Surface Corrosion Research Articles

Study on electrochemical polishing mechanism of TC4 titanium alloy

To achieve a high-quality and precise surface on TC4 titanium alloy for demanding engineering applications, electrochemical polishing (ECP) technology was employed to investigate the polishing process of TC4 titanium alloy in an ethylene glycol-sodium chloride green electrolyte. The macro and micro morphology, surface roughness, material removal rate, surface elements, surface corrosion resistance, and surface hardness of TC4 titanium alloy were measured before and after polishing. Single-factor experiments were conducted to explore the effects of processing gap, electrolyte temperature, polishing voltage, and polishing time on TC4 titanium alloy surface quality. Optimal polishing parameters were determined to be an electrode gap of 12 mm, a voltage of 20 V, a temperature of 40 °C, and a polishing time of 10 min. The experimental results indicated that after electrochemical polishing, the workpiece surface roughness Ra decreased from 256 nm to 25 nm, achieving a roughness reduction rate of 90.23%, the material removal rate was 3.348 μm min−1. The self-corrosion potential of the polished surface increased from −0.416 V to −0.375 V and the self-corrosion current density decreased from 4.447 × 10−7 A·cm−2 to 1.873 × 10−7 A·cm−2, the surface indentation hardness of the workpiece decreased from 5.8669 GPa to 4.6726 GPa. Based on the characterization of polished surface, the mechanism of electrochemical polishing of TC4 titanium alloy was proposed. The results demonstrate that electrochemical polishing of TC4 titanium alloy is highly efficient, involves no mechanical action, and causes no subsurface damage, making it a promising technology to meet medical requirements.

A comparative investigation on the surface characteristics of AISI 304 and AISI 1045 steel influenced by turning combined with ball burnishing

Burnishing is a popular superfinishing procedure in the manufacturing industry that induces plastic deformation to the finished product by the application of a highly polished and hardened deforming element known as a burnishing tool. Research work on the burnishing process is numerous. However, the reports containing the comparative investigations are lacking. In this work, the effect of ball burnishing parameters namely penetration depth, burnishing spindle speed, and number of passes has been compared and analyzed on AISI 1045 and AISI 304 steels with respect to surface roughness, hardness, wear resistance, and corrosion resistance. Results indicate that the combination of a feed rate of 0.12 mm/rev, spindle speed of 160 rpm, and penetration depth of 0.025 mm with four passes generated minimum surface roughness (AISI 1045). However, maximum surface hardness is obtained with a feed rate of 0.12 mm/rev, spindle speed of 160 rpm, and at 0.085 mm penetration depth under one pass (AISI 304). The lowest specific wear rate is achieved with a feed rate of 0.12 mm/rev at a spindle speed of 160 rpm and a penetration depth of 0.085 mm in one pass (AISI 304). The burnishing process influenced both materials, AISI 304 and AISI 1045, under varying parametric conditions. The maximum reduction in surface roughness is 68.1% for AISI 304 and 79.3% for AISI 1045, while surface hardness improves by 27% for AISI 304 and 22% for AISI 1045. Additionally, the burnishing process reduces the specific wear rate by 49.3% for AISI 304 and 45.4% for AISI 1045. The refinement of grains during the burnishing process enhances corrosion resistance compared to the unburnished surface.

Effect of Ce on structural evolution and corrosion resistance of HRB500E rebar corrosion layer

HRB500E rebar is a low-alloy high-strength steel with excellent mechanical properties and good plasticity but suffers from deficient corrosion resistance. This can be solved by adding trace elements, including rare earth elements. Herein, the corrosion-resistant behavior of rebar was evaluated by weightlessness testing and electrochemical measurements, and the effects of Ce on the structural evolution of the corrosion product layer were investigated by scanning electron microscopy (SEM), Electron Probe X-ray Micro-Analyzer (EPMA), X-ray diffraction (XRD), and X-ray photoelectron spectroscopy (XPS). The results showed that adding Ce to the rebar improved the densification of the reinforcing surface corrosion products, as well as reduced the corrosion rate of the experimental rebar. Compared to C0 sample without Ce, the rebar sample containing 0.044 wt.% Ce displayed increased Ecorr by 0.051 V, decreased Icorr by 15.573 mA cm−2, enhanced Rc of the corrosion product layer by 112.71 Ω cm2, incremented α-FeOOH content in the corrosion product layer, and boosted ratio of α/γ* in the corrosion product layer by 10.11%. Furthermore, the oxide (CeO2) formed by Ce in the corrosion layer of the rebar bar surface existed in the rust layer, resulting in a stable corrosion product layer with improved blocking ability of the corrosive medium. Overall, the addition of Ce at certain ratios looks promising to produce HRB500E rebar with excellent corrosion resistance and extended service life under harsh conditions.

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

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

Influence of the activation time of magnesium surfaces on the concentration of active hydroxyl groups and corrosion resistance

Magnesium alloys have been extensively studied as degradable biomaterials for clinical applications due to their biocompatibility and mechanical properties. However, their poor corrosion resistance can lead to issues such as osteolysis and the release of gaseous hydrogen. This study investigated the influence of the activation time of magnesium surfaces in a sodium hydroxide (NaOH) solution on the concentration of active hydroxyl groups and corrosion resistance. The results indicated that immersion time significantly influences the formation of a corrosion-resistant film and the distribution of surface hydroxyl groups. Specifically, specimens treated for 7.5 h exhibited the highest concentration of hydroxyl groups and the most uniform oxide film distribution. Electrochemical tests demonstrated capacitive behavior and passive surface formation for all evaluated times, with the 7.5-h immersion in NaOH yielding superior corrosion resistance, lower current density, and a more efficient and thicker protective film. SEM and EDS analyses confirmed increased formation of Mg(OH)₂ for samples treated for 5 and 7.5 h, while a 10-h treatment resulted in a brittle, porous layer prone to degradation. Statistical analysis using ANOVA and Fisher's LSD test corroborated these findings. The optimal 7.5-h alkali treatment enhanced magnesium's corrosion resistance and surface properties, making it a promising candidate for orthopedic implants. However, further studies are necessary to assess biocompatibility and physiological responses before clinical implementation.

Corrosion Behavior of Ferritic 12Cr ODS and Martensitic X46Cr13 Steels in Nitric Acid and Sodium Chloride Solutions.

This paper presents corrosion resistance results of a 12Cr ferritic ODS steel (Fe-12Cr-2W-0.5Zr-0.3Y2O3) fabricated via a powder metallurgy route as a prospective applicant for fuel cladding materials. In a spent nuclear fuel reprocessing facility, nitric acid serves as the primary solvent in the PUREX method. Therefore, fundamental immersion and electrochemical tests were conducted in various nitric acid solutions to evaluate corrosion degradation behavior. Additionally, polarization tests were also performed in 0.61 M of sodium chloride solutions (seawater-like atmosphere) as a more general, all-purpose procedure that produces valid comparisons for most metal alloys. For comparison, martensitic X46Cr13 steel was also examined under the same conditions. In general, the corrosion resistance of the 12Cr ODS steel was better than its martensitic counterpart despite a lower nominal chromium content. Potentiodynamic polarization plots exhibited a lower corrosion current and higher breakdown potentials in chloride solution in the case of the ODS steel. It was found that the corrosion rate during immersion tests was exceptionally high in diluted (0.1-3 M) boiling nitric acid media, followed by its sharp decrease in more concentrated solutions (>4 M). The results of the polarization plots also exhibited a shift toward more noble corrosion potential as the concentrations increased from 1 M to 4 M of HNO3. The results on corrosion resistance were supported by LSCM and SEM observations of surface topology and corrosion products.

Surface topography and corrosion resistance of AISI 630 stainless steel after finish turning under different cooling methods

AISI 630 stainless steel (SS) is widely used for medical devices. This paper describes the effects of dry, flood and minimum quantity lubrication (MQL) machining conditions on the surface topography and corrosion resistance (CR) of AISI 630 SS after finish turning. Small areas of valleys and large areas of peaks were observed on the surfaces with minimum surface roughness (SRmin) after dry machining at the feed rate (f) of 0.1 mm/rev and at the f = 0.14 mm/rev using the MQL method. Only small areas of peaks were observed after flood machining at the f = 0.1 mm/rev. Regardless of cooling methods, regularly distributed deep valleys and high peaks were observed on the surfaces with maximum surface roughness (SRmax) machined at the f = 0.35 mm/rev. Surfaces of the samples with SRmin and SRmax under flood machining and with SRmax under MQL machining had high oxygen content in the range of ∼ (20−30) %wt. during 7–72 days of the sample storage in SBF. Such an oxygen content is observed on the machined surfaces for which maximum peak height Sp parameters were in the range of ∼ (10–16) μm and maximum valley height Sv – ∼ (8–10) μm. Compared to SRmin, high ion diffusion was observed on surfaces with SRmax. This means that surfaces with regular deep valleys and high peaks provide high ion mobility between them. In addition, compared to dry and MQL machining, higher resistivity was obtained for the samples under flood machining. Depending on the industrial application requirements, the passivity and CR of AISI 630 SS can be modulated by selecting machining conditions and surface topography. It has been established that in order to achieve favorable CR of the AISI 630 SS surface after finish turning, the flood method is recommended.

Self-assembled polysilane artificial solid electrolyte interphase layer towards highly reversible zinc electrochemistry

Commercial applications of aqueous Zn batteries primarily encounter challenges related to surface corrosion and dendrite formation. In this study, a hydrophobic polysilane layer functionalized with −CF3 groups (CF3-PSiOX) is tailored for Zn anode through a two-step process involving self-assembly and condensation. The CF3-PSiOX layer functions as a protective barrier, effectively isolating water and inhibiting corrosion. Moreover, the primary interactions between −CF3 and Zn2+ guides the diffusion and deposition processes of Zn2+ while optimizing the de-solvation process, ultimately resulting in dendrite inhibition. Hence, cells with CF3-PSiOX layer boasts a high Coulombic efficiency (∼99.8 % after 1500 cycles), a long lifespan (over 2400 h), and optimized capacity retention (73.3 % over 1000 cycles). The self-assembled polysilane layer with customizable groups offers a novel approach for tuning the interface properties of Zn anodes and establishes a general principle for interface adjustment applicable to alternative metallic electrodes.

Structure and properties of surface layer of TiNi alloy subjected to ion-plasma- and ultrasonic treatment

The paper presents the results of research on morphology, elemental composition, microhardness, corrosion properties of the surface layer of TiNi alloy subjected to ion-plasma (vacuum-arc method) deposition of TiN coating and ultrasonic treatment (UT) with different number of passes (n). The SEM method showed that ultrasonic treatment provides a significant reduction in the amount of the droplet phase on the TiN coating surface. The surface discontinuity of TiN coating at local points was observed with an increase in the number of passes during ultrasonic treatment. The effect of combined processing methods on the microhardness of TiNi sample was studied. It was shown that the synergistic effect can be observed for two hardening methods. The combined strengthening method increased the microhardness of TiNi alloy (1.6 GPa in the as-received state): due to the deposition of a TiN coating – up to 10.9 GPa, due to subsequently ultrasonic treatment – up to 14.5–18.4 GPa depending on the number of passes. For UT + TiN scheme, it was shown that the open circuit potential Ecorr was about –250 mV which is practically independent of the number of passes and determined by the potential value of TiN coating. For TiN + UT scheme, it was found that with an increase in the number of passes, the value of Ecorr shifts towards more negative values approaching the open circuit potential value of the TiNi sample in the as-received state (–350 mV). The analysis of Scanning Vibrating Electrode Technique (SVET) results showed high electrochemical compatibility of substrate (TiNi) and coating (TiN) materials in a chloride environment with minimal current density fluctuations for the samples subjected to UT + TiN and TiN + UT (n = 1). The proposed method for TiNi alloy treatment according to TiN + UT scheme (n = 1) promotes an improvement of surface morphology and corrosion resistance.

Bending behaviour of surface corroded and perforated corroded steel tubes repaired by laser cladding additive manufacturing

In recent years, laser cladding (LC) technology has been increasingly applied and investigated for repairing damaged surface on metal structural components. However, there are limited experimental studies on the bending behaviour of the LC repaired steel components. And an effective repair method for the perforated corroded steel components is still lacking, therefore, this paper introduces a novel LC repair method for such steel tube. Four-point bending tests were conducted on four specimens, including one intact steel tube (IT), one surface corroded steel tube (SCT), one surface corroded steel tube repaired by LC (SRT), and one perforated corroded steel tube repaired by LC (PRT) to verify the effectiveness of the LC repair methods by evaluating their structural performance in terms of bending capacity, rotational stiffness, and ductility. The experimental results showed that the bending strength and rotational stiffness of the SRT and PRT can be fully restored and even slightly higher than those of the IT. The strain analysis indicated that the LC repair method can significantly reduce stress/strain concentration caused by surface corrosion and perforation corrosion. The experiments were replicated numerically by means of finite element (FE) analysis and parametric studies were performed to investigate the effect of different factors on the bending behaviour of the PRT and SRT. Furthermore, design formula for predicting the elastic bending capacity of the LC repaired steel tube was developed.

Study on Chalcopyrite Dissolution Mechanism and Bioleaching Community Behavior Based on Pulp Concentration Gradient at 6 °C

Low-temperature bioleaching is relevant to the recovery of metals in alpine mines, but its development has been constrained by low bioleaching rates at high pulp concentrations. To this end, the bioleaching effect of the microbial community after the domestication of pulp concentration at 6 °C was studied. Domestication improved the bioleaching rate of copper. Environmental scanning electron microscopy (ESEM), X-ray diffraction (XRD), and electrochemical measurements revealed that the domestication process aggravated the corrosion of the chalcopyrite surface by accelerating its dissolution reaction. High-throughput sequencing technology indicated that Acidithiobacillus spp., Leptospirillum spp., and Acidiphilium spp. were the major lineages of the domesticated microbial community. The analysis of the microbial community revealed that domestication changed the microbial structure, enhancing the adaptability of the microbial community to pulp concentrations and acidic conditions. This study uncovered the mechanism by which domestication enhanced the bioleaching efficiency of the microbial community at low temperatures.

Effect of plating time on surface morphology and corrosion behavior of electroless Ni-P coating in simulated concrete pore solution

As a protective coating, electroless Ni-P (ENP) coating with various deposit times was fabricated on the carbon steel. The morphology, microstructure, and composition of the ENP coating were investigated via SEM, AFM and XRD. The anti-corrosion capability and protective mechanism of the coating exposed to chloride-contaminated simulated concrete pore solution (CL-SCPS) were evaluated by OCP, potentiodynamic polarization, EIS, and Mott-Schottky analysis. As deposit duration increased, the Ni and P content percentage and compactness of ENP coating increased, but “trenches” appeared. The corrosion behavior of ENP coating was closely related to the thickness and surface morphology. That is to say, the coating with the thin layer and defects could represent low corrosion resistance. Moreover, passivation would occur on the ENP coating in an alkaline environment. The performance of the passive film was also related to the thickness and morphology of the coating. The oxidation products could partially repair the surface “trenches”. The ENP coating with an 80-min deposit duration had the highest corrosion resistance in the short immersion stage. Coating with a 60-min deposit duration represented optimal corrosion resistance and desirable electrochemical stability in the long-term service in aggressive media.

Modeling and tracing of polycarbonate (PC) degradation in soil microcosm with a PC microplastics quantification method based on pyrolysis GC–MS

Understanding the migration and transformation of polycarbonate (PC) plastic wastes in the natural environment is crucial for assessing their environmental impact and bioremediation. In this study, PC plastic degradation was modeled and traced in soil microcosm by investigating physiochemical properties changes of PC, the formation of microplastics, and changes in soil microbial communities. Notably, PC microplastics quantification method was also successfully devised by pyrolysis gas chromatography mass spectrometry and also applied herein. Through gel permeation chromatography analysis, the molecular weight of the naturally aged PC film obviously reduced, whereas no change for unaged ones. After 12 months of soil burial, the surface corrosion and holes formation were emerged on the surfaces of both PC films in the non-sterilized soil harboring indigenous microorganisms by scanning electron microscope. The worsened thermal stability of both PC films in non-sterilized soil was demonstrated by thermogravimetric analysis. Meanwhile, the presence of increased hydroxyl group absorption and decreased carbonyl peak highlighted molecular chain breakage in both PC films by Fourier transform infrared spectroscopy. In particular, all the changes were more significant in aged PC than unaged ones. Furthermore, the increase of quantified PC microplastics on the surface of PC film in the non-sterilized soil accompanied the decreasing of microbial diversity and the enrichment of potential functional microorganisms. These findings revealed that the combination of natural aging and indigenous microbes exhibited a noticeable performance in PC plastics degradation in soil microcosm, providing new insights into the degradation mechanism of PC plastic wastes in the natural environment.

Root cause analysis of corrosion failure of a firefighting pipeline

This is a specific case of corrosion damage to underground pipelines in the Arabian Gulf region caused by stray current corrosion. The damage occurred in a fire protection piping system connected to a sprinkler system. The investigation revealed that the corrosion surface morphology was localized and had historically occurred in the same location of previously failed pipe sections. Despite previous attempts to correct the problem, the cause remained undetected and undetermined. It was determined that the failure was due to electromagnetic forces generated by the proximity of high AC and DC voltages. Specifically, the stray current corrosion was caused by interference from electrical cables, including a high-voltage cable and a ground discharge from electrical electrodes. To prevent future failures, it was strongly recommended that all existing conduit pipes in the affected section be insulated with double-layer insulating tape, which has high impedance and dielectric properties.

Factors Influencing Chloride Ion Diffusion in Reinforced Concrete Structures.

Reinforced concrete structures are prone to the corrosion of steel bars when exposed to chloride-rich environments, which can severely impact their durability. To address this issue, a comprehensive understanding of the factors influencing chloride ion diffusion in concrete is essential. This paper provides a summary of recent domestic and foreign research on chloride ion transport in concrete, focusing on six key factors: water-binder ratio, additive content, crack width, ambient temperature, relative humidity, and dry-wet cycles. The findings show that the diffusion coefficient of chloride ions in concrete increases with a higher water-binder ratio and decreases with increased additive content. Additionally, wider cracks result in a greater diffusion of chloride ions. The permeability resistance of concrete to chloride ions decreases with rising temperature and humidity, and dry-wet cycles further accelerate the diffusion of chloride ions. The article concludes by discussing various anti-corrosion measures, such as the use of corrosion inhibitors, surface coatings, and electrochemical treatments, to ensure the longevity of the structure. Finally, directions for future research are proposed.

Effects of the Ultrasonic Surface Rolling Process on the Surface Integrity, Wear Resistance, and Corrosion Resistance of 4Cr5MoSiV1 Tool Steel Before and After Quenching

Effects of the Ultrasonic Surface Rolling Process on the Surface Integrity, Wear Resistance, and Corrosion Resistance of 4Cr5MoSiV1 Tool Steel Before and After Quenching

Effect of Chlorhexidine and Povidone-iodine Mouth Rinses on Corrosion Resistance and Surface Characteristics of Stainless Steel Orthodontic Brackets – An in vitro and in vivo Study

Abstract Background: Stainless steel (SS) orthodontic brackets may have varying corrosion resistance when used with mouthwashes during orthodontic treatment. Studying their effects on orthodontic brackets will be beneficial. Aim: The study’s objective was to analyze the surface characteristics of SS orthodontic brackets and their resistance to corrosion, exposed to chlorhexidine and povidone-iodine mouth rinses – an in vitro and in vivo study. Materials and Methods: The in vitro test: MBT 0.022” slot SS orthodontic brackets were immersed in three groups – Group A – Modified Meyer-Fusayama artificial saliva (AS), Group B – Chlorhexidine, and Group C – Povidone-iodine mouthwash. The in vivo test: Brackets were conventionally bonded on the patient’s teeth and divided into Group I – control group, Group II – patients used chlorhexidine, and Group III used povidone-iodine mouth rinse. The corrosion resistance and surface characteristics of SS brackets were determined using scanning electron microscope (SEM), electrochemical impedance spectroscopy, and X-ray photoelectron spectroscopy. Results: Higher corrosion resistance was obtained for brackets immersed in chlorhexidine mouth rinse. The polarization resistance value of the orthodontic SS bracket was 109 MΩ, 1383 MΩ, and 769 MΩ immersed in AS, chlorhexidine, and povidone-iodine mouth rinse, respectively. After surface chemical analysis, XPS data showed the largest intensity peak of metallic chromium (CrO) fresh sample and in the sample immersed in chlorhexidine mouthwash. According to SEM, brackets immersed in chlorhexidine showed a relatively smooth surface. Conclusion: In this study, chlorhexidine was found to be less corrosive followed by povidone-iodine.

Research of a new multifunctional composition against the corrosion of the internal surface of oil pipelines in the mine shaft

For the first time, a chloroprene reagent (named as Z-1) has been used against corrosion in various aggressive environments under laboratory conditions. The corrosion protection properties of the reagent Z-1 have been studied in formation waters taken from oil wells No. 2646, 33151, 4012, 31193 and 33016 in operation at Balakhani Oil OGED. Samples made of Ct3 and P-105 brand steels with dimensions of 42155 mm have been used during the tests. Experiments have been performed under dynamic conditions at room temperature for six and twenty-four hours, and the corrosion rate has been determined by gravimetric method. During the experiments, concentrations of 10, 15, 20 and 25 mg/l of Z-1 composition were used. The analysis of results from numerous experiments conducted with both types of steel revealed that the optimal concentration of the composition is 25 mg/l. The protection efficiency of the composition Z-1 in the formation waters of the abovementioned oil wells during the six-hour experiment was as follows: for Ct3 samples, it ranged from 75% to 94%, 75% to 97%, 76% to 98%, 72% to 94%, and 68% to 87%, respectively, while for P-105 steel samples, it ranged from 76% to 96%, 72% to 92%, 73% to 85%, 70% to 90%, and 72% to 96%, respectively. During 24-hour corrosion tests, the protection efficiency of the composition Z-1 was 73–92%, 74–96%, 75–97%, 70–92%, and 66–85% for Ct3 steel samples and 75–94%, 70–91%, 72–83%, 68–89%, and 71–95% for P-105 steel samples, respectively.

Ni–Cr dental alloys - porcelain firing impact on corrosion properties and surface characteristics

Biocompatibility is a critical aspect of the use of materials in the human body. The use of base metal alloys in dentistry is primarily regulated by health and safety standards set by regulatory authorities in various countries. The porcelain-fused-to-metal (PFM) process applied to Ni-Cr dental alloys can alter their properties, particularly in terms of corrosion and surface characteristics. This study aimed to assess the effect of the heat processing used for dental porcelain firing on these properties. The two casted alloys: Ceramic N and Ivoclar Vivadent 4all, used in the study were characterized by analyzing the microstructure by scanning electron microscopy (SEM), composition with energy dispersive x-ray spectroscopy (EDS), hardness, surface profile and electrochemical corrosion resistance (Ecorr, jcorr, polarization curve, Ebr and electrochemical impedance spectroscopy (EIS) results), as well as ions release before and after the simulated porcelain firing. Based on the conducted research the following conclusions can be drawn: Analyzes of the material characteristics before and after the simulation showed that the discussed process, although it does not cause the formation of chemical impurities on the surface of the alloys, results in changes in the chemical composition and structure of surface oxides, increases roughness and reduces hardness. The results of the corrosion examinations showed a deterioration in anti-corrosion properties after the simulation. The statistically significant decrease in corrosion resistance may result from the increased heterogeneity of the surface oxide layers and partial changes in their composition.

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 ± 0.0004 mm/y and the application of a constant load results in an increase in the corrosion rate to 0.26 ± 0.013 mm/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 29.5 µm, 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.