Corrosion Of Steel Research Articles

Steel corrosion process in ultra-high performance concrete monitored by fiber bragg grating sensor

The steel corrosion in Ultra-High Performance Concrete (UHPC) would cause degradation of structural performance or even structural failure. It is an urgent need to monitor and predict the steel corrosion in UHPC, however it is still a tough task. In this paper, Fiber Bragg Grating (FBG) sensors are applied for monitoring the steel corrosion process in UHPC, by combining with steel bar, which is equidistant winding with the sensors, and connected with power supply for accelerating corrosion. The UHPC specimens embedded with steel bars are surrounded by sodium chloride (NaCl) solution, and the steels are artificially corroded with different current densities for investigation. The steel corrosion in Original C60 and Marine Concrete 60 (Marine C60) are applied for comparison. The volume expansion coefficient for monitoring the steel corrosion process, is carried out by FBG sensors, and further comprehensively monitored by three grating sensors. The results suggest that the steel corrosion process in UHPC is slowly with current density lower than 100 μA/cm2, and largely increases with current density higher than 500 μA/cm2, the volume expansion coefficient of corroded steel in UHPC is in range of 2.02–2.62 in this test, which is much different from Original C60 and Marine C60.

Investigating the Effects of Urea-Zinc Sulfate-L Phenylalanine on the Corrosion Inhibition of Mild Steel Exposed to pH-4 Sulfuric Acid

Background: Corrosion of mild steel is a risk to material and stability. The practice of corrosion inhibitors is a cost-effective corrosion modification method for mild steel. Organic inhibitors rich in electrons might have an excellent ability to prevent corrosion. This study aims to assess the inhibitory effect of the mixture of Urea, Zinc Sulfate, and L-Phenylalanine, which has a high electron density Methods: MS corrosion was experimentally performed using H2SO4 at a pH of 4. Different gravimetric and conventional techniques, such as polarization, AC impedance AFM, UV, and fluorescence, were used to examine the studied data. Results: According to gravimetric measurements, this combination produced 93% effective inhibition. The findings of the impedance test proved that the mixture of inhibitors that was adsorbed on the metal surface effectively prevented corrosion. Conclusion: Likewise, according to the Polarization measurements, the inhibitor exhibits mixed-type performance with significant cathodic activity. UV, Fluorescence, and AFM findings showed that MS corrosion was suppressed because the inhibitor molecule adhered to the metal's surface and reduced.

An investigation of the corrosion behavior of zinc-coated stainless steel orthodontic wires: the effect of physical vapor deposition method

BackgroundReleasing of metal ions might implicate in allergic reaction as a negative subsequent of the corrosion of Stainless Steel (SS304) orthodontic wires. The aim of this study was to evaluate the corrosion resistance of zinc-coated (Zn-coated) SS orthodontic wires.MethodsZinc coating was applied on SS wires by PVD method. Electrochemical impedance spectroscopy (EIS), Potentiodynamic polarization tests and Tafel analysis methods were used to predict the corrosion behavior of Zn-coated and uncoated SS wires in both neutral and acidic environments.ResultsThe values of Ecorr ,icorr and Rct ,which were the electrochemical corrosion characteristics, reported better corrosion behavior of Zn-coated SS wires against uncoated ones in both artificial saliva and fluoride-containing environments. Experimental results of the Tafel plot analyses were consistent with that of electrochemical impedance spectroscopy analyses for both biological solutions.ConclusionApplying Zn coating on bare SS orthodontic wire by PVD method might increase the corrosion resistance of the underlying stainless-steel substrate.

Investigation of iron dissolution mechanism in acidic solutions with and without dissolved CO2 – Part I: EIS measurements

ABSTRACT Aqueous CO2 corrosion of mild steel is one of the major problems in the oil and gas industry. While current understanding primarily focuses on cathodic reaction mechanisms, less attention has been given to the impact of aqueous CO2 on the anodic iron dissolution reaction. In contrast, the mechanism of iron dissolution in strong acidic environments has been thoroughly investigated. Among the reaction mechanisms found in the open literature, a multi-path mechanism was identified that could explain the iron dissolution in strong acidic sulfate solution; both in terms of steady state polarization sweeps and impedance data at various pH values and current densities. However, the role of aqueous CO2 in solutions containing chlorides on the mechanism of iron dissolution had remained an open question. The present study used electrochemical impedance spectroscopy (EIS) as the main technique, to study the mechanism of iron dissolution in strong acid chloride solution with and without the presence of CO2. Results showed that the presence of chloride ions (0.5 M) decreases the rate of iron dissolution by competing with hydroxide ions to adsorb on the metal surface, forming chloride-containing intermediate species that participate in the iron dissolution reaction. The resulting decrease in the availability of hydroxide intermediates, which are more effective at enhancing the reaction rate compared to chloride-containing intermediates, leads to an overall decrease in the rate of iron dissolution. While the presence of CO2 increases anodic current density, EIS investigation revealed that neither aqueous CO2 nor other carbonic species directly react on the bare metal surface to form adsorbed intermediates involved in the anodic reaction. EIS investigation suggested that aqueous CO2 may induce changes in the chemical composition of adsorbed species, rate constants, and surface coverage, thereby altering the kinetics of the underlying reactions.

Corrosion Inhibition Performance of Brachystegia eurycoma Leaf Extract on Mild Steel in Acid Media

The aim of this work is to investigate the corrosion inhibition of B. eurycoma leaves extract as a natural inhibitor for mild steel corrosion in 3 M H2SO4 solution. The corrosion inhibitory activity was analyzed by electrochemical impedance spectroscopy (EIS) and potentiodynamic polarization. The surface roughness and its properties through scanning electron microscopy (SEM). The obtained result from EIS divulges that the gradual increase in inhibitor concentration and time of immersion leads to progressive increase in inhibition efficiency. At the end of 8 hours immersion time and inhibitor concentration of 1000 mg/l the highest inhibition efficiency of (88%) was obtained. The potentiodynamic polarization results indicated that addition of B. eurycoma leaves extracts hindered the reaction rates of anodic and cathodic reactions thereby performing as mixed- type inhibitor. The corrosion current density also revealed that in the presence of B. eurycoma leaves extracts the value of corrosion density reduced considerably from 265.2 \(\mu\) A/cm2 for sample without inhibitor to 67.8 \(\mu\) A/cm2 for sample with inhibitor. Again, it was observed that in the presence B. eurycoma leaves extracts the mechanism of hydrogen (effervescence) evolution was unique whereas the anodic dissolution of iron mechanism experienced the impact of the inhibitor. SEM inspection revealed that the mild steel surface showed smoother and lower damage in the presence of inhibitor. Obvious correlations were found between corrosion inhibition efficiency and some quantum chemical parameters such as energy of highest occupied molecular orbital (EHOMO), energy of lowest unoccupied molecular orbital (ELUMO), energy gap (EL–H) and electronic density etc. The obtained results were further elucidated with frontier molecular orbital theory.

Evaluation of vateria indicia leaves extract as a green source of potential corrosion inhibitor against mild steel corrosion in 1M HCl solution: electrochemical, and surface characterisation studies

Evaluation of vateria indicia leaves extract as a green source of potential corrosion inhibitor against mild steel corrosion in 1M HCl solution: electrochemical, and surface characterisation studies

Corrosion of austenitic and ferritic steels, Kovar, and molybdenum in liquid Sb-Bi alloys with different compositions

Sb-Bi alloys may be applied as positive electrode in liquid metal batteries. In this work, the material compatibility of two steels (SS 316L and T91), Kovar 4J29, and molybdenum with SbBi9, Sb2Bi8, and Sb3Bi7 is investigated in static corrosion tests for 740 h at around 450 °C. Kovar shows severe dissolution attack (800 µm depth for SbBi9), which is mitigated at higher Sb contents due to the formation of Fe-Sb compounds. Both steels exhibit moderate corrosion depths (10–20 µm) for all Sb-Bi alloys thanks to the additional formation of stable Fe-Cr-Sb compounds. Good corrosion resistance is obtained for molybdenum.

Unraveling short-term O2 contamination on under deposit corrosion of X65 pipeline steel in CO2 saturated solution

The impact of short-term O2 contamination on the deposit-covered pipeline steel under a CO2-saturated solution was investigated using steel coupon and wire beam electrode. Results show that the brief exposure to O2 destroyed the FeCO3 film, and converted it into porous iron oxides, weakening its protection property. However, upon CO2 reinjection, the dense FeCO3 film regrew soon underneath the damaged FeCO3 layer on the bare steel, restoring its protective properties. Conversely, the localized corrosion beneath the deposits persisted and worsened, fueled by macro-cell current between the bare steel and the deposit-covered steel.

Influence of metal ions on cysteine as a corrosion inhibitor for low carbon steel in sulfuric acid: Polarization, EIS, XPS, and DFT analysis

This study examines the effectiveness of cysteine as an eco-friendly in inhibiting the corrosion of low-carbon steel in a sulfuric acid solution and the impact of adding various metal ions (Cu2+, Ni2+, and Co2+) to the media. All solutions were prepared using distilled water. The results show that 5 mM cysteine inhibits corrosion (IE = 65%), increasing to 93.5% in the presence of 4×10-5 M Cu2+ ions, but decreasing with the addition of Co2+ or Ni2+ ions. The inhibitive action of cysteine-Cu is the best one and that may be attributed to the formation of a protective coating on the metal surface, which prevents chemical reactions in an aggressive environment. Moreover, the DFT calculation found that the adsorption energy increased from −17.2 to −97.7 and −104.6 kcal/mol in the case of cysteine, Cysteine-Cu SAM, and Cysteine-Cu(II) Salt and the closest atom to the surface reduced from 2.576 to 2.128 and 2.146 Å which indicates Cysteine-Cu better adhere to the surface. SEM, XRD, and XPS were used to analyze the formation of the protective layer. This has the potential to develop new and more effective corrosion inhibitors for industrial applications.

Rust Prevention Property of a New Organic Inhibitor under Different Conditions.

The corrosion resistance properties of a new type of environmentally-friendly organic inhibitor containing amino ketone molecules are presented in this paper. To evaluate the prevention effect of the inhibitor on corrosion of reinforcement, the electrochemical characteristics of steels in the simulated concrete pore solution (SPS) were investigated under varied conditions of the relevant parameters, including concentrations of the inhibitor and NaCl, pH value, and temperature. The inhibition efficiency of the material was characterized through electrochemical impedance spectroscopy (EIS), potentiodynamic polarization, and the weight loss of steels. The results reveal a significant improvement in the corrosion resistance of steels with the inhibitor. A maximum resistance value of 89.07% was achieved at an inhibitor concentration of 4%. Moreover, the new organic inhibitor exhibited good corrosion protection capability for steels under different NaCl concentrations. Its inhibition efficiency was determined to be 65.62, 80.06, and 66.30% at NaCl concentrations of 2, 3.5 and 5%, respectively. On the other hand, it was found that an alkaline environment was favorable for an enhanced corrosion prevention effect, and an optimal pH value of 11.3 was observed in this work. Besides, the inhibition efficiencies at different temperatures showed a trend of 25 > 35 > 40 > 20 > 30 °C, with a maximum value of 81.32% at 25 °C. The above results suggest that the new organic material has high potential to be used as an eco-friendly and long-term durable inhibitor for steel corrosion prevention under complex conditions.

Synthesis and characterization of selenium-polyvinyl alcohol nanoparticles as eco-friendly corrosion inhibitor for carbon steel in 1.0 M H2SO4

Selenium nanoparticles capped with polyvinyl alcohol (Se-PVA NPs) have been synthesized by chemical reduction using ascorbic acid as a reducing agent. The synthesized nanoparticles were characterized using XRD, DLS, zeta potential, FT-IR, and TEM analysis and found to be stable. The solution of Se-PVA NPs was used as a carbon steel corrosion inhibitor in 1.0 M H2SO4. The effect of the presence of Se-PVA NPs in the corrosion medium was studied by potentiodynamic polarization and gravimetric analyses In the presence of Se-PVA NPs with a concentration of 600 ppm at 303 K, corrosion inhibition efficiency values of 92.86 % and 92.3 % were recorded by potentiodynamic polarization and gravimetric analysis methods, respectively. Over the Se-PVA NPs concentration range 100–600 ppm, it was found that increasing the concentration increases the inhibition efficiency, while the temperature has an adverse effect, inhibition efficiency values of 80.0 % was recorded at 323 K for the 600 ppm Se-PVA NPs solution. The potentiodynamic polarization measurements suggested that Se-PVA NPs work as a mixed-type inhibitor. The corrosion inhibition process was confirmed by testing the used specimens’ metal surface using SEM and AFM techniques, which showed that the acidic medium’s negative impact (distortion and roughness) on the carbon steel surface was reduced significantly in the presence of Se-PVA NPs. The inhibitor’s adsorption on the metal surface was studied. It obeys the Langmuir isotherm with a mixed-type adsorption process. The related kinetic and thermodynamic parameters were investigated.

Experimental Investigation of Producer Gas Effects on Coated Pipelines in Biomass Downdraft Gasifier System

Abstract This research examines the performance of epoxy, ceramic, and graphene coatings on stainless steel 316 in a producer gas environment, focusing on corrosion and erosion resistance. This research aimed to identify the most effective coating for applications in harsh gasification environments. In this research, various analyses, including microstructural examination, hardness and weight measurements, FESEM analysis, and EDAX analysis, were conducted to evaluate the performance of the coatings. The producer gas was passed on to all the coated samples for a period of 100 hours. The significant findings include the superior corrosion and erosion resistance of ceramic-coated stainless steel, as evidenced by low weight fluctuations, maintained hardness levels, and elemental stability. Graphene coatings exhibit high hardness but increased porosity, raising concerns about durability, while epoxy coatings are vulnerable to gas-induced structural alterations. The inclusion rating analysis underscored the ceramic coatings' ability to preserve consistent material properties. Overall, ceramic coatings have emerged as the preferred option for gasification environments due to their structural resilience, inclusion integrity, and elemental stability. Considering the inclusion integrity, mechanical strength, weight stability, and elemental stability, ceramic-coated stainless steel 316 samples exhibit better resistance toward producer gas influence. This research contributes valuable insights for material selection in applications exposed to harsh gasification environments, emphasizing the importance of coating selection for long-term durability and performance.

Investigation of microbiologically influenced corrosion of low alloy steels with different Cr contents in simulated oilfield produced water

Abstract Microbiologically influenced corrosion has become a predominant cause of pipeline and equipment failure in oil and gas fields. This research examines the corrosion behavior of steels with varying chromium contents in simulated shale gas formation water environments. Weight loss testing, Scanning Electron Microscopy (SEM), Energy Dispersive X-ray Spectroscopy (EDS), Focused Ion Beam (FIB), Transmission Electron Microscopy (TEM), and X-Ray Photoelectron Spectroscopy (XPS) were employed. The findings suggest that an elevated Cr content in steel results in a gradual reduction in its uniform corrosion rate in a CO2-SRB coexistence environment. This can be primarily attributed to the significant distribution of Cr content throughout the entire product film, including both biofilm and corrosion products, thereby enhancing the product film's protectiveness. Additionally, the competitive corrosion between CO2 and SRB, as well as the influence mechanism of Cr on corrosion, were discussed.

Influence of Thermal Aging Treatments on Intergranular Corrosion and Cyclic Oxidation Behavior of Low Nickel and Nickel-Free Austenitic Stainless Steels

Influence of Thermal Aging Treatments on Intergranular Corrosion and Cyclic Oxidation Behavior of Low Nickel and Nickel-Free Austenitic Stainless Steels

STUDYING THE INFLUENCE OF NEW COMBINED INHIBITORS ON THE PROCESSES OF CORROSION AND SALT DEPOSITION IN OIL-FIELD EQUIPMENT

Aggressive salts contained in formation waters accelerate the processes of corrosion and salt deposition in oilfield equipment, which leads to unforeseen accidents, contamination of soil and groundwater with harmful substances, as a result of which the ecological balance of the environment is disrupted. Corrosion and scaling that occur during oil production create difficulties during the operation of wells, and, consequently, increase the cost of produced oil.This article covers the results of studies concerning two compositions developed from technical phosphatide - an emulsion obtained by hydration of vegetable oils, as well as sodium hexametaphosphate, ammophos and polypropylene glycol bottoms. When vegetable oils are treated with water and steam (hydration process), the phospholipids contained in the oils combine with water and are released in the form of precipitates called phosphatide emulsions. Such emulsions consist of 45–75 % water, and the rest is phospholipids in the vegetable oil sediment.Technical phosphatides are a group of esters that contain a phosphoric acid residue associated with an amino alcohol. They are natural surfactants and are non-toxic.Preliminary studies have shown that each of the chemical compounds included in the developed reagents has certain inhibitory properties, but when formulated, these compounds provide a synergistic effect.Based on the results of laboratory studies, it was found that at an optimal concentration of reagents of 200 mg/l, the developed compositions provide protection of equipment from corrosion destruction by 94–95 %, and from scaling by 87–88 %. The developed mixed-type inhibitors at optimal concentrations equally effectively inhibit both cathodic and anodic processes on the electrode.The use of these inhibitors leads to the prevention of steel corrosion in the two-phase oil-electrolyte system, as well as to a significant reduction in the rate of scaling.The proposed new compositions can be used in oil wells and in-field transport systems, as well as in reservoir pressure maintenance systems to protect against corrosion and scale deposits.Field tests of the corrosion inhibitor were carried out in deep pumping wells at the Bibieybatneft oil and gas production department. Tests have shown that as a result of using the inhibitor, the protective effect at a concentration of 200 mg/l was 89–90 %, and the effect of salt deposition was 70 %.

Effect of hydrocarbon volume ratio in sweet top-of-the-line corrosion under water-hydrocarbon co-condensation

Wet gas pipelines transport unprocessed natural gas that contains water and carbon dioxide (CO2), which combination can lead to severe wall loss caused by CO2 or sweet corrosion in carbon steel. Under specific conditions, CO2 corrosion occurs at the top section of the pipeline, which is known as top-of-the-line corrosion (TLC). TLC tests were conducted in the water-hydrocarbon co-condensation environment using 10 vol% n-heptane and 25 vol% n-heptane to simulate the internal condition of a wet gas pipeline to study the effect of hydrocarbon volume ratio towards TLC. The presence of n-heptane showed minimal effect on the gas temperature profile; however, n-heptane suppressed the water condensation, resulting in a tremendous decrease in the water condensation rate (WCR). The TLC rates were found to be lower in the presence of n-heptane, which can be attributed to the reduced WCR and water-wetted areas. The presence of n-heptane had no significant effect on the pitting rates but showed an increasing pit ratio as the n-heptane volume increased. TLC tests were conducted at three durations: one day, two days and three days showing that n-heptane has no significant effect on corrosion kinetics.

Comprehensive analysis of a thiazole-substituted corrosion inhibitor's impact on N80 carbon steel in acidic conditions: Integrating computational predictions with experimental verifications

The present investigation elucidates the effectiveness of a newly developed organic inhibitor, namely 6,6-diphenyl-2,3-dihydroimidazo[2,1-b]thiazol-5(6H)-one (PHIT) in inhibiting the corrosion of N80 carbon steel (N80-CS) in 15 wt% HCl at 303 K. An integrative approach combining theoretical insights through Density Functional Theory (DFT) and molecular dynamics (MD) simulations with empirical data derived from a suite of analytical techniques (namely, weight loss measurements, electrochemical impedance spectroscopy (EIS), potentiodynamic polarization (PDP), and scanning electron microscopy (SEM)), was employed to assess the corrosion inhibition performance. The research identified the thiazolone fragment as the predominant site of activity within the PHIT molecule. According to EIS results, a significant reduction in the effective double-layer capacitance from 174 (blank) to 36.17 μF/cm2 was registered following the addition of 5 × 10−3 mol/L PHIT to the HCl medium. Moreover, at a low concentration of 10−4 mol/L, the inhibition efficiency reached a maximum of 95 %. The immersion time had a significant effect on the inhibitor's polarization resistance, peaking at 48 h (596 Ω cm2), then experiencing a minor reduction at 72 h (457 Ω cm2), in comparison to the blank measurement at 0.5 h (231 Ω cm2). Besides, the inhibitor demonstrated a high degree of effectiveness across various temperatures with a slight decrement in efficiency from 96.5 % at 303 K to 94 % at 363 K. PDP results confirmed the tested compound as an anodic-type inhibitor. These results affirmed the potential of PHIT as a highly efficacious organic inhibitor for N80-CS in acidic conditions, encouraging further development of its derivatives.

Impact of gravity on biofilm growth and corrosion of X65 pipeline steel by a sulfate reducing bacterium

Desulfovibrio ferrophilus (IS5) corrosion of X65 carbon steel was impacted by gravity. Six o’clock position (6P) had the highest sessile count due to gravity assisting planktonic cell settling in early biofilm formation, leading to most severe static corrosion followed by 9P and 12P. The 7-d weight loss at 6P was 49.6 ± 4.4mg/cm2 (3.3mm/a in uniform corrosion rate) followed by 9P with 35.7 ± 2.6mg/cm2 (2.4mm/a) and 12P with 20.5 ± 5.5mg/cm2 (1.4mm/a). The trend was supported by electrochemical measurements. The weight loss differences reduced considerably when there was agitation, supporting the gravity hypothesis.

The effect of different heavy metals pollutants in refinery effluent on corrosion rate of carbon steel

The presence of heavy metal pollutants in refinery effluent significantly impacts the corrosion rate of carbon steel. The focus of this research is to analyze the impact of various inorganic pollutants, including copper, vanadium, nickel, and chromium ions, on the corrosion of carbon steel across different solutions. After conducting a thorough examination of various operating conditions, including pollutant concentration (ranging from 300-3000 ppm), temperature (30-60? C), and flow velocity (0-800 rpm). Our research shows that copper ions have the highest corrosion rate, with vanadium ions being a close second. Conversely, nickel and chromium had the most negligible impact on corrosion rate and, in some instances, even exhibited corrosion inhibition effects. It was also observed that an increase in flow velocity and temperature significantly amplified the corrosion rate of the metal ions investigated.

Evaluation of inhibition performance of methylimidazolium ionic liquids on surface of mild steel in sulfuric acid

In the present study, the microwave irradiation approach was used to synthesize two methylimidazolium-based ionic liquids (MImILs), specifically 1-Heptyl-3-methylimidazolium bromide [HMImBr] and 1-Benzyl-3-methylimidazolium bromide [BzMImBr]. Several spectroscopic methods have been used to characterize the produced compounds. Gravimetric and electrochemical techniques were employed to examine their ability to prevent corrosion of the mild steel in a 0.5 M sulfuric acid solution. Amongst all the evaluated ionic liquids, [BzMImBr] having an aromatic ring instead of hexyl ((–CH2)5–CH3) hydrocarbon of [HMImBr] manifests better inhibition efficiency of 95.49 % at 1000 ppm concentration. The experimental ionic liquids negatively impact both the anodic and cathodic Tafel reactions, exhibiting mixed-type inhibition properties, as demonstrated by the findings of the potentiodynamic polarization investigations. Through their adsorption employing their electron-rich centres, the examined ionic liquids create a corrosion-protective covering, and their adsorption follows the Langmuir isotherm model. Negative values of ΔGads indicate the spontaneous nature of [HMImBr] and [BzMImBr] adsorption, whereas values between −20 and −40 KJ mol−1 indicate the physio-chemisorption mode of adsorption. Energy dispersive X-ray spectroscopy (EDS), atomic force microscopy (AFM), and field emission-scanning electron microscopy (FE-SEM) techniques were used to assess and evaluate surface morphology. The DFT-based analysis indicates that aromatic rings played a significant role in the charge sharing (donation and acceptance) in [BzMImBr].