Despite the engineering promise offered by the co-existence of organic substances in protecting vulnerable metallic materials from corrosive environments, the interaction and formation mechanisms that induce the development of new materials with improved structural properties remain less understood. This study investigated the corrosion inhibitory properties of two acenaphthene derivatives, acenaphthylene-1,2‑dione (ACP) and 1,2-dihydroacenaphthylen-1-ol (DCP), as inhibitors for N80 steel in a 15 % HCl solution. The anticorrosive effectiveness of ACP and DCP compounds was evaluated through multiple research methods, including weight loss analysis, electrochemical impedance spectroscopy (EIS), potentiodynamic polarization (PDP), and surface characterization using scanning electron microscopy (SEM). The experimental findings demonstrate that ACP exhibits superior inhibition performance compared to DCP, with an inhibition efficiency of 93.54 % for ACP and 73.12 % for DCP at an optimum concentration of 5 × 10–3 M. EIS data show that the charge transfer resistance increases with higher concentrations of both compounds. PDP results indicate that ACP and DCP act as mixed-type inhibitors without altering the corrosion mechanism. The kinetic parameters of corrosion adsorption follow the Langmuir isotherm, highlighting a competition between physical and chemical interactions. To investigate how the geometric structures resulting from functional groups influence their interaction with the metal surface, theoretical calculations employing density functional theory (DFT), molecular dynamics (MD), and density-functional tight-binding (DFTB) were conducted. These calculations were aimed at gaining insights into the adsorption behavior of ACP and DCP on the metal surface and their interfacial mechanism. The calculations demonstrate that the molecule possessing twin donor atoms along with p-type orbitals of aromatic rings significantly influenced the formation of a protective film with a uniform distribution. This configuration exhibited superior corrosion performance compared to a molecule containing only one hydroxyl group (—OH). Theoretical calculations further suggest that ACP exhibits stronger adsorption ability, with the two oxygen atoms identified as the most reactive sites, indicating their tendency to donate electrons to the iron surface. The robust resonance-stabilized structure of ACP enhances the stability of the molecules, facilitating its interaction and adsorption onto the metal surface compared to the DCP inhibitor. Overall, the superior inhibition performance of ACP is attributed to the close bonding of twin donor fragments within the ACP molecule, forming a more compact adsorbed inhibitor film on the steel surface.

Comparative Study of the Tribocorrosion Performance of NiTiNOL60 in Acidic, Alkaline, and Saline Environments

AbstractIn order to enhance the durability of tribological interfaces, an investigation into the synergistic effects of sliding wear, corrosion, and their interactions is crucial. This study focuses on understanding the deformation mechanisms of NiTiNOL60, a nickel-rich nickel-titanium alloy, during sliding against Al2O3 in different corrosive environments, including acidic, alkaline, and saline mediums. The pH of the environments is found to play a significant role in the tribocorrosion process, leading to electromechanically induced transformations and various wear patterns. Plastic deformations are observed on the wear track surfaces, particularly in the severe and mild wear regimes. In an alkaline environment, depassivation of the oxide layer triggers oxidational wear, with the depassivation rate dependent on factors like contact pressure, sliding velocity, and passive film properties. The wear volume is highest in saline environments, with contributions from mechanical wear, corrosion, and third-body abrasion. Grain deformations occur in the alkaline environment due to shear forces, while in the acidic medium, corrosion accelerates mild wear involving abrasion and delamination. The findings provide insights into wear mechanisms and localized corrosion, highlighting the influence of H+ and OH− groups (pH values) on corrosive wear and crack propagation.

An investigation on bending fatigue in a corrosive environment of dual-phase 1000 sheet steel RSW joints and damage model via experiment and numeric analysis

Fatigue, corrosion, and fatigue damage models are best addressed to improve and understand the service performance of materials, particularly automotive steel. This study is an attempt to experimentally and finite element investigates plain bending fatigue performance and damage model of DP 1000 sheet steel resistance spot welding (RSW) joints in 3% NaCl aqueous corrosive treatment. RSW applications were carried out using different weld currents. The joint samples were then subjected to optical image analysis, tensile shear, and fatigue tests (3% NaCl-aqueous and normal atmosphere). A proper damage model of RSW junctions was developed and corrected by numeric analysis. Besides, RSW nugget formation, tensile shear, and plain bending fatigue tests were also applied. Consequence, fatigue behavior, tensile load carrying capacity, and effective fracture behavior of resistance spot welded joint specimens were evaluated. Results showed that a corrosive environment negatively affected fatigue performance. With the developed model, it was observed that the fatigue life of the samples decreased by 30–35% in the fatigue tests performed in the corrosive environment. Experimental and numerical analysis results of plain bending were compatible.

Corrosion Behavior and Corrosion Prediction of Carbon Steel under Dynamic Atmospheric Corrosion Environment in Harbin

Corrosion Behavior and Corrosion Prediction of Carbon Steel under Dynamic Atmospheric Corrosion Environment in Harbin

Simulation on the effect of filling porous medium on the performance of thermally conductive plastic heat sinks

High thermally conductive plastics have the characteristics of corrosion resistance, easy processing, and high thermal conductivity and can be used in corrosive environments or complex-shaped heat sinks. However, its thermal conductivity is still significantly lower than that of traditional metal heat sinks. Therefore, it is necessary to optimize the heat dissipation performance design. Based on the N–S equation and the k-ε turbulence model, the effect of porous media filled in the thermally conductive plastic heat sinks on its heat dissipation performance is studied. We compared this optimizing method with adding vortex generators in the literature. The maximum temperature of the heat sink bottom decreases by 9.3 °C. The pressure drop reduces by 55 %, and the Nusselt number increases by 9.3 %. The optimized heat sink has a hydrothermal performance factor (HTPF) 1.41. The heat dissipation performance can be similar to that of an aluminum heat sink. This study provides optimization ideas for expanding the application of thermally conductive plastics in heat sinks.

External magnesium sulfate attack on hydrated Portland-limestone cements: Effect of the concurrent presence of sodium chloride in the corrosive environment and metakaolin admixture in the binder

Magnesium sulfate attack on Portland-limestone cement pastes at low temperature was investigated considering the concurrent presence of sodium chloride in the corrosive solution. The common deterioration mechanism, involving leaching of portlandite and C─(A─)S─H phase and formation of crystalline phases and amorphous cross-linked aluminosilicate structures, was mitigated in the pastes made from ordinary or Portland-limestone cements by increasing amounts of dissolved sodium chloride. Conversely, it was intensified in the blend with metakaolin by the additional decomposition of C─A─H phases with the formation of amorphous aluminate hydrate. The reduced cross-linking of the aluminosilicate structures is attributed to the structural association of sodium in the low-Ca/Si chains. C─A─H phase was also consumed in the heavily deteriorated cement paste with the highest limestone content. The mitigating effect of sodium chloride is proposed to be due to the corrosive environment's reduced acidity and the protective effect exerted by the sodium ions absorbed at the surface of aluminosilicate structures.

Study on the corrosion fatigue properties of ultrasonic surface strengthened axle steel

Owing to fatigue damage and environmental erosion, locomotive axles are prone to premature failure during service. It is therefore very important to improve the corrosion fatigue properties of axles. In this paper, the fatigue behavior of ultrasonic surface strengthened axle steel under corrosive environment was studied. The surface integrity of ultrasonic strengthened axle steel was characterized by microscopic analysis and hardness test. The fatigue data and fatigue fracture of axle steel under corrosion environment were compared. Also, the mechanism of the corrosion environment on fatigue crack initiation and propagation was analyzed. Results show that serious plastic deformation is generated in the surface of axle steel after ultrasonic strengthening. The grains in surface layer are obviously refined and get coarse gradually as deep into the matrix. The hardness of surface layer is greatly improved as well. The maximum value is located on the outermost surface, about 2 times of the matrix. Under the same fatigue load, the fatigue cycle number for ultrasonic strengthened axle steel is more than that of original sample. This is due to grain refinement, work hardening, and residual compressive stress induced by ultrasonic strengthening, which inhibits fatigue crack initiation in corrosion environment.

Development of Environmental Monitoring Sensor for Steel Corrosion in Concrete based on Micro-Electro-Mechanical Systems (MEMS)

Many bridges located near marine environments usually have high risk to lose their structural performance due to corrosion of reinforcing bars with chloride attack. While a huge amount of budget to maintain may be consumed for the structural maintenance methodologies, an efficient monitoring system for Reinforced Concrete (RC) structures in the corrosive environment is strongly demanded. Thus, structural health monitoring in real situations is significant for bridge asset management. The alternative way for preventing severe damage propagation is proactively monitoring the environmental condition containing chloride ion and its effect on the durability of concrete structures, for which numerous methods have been conventionally suggested such as dry gauze method to capture chlorides in air. In this study, Micro Energy Harvester (MEH) based on Micro-Electro-Mechanical Systems (MEMS) is technically applied to develop a sensor to identify the corrosion environment with chlorides in the exposure condition. MEMS is a rapidly evolving device, which enables to monitor the changes in natural frequency and amplitude at nodal locations of the targeting structure due to vibration-based electrostatic power generation induced by the corrosive environment. The purpose of this research is to develop a system for detecting the high corrosion-prone areas and finding the suitable metal sheet material for various chloride ion conditions, using the metal sheet as a cantilever structure for the MEMS device. 4 types of metal, aluminium, copper, iron and zinc are considered for the parametric experiments. Several scenarios are considered including chloride ion concentration, temperatures, and wet and dry conditions to compare the dominant frequency changes of each metal sheet and determine their sensitivity to corrosion environment. From the preliminary results, iron and zinc have a significant drop in frequency with the elapsed exposure period, which indicates that they are highly sensitive to the external chloride ion environment. These results offer an innovative and proactive approach to structural health monitoring for further developed applications. It enables prompt maintenance and early detection of potential issues for corrosion of steel bars in concrete, ensuring the longevity and safety of RC bridge structures.

STUDYING THE PHYSICAL AND CHEMICAL PROPERTIES OF AMINE AND AMIDE CONTAINING ORGANIC INHIBITORS

In this work, new inhibitors of metal corrosion in sulfuric acid environments are studied depending on the duration of the process, inhibitor concentration and temperature. The main parameters for the synthesis of new metal corrosion inhibitors St.3 and St.12 grades using amine and amide containing organic substances are determined and methods for obtaining these inhibitors are described. The physicochemical properties of amine and amide containing organic inhibitors of corrosion and scaling in acidic process environments have been studied.

Study on seawater corrosion resistance of copper alloy

Abstract The Marine environment is a very complex and corrosive environment. Marine corrosion environment can be generally divided into Marine atmospheric environment and seawater environment. Because the seawater is rich in a variety of free ions mixed with corrosive media, the main component is sodium chloride, in addition to containing magnesium, potassium, iodine, bromine, and other elements of salt, which has strong corrosion to metal materials, if serious, it will cause safety accidents. Therefore, ensuring the effectiveness of the anticorrosion system is very important for the safe and reliable operation of the offshore platform. pulse plating is used and the metal nickel coating and metal nickel-chromium coating are prepared to analyze the microstructure and corrosion resistance of each film layer. From the macroscopic, it can be found that three coatings have more or less corrosion phenomenon, there is obviously no nickel-chromium and nickel layer on the surface of nickel-chromium corrosion defects, and through scanning electron microscopic observation, microscopic level nickel chromium corrosion after corrosion phenomenon is the least of three layers, which suggests that nickel chromium seawater corrosion resistance is strong. The three layers are then electrochemical corroded to study the corrosion resistance of the three layers. The results show that the corrosion resistance of the nickel-plated layer, nickel-chromium coating, and nickel-iron chromium coating prepared in the copper substrate is improved successively, which shows the influence of different membrane elements on the corrosion resistance of copper substrate against seawater medium. Although the composition parameters of the various membrane layers vary, they experience the same corrosion mechanism-pitting; Nickel chromium and chromium, iron and other atoms are present in the nickel matrix in the form of solid solution and finally form the solid solution alloy coating. For nickel-chromium coating, the content of iron and chromium in the surface layer has a certain influence on the corrosion resistance of the metal coating. The electrochemical parameters of nickel plating are studied separately, and the comparison with the nickel-chromium alloy coating and the coating is conducted. The equivalent circuit is fitted and determines the largest impedance value and the largest phase Angle among the three membrane layers, which finally has the strongest seawater corrosion resistance.

Analysis of the glass fibre/chicken feathers reinforced hybrid composite

AbstractIn this paper glass/chicken feathers reinforced epoxy composite and glass/chicken feathers reinforced polyester composite was prepared in the laboratory at different percentage of the glass and chicken feathers. Tensile properties, flexural properties, shore hardness and impact strength of the glass/chicken feathers reinforced epoxy composite and glass/chicken feathers reinforced polyester composite was studied experimentally and compared at different percentage of the glass and chicken feathers. The composite will be used in humid and corrosive environment; therefore, water absorption and acid corrosion test were performed. To understand the degradation behaviour of the composite, soil test was performed. Scanning electron microscopy analysis was carried out to find the fracture and interfacial characteristics of the composites after tensile test. This hybrid composite can be used in automobile, structural and defense sector.

Kopsia terengganensis’ alkaloids as potential green inhibitors for mild steel corrosion in CO2-saturated 3.5% NaCl medium

The corrosion inhibition potential of alkaloids from Kopsia terengganensis bark extract (KTBE) in mitigating the mild steel corrosion in a CO2-saturated 3.5% NaCl medium was evaluated. Standard corrosion evaluation methods, including weight loss test, electrochemical impedance spectroscopy (EIS), and potentiodynamic polarization (PD) were employed, which revealing a concentration-dependent enhancement in KTBE's inhibition efficiency. At 500 ppm, the corrosion inhibition efficiency recorded the highest value of 90.63% based on the weight loss study and 87.38% based on electrochemical analysis. Tafel slopes in PD studies affirmed that KTBE functioned as an anodic-type inhibitor. The adsorption of the inhibitor is in accordance with the Langmuir adsorption isotherm with an adsorption free energy (ΔG°ads) of −26.47 kJ/mol, suggesting the binding of KTBE molecules by means of physisorption. Surface analysis conducted through scanning electron microscopy (SEM), energy dispersive X-ray (EDX) spectroscopy, and Fourier transform infrared spectroscopy (FTIR) confirmed the formation of a protective inhibitive layer on the surface of mild steel. The proposed corrosion inhibition mechanism involves electrostatic interactions between KTBE molecules and the mild steel surface. This comprehensive investigation underscores KTBE's potential as an effective corrosion inhibitor in corrosive environments.

The structure evolution of austenite stainless steel with pre-shot peening during plasma nitriding

Abstract Austenitic stainless steel is a very promising metal bipolar plate for proton exchange membrane fuel cells (PEMFC), which has advantages such as high mechanical strength, easy processing, and low cost. However, it is prone to corrosion in the acidic environment of PEMFC, which can have adverse effects on its lifespan and conductivity. By adopting a composite modification method to generate a dense nitride structure on the surface of 304 stainless steel bipolar plates, the corrosion resistance of the bipolar plate substrate can be improved. In this paper, shot peening pretreatment and plasma nitriding hybrid modification methods were employed to improve nitriding efficiency and reduce nitriding critical temperature, which generated a modified layer with good corrosion resistance on the surface of 304 austenitic stainless steel.

Evaluation of soil accelerated corrosion of typical grounding materials used for electrical equipment

Abstract At present, research methods for soil corrosion include sample weight loss methods, physical and chemical properties research, electrochemical research, indoor accelerated corrosion tests, etc. However, most existing soil corrosion evaluation methods have many drawbacks, such as high research costs, long experimental cycles, long results transformation cycles, and significant environmental limitations. In this paper, based on the electrochemical test results of environmental corrosion factors using typical grounding materials, a corrosion simulation solution load spectrum and an accelerated corrosion experimental system corresponding to the soil corrosion environment level were established. The accelerated corrosion samples were thoroughly studied and analyzed using macroscopic morphology observation, microscopic morphology analysis, and energy spectrum analysis. The results show that the soil accelerated corrosion method has strong stability and small deviation, which applies to the study of accelerated corrosion in the soil environment of grounding materials.

An electrochemical study of iron carbonate layers formed on carbon steel during corrosion in elevated pressure CO2 environments

Iron carbonate (FeCO3) layers influence the electrochemical properties of carbon steel during aqueous corrosion in carbon dioxide–saturated environments. In this study, electrochemical measurements conducted in an autoclave at 80°C and 5 barg are combined with cross-sectional imaging to elucidate interfacial properties of X65 carbon steel at key stages of FeCO3 layer development. The effects of evolving system chemistry are also considered by variation of the X65 surface area to solution volume (A/V) ratio. FeCO3 reduces general corrosion rates through a combination of active site blocking and restriction of mass transport, with resultant layer properties dependent on the A/V ratio.

2D materials for marine corrosion protection: A review

The pervasive issue of metal corrosion in various industrial environments, especially in marine settings, incurs significant economic costs and hazardous failures. Traditional protection methods, although diverse, fall short in durability and environmental adaptability, necessitating advanced solutions, such as two-dimensional (2D) materials, including graphene, layered double hydroxides, boron nitride, MXenes, and MoS2. These materials offer exceptional barrier properties against corrosive agents due to their high surface area and minimal thickness, enhancing the lifespan and reliability of metal assets under harsh conditions. Innovations such as self-repairing coatings and advanced application techniques, such as automated spraying and rapid photocuring, further augment their effectiveness. In this Review, recent advancements in the development and application of 2D material-enhanced coatings are reviewed, underscoring their potential in revolutionizing marine corrosion protection through improved performance metrics and sustainability. The challenges and prospects of these novel materials are also discussed, highlighting the need for further research to overcome application hurdles and realize their full potential in industrial uses.