Corrosion Performance Of Steel Research Articles

Sonophotopythochemical Functionalization of Graphene Oxide - Al - Zn Bimetal Nanocomposite for Corrosion Inhibition

The corrosion performance of steel in the marine environment has been a primary concern of engineers and garnered significant interest due to its industrial significance. To address this concern, the incorporation of green corrosion inhibitors as coating materials in mild steel has been extensively studied recently. This paper explores the synthesis of graphene doped with bimetal aluminum-zinc (GO-Al-Zn) nanocomposites via sonophoto-phytochemical functionalization using Chayote (Sechium edule) leaf extract as the doping agent to produce a corrosion inhibitor. The synthesized nanocomposites were characterized using FTIR, SEM-EDS, XRD, and TEM. The optimal nanocomposite, with a 55% Al - 45% Zn ratio, demonstrated successful bio-reduction, good dispersion, reduced particle size, and a rhombohedral crystal structure. When incorporated into an epoxy coating and applied to mild steel, the GO - 55% Al - 45% Zn coating achieved a high corrosion inhibition efficiency of 98.06% (gravimetric method) and 98.45% (electrochemical method) in 3.5 wt% NaCl solution. This study highlights the promising potential of GO - 55% Al - 45% Zn nanocomposite as an eco-friendly corrosion inhibitor. Future research should explore optimizing the functionalization process and exploring long-term environmental stability.

Research on corrosion performance of Q235B steel in industrial coastal atmospheric environment

This study aims to obtain the effect of SO2 on the corrosion of Q235B low carbon steel in simulated coastal industrial atmospheres.The corrosion performance of the steel in the simulated atmospheres was studied using wet/dry cyclic corrosion test (CCT), electrochemical testing analysis, scanning electron microscopy, X-ray diffraction, and COMSOL finite element simulation methods. As a result the influence of SO2, the corrosion rate of Q235B steel increases rapidly in the initial stage of corrosion, and gradually decreases in the later stages, eventually stabilizing. There is a gradual increase in ferrite content on the surface of the steel during the initial stage of corrosion. In addition, the main components of the rust layer α-FeOOH and γ-FeOOH, and high concentrations of SO2 promote α-FeOOH formation and inhibit γ-FeOOH formation.

Exploring the corrosion performances of carbon steel in flowing natural sea water and synthetic sea waters

ABSTRACT The corrosion performances of the EH 36 carbon steel in stagnant and flowing natural sea water and synthetic sea waters were investigated. Results show that the general corrosion rates of the steels are close in stagnant natural sea water and synthetic sea waters. The corrosion rate, corrosion feature and the rust components of the steels in flowing 3.5% NaCl solution were significantly different from those of the steels in flowing natural sea water, indicating 3.5% NaCl solution could not restore the flow accelerated corrosion (FAC) performance of carbon steels in marine environment. The pH difference between 3.5% NaCl solution and natural sea water is not the main contributor for FAC performance changing. The corrosion performance of the steel in ASTM D1141 synthetic sea water was similar to that in natural sea water within small deviations of the corrosion rate at both static and flowing conditions.

Challenge and Review of Hydrogen Sulfide Corrosion Resistance Steels for Oil Country Tubular Goods

Corrosion of oil country tubular goods not only causes huge economic loss, but also brings serious environmental pollution. Stress corrosion cracking of oil country tubular goods in the sulfur-containing environment is the principal corrosion failure form in the exploitation of oil and gas process. Therefore, extensive investigations on hydrogen sulfide corrosion of steels for oil country tubular goods have been carried out. The aim of this work is to review the research progress on the hydrogen sulfide corrosion performance of steels for oil country tubular goods. The influence of alloy elements, defects, environmental factors and mechanical factors on hydrogen sulfide corrosion resistance of steels for oil country tubular goods were discussed. The future work in hydrogen sulfide corrosion performance of oil country tubular good and new sulfur-resistant steels for oil country tubular goods development were prospected.

The Interaction of Biofoulants and Calcareous Deposits on Corrosion Performance of Q235 in Seawater.

An understanding of the interaction of calcareous deposits and biofoulants on the corrosion performance of steel during the fouling stage is both interesting and necessary. So, the effects of these factors on Q235 carbon steel were investigated and discussed for 20 weeks under real ocean conditions. The results indicate that calcareous deposits are favorable for the attachment of marine microorganisms. However, macroorganisms prefer adhering directly to the substrate. The generations of calcareous deposits have priority over the biofilm attachment under the condition of cathodic protection. Calcareous deposits can prevent steel against corrosion for four weeks without cathodic protection.

Effect of GGBS and chloride on compressive strength and corrosion performance of steel in fly ash-GGBS based geopolymer concrete

This study investigates the effect of GGBS on strength and corrosion performance of steel in chloride contaminated fly ash-GGBS based geopolymer concrete (GPC). Fly ash and fly ash-GGBS based GPC mixes were added with 0% and 3.5% of NaCl during the time of preparation. Corrosion potential measurement and corrosion current density by linear polarization resistance (LPR) measurement were performed on reinforced cylindrical GPC specimens. Results indicated that the fly ash-GGBS based GPC showed higher compressive strength as compared to fly ash based GPC, due to formation of N-(C)-A-S-H and C-S-H gel in fly ash-GGBS based GPC which is evident from FESEM analysis. The chloride admixed GPC mixes achieved lower compressive strength than that of control (0% NaCl) GPC mixes. There was a higher probability of corrosion initiation and higher corrosion current density of steel reinforcement in NaCl added GPC as compared to the control GPC.

Novel synthesized cationic surfactants based on natural piper nigrum as sustainable-green inhibitors for steel pipeline corrosion in CO2-3.5%NaCl: DFT, Monte Carlo simulations and experimental approaches

CO2-Corrosion is a widespread issue in oil and gas production, and various storage media have different impacts on the corrosion performance of steel used for tubes. In this paper, three novel cationic surfactants based on natural piper nigrum for inhibiting CO2-corrosion have been synthesized. The structure configurations of the prepared surfactants were confirmed by various spectral and physico-chemical tools viz. FTIR, 1H NMR, 13C NMR and surface activity measurements. The measurement of contact angles was used to evaluate the wettability of all synthesized surfactants. The inhibition capacities of the titled surfactants, for steel pipelines (C1018-steel) corrosion in CO2-3.5%NaCl were studied by electrochemical (open-circuit potential vs. time, Tafel and EIS) measurements, surface morphology (FE-SEM/EDX) examinations, DFT, and Monte Carlo simulations. The empirical findings indicated that the prepared natural surfactants had superior inhibition action, and their maximum inhibition capacities were ranged from 96.7 to 98.9%. Tafel data displays the features of these surfactants are considered as inhibitors of the mixed-type; and their adsorption mode on the C1018-steel/medium interface is consistent with the Langmuir isotherm model. The formation of a protective layer on the C1018-steel interface was investigated using FE-SEM/EDX. DFT calculations were carried out to correlate theoretical parameters with experimental outcomes. The Monte Carlo simulations affirm the adsorption capability of the synthesized surfactants on the iron (110) crystal. The present report provides extremely significative findings in preparing and designing novel sustainable-green inhibitors with high inhibition power.

Corrosion Control in CO2 Enhanced Oil Recovery From a Perspective of Multiphase Fluids

Carbon capture and storage (CCS) combined with CO2-enhanced oil recovery (EOR), has been recently viewed as an economical and effective method for the reduction of carbon emissions. However, corrosion is a challenging issue in the whole chain process of CO2-EOR production if water presents and mild steel pipeline is used. In this paper, the corrosion risk of pipeline at different stages of CO2-EOR production is systematically assessed based on a detailed analysis of the fluid characteristics. According to the fluid state of CO2, water and crude oil, current understandings on the corrosion behavior of steel materials in multiphase flow conditions are reviewed. Furthermore, the intermittent water wetting phenomena and the fluid behavior of water droplets or clusters in an electrolyte/non-electrolyte emulsion are correlated with the steel corrosion performance, providing new insights into the corrosion phenomena. Besides application of corrosion resistant materials and selection of corrosion inhibitors, tailoring of processing parameters, such as enhancing the water entrainment, shortening the water contact time, and reducing the solution corrosivity, is highly recommended as an effective method for corrosion control in aggressive CO2-EOR production conditions. Based on these, some important future research topics on the corrosion in multiphase fluids are suggested.

TES-PS10 postmortem tests: Carbon steel corrosion performance exposed to molten salts under relevant operation conditions and lessons learnt for commercial scale-up

Abstract Postmortem tests were performed over components removed from the TES-PS10 pilot plant after almost four years of continuous operation being exposed to solar salts under representative commercial operation conditions. Accordingly, corrosion performance of plates sections extracted from both storage tanks and samples cut from the hot molten salts pump were evaluated. Corrosion damage extension, oxides layers morphology, and corrosion products chemistry were analyzed by X-ray diffraction, energy dispersive X-ray spectrometry, optical microscopy, and SEM. In addition to materials compatibility with molten salts, mechanical tests were carried out over the storage tanks plates sections. Although the corrosion damage extension over the plates extracted from storage tanks was low and the mechanical properties were according to the standard, some interesting observations were seen. For example, a sample extracted from the hot storage tank and exposed to intermittent contact with molten salts showed some areas characterized by the growth of a non-protective oxide scale. Moreover, localized corrosion with slight penetration through the base material was identified for all storage plates samples under evaluation. On the other hand, the molten salt pump parts under study showed adherent and uniform oxides layers without detecting corrosion–erosion phenomena. Some cavities were found in the discharge elbow, and these imperfections were associated to a bad metallurgical quality during casting. Summarizing, corrosion phenomena suffered by the components under evaluation could be corrected in future plants by applying the lessons learned discussed in this study. As conclusion, materials selection analyzed within this postmortem evaluation is valid from the corrosion point of view to be used in the design of commercial TES systems in PTC plants.

Effect of steel fibers with galvanized coatings on corrosion of steel bars embedded in UHPC

Ultra-high-performance concrete (UHPC) is widely accepted for its super-high durability. However, the corrosion performance of steel reinforcing bars embedded in UHPC and the improved protection of UHPC cover to steel bars are seldom studied. Furthermore, whether using steel fibers in UHPC will accelerate or slow down the corrosion of steel bars is of special interest. In this study, the effects of two types of steel fibers with different galvanized coatings (brass and zinc coated fibers) on the electrical resistance of UHPC and corrosion resistance of embedded steel bars were investigated. Electrochemical tests were conducted for 1 year in 3.5 wt % NaCl solution. The tests included open circuit potential (OCP), linear polarization resistance (LPR), Tafel polarization, and electrochemical impedance spectroscopy (EIS). Test results showed that ASTM C876 was not applicable to UHPC to determine corrosion state of embedded steel bars based on the OCP values. This is because the dense microstructure of UHPC can limit the penetration of oxygen and significantly lower OCP values. The corrosion rates in terms of corrosion current densities of steel bars from the LPR and Tafel polarization tests showed a decreasing trend with time, hence indicating that the steel bars were in passive state. Furthermore, chloride was not detected in the UHPC matrix after the electrochemical tests. This proved that corrosion did not occur on the steel bar surface in the testing period. The electrochemical resistance of UHPC matrix, the resistance of passive film, and the charge transfer resistance of the steel bars from the EIS test displayed a long-term increasing trend. However, when the conductive steel fibers increased from 0 to 2%, by volume, the UHPC matrix resistance decreased by more than 40%. It was also found that the fiber type and fiber content did not affect the resistance of passive film and charge transfer resistance of embedded steel bars. Galvanic corrosion did not happen due to uniform distribution of the fibers along the cast specimens. When proper casting method was employed, both brass and zinc-coated steel fibers can be safely used in UHPC for fiber volume up to 2%.

A bilayer GO/nanofibrous biocomposite coating to enhance 316L stainless steel corrosion performance

A bilayer coating has been synthesized to be coated on the 316L stainless steel (SS) for bone implant application. The first layer consisted of graphene oxide (GO) which was coated via the electrophoretic deposition method. The second layer including Poly (ε-caprolactone) (PCL)/Gelatin-forsterite nanofibers was electrospun on the first layer. The morphology of the bare 316L SS, GO-coated, electrospun nanofibers, and nanofibers-coated samples were investigated using scanning electron microscopy (SEM). The electrospun nanofibers were also characterized by Fourier transform infrared spectroscopy (FTIR) and confirmed the presence of PCL, gelatin, and forsterite in the nanocomposite coating. Furthermore, the morphological investigation of the nanofibers revealed that 80:20 weight of PCL to gelatin did not show any beads, making them for coating on the GO coatings. In addition, the corrosion behavior of the coated samples was assessed by potentiodynamic polarization and electrochemical impedance spectroscopy (EIS). The samples coated with GO and GO/PCL-gelatin-forsterite 1% showed the best corrosion resistance in comparison with other samples. Consequently, the prepared bilayer biocomposite coating including 1 wt% forsterite nanoparticles can be a promising candidate for orthopedic implants.

Study of Rust Layer of TRIP Steels in Marine Environments

The rust layer plays an important role in the corrosion of TRIP steels in marine environments. In this paper, salt spray tests were conducted in laboratory for the specimens after two-stage heat treatment. The results have shown that the corrosion performance of steel B is higher than that of steel A. The corrosion products in rust layer were a complex mixture of α-FeOOH, γ-FeOOH, Fe3O4and γ-Fe2O3after the salt spray tests. The contents of α-FeOOH in rust layer are more than those of γ-FeOOH in steel B. Steel B exhibits compact rust layers. This is attributed to the fact that alloying elements such as Ni, Cr, Cu and Mo can enrich at the rust layer/substrate interface. Therefore, the corrosion performance of steel B was improved.

Materials selection for thermal energy storage systems in parabolic trough collector solar facilities using high chloride content nitrate salts

The increasing role of concentrated solar power (CSP) within the renewable energy portfolio is attributed to the possibility of integrating thermal energy storage (TES) systems. Then, CSP technology has become one of the most interesting clean options to deliver dispatchable power on demand. Nowadays, commercial facilities use high quality solar salts (60%:40% NaNO3 and KNO3 by weight) as storage medium due to the attractive properties of this fluid to be applied under CSP operation conditions. Taking into account that CSP installations are designed with really large TES systems containing tens of thousands of tons, the use of lower quality nitrates salts would reduce the molten salts inventory cost and finally the investment cost of the CSP storage systems at commercial scale. The most important drawback of selecting low quality nitrates salts for high temperature CSP applications is the corrosion impact produced by impurities. Accordingly, chlorides have been identified in the state of the art as the impurity with higher effect over corrosion. This work is focused on A516 Gr70 carbon steel corrosion performance evaluation under high-chlorides content nitrates salts (1.2% and 3% by weight) at 400°C. In addition, the feasibility of using the proposed low purity mixtures with current CSP facilities materials selection is analyzed. Results reported within this study show the critical effect of chloride content over corrosion mechanism producing lack of adherence between base metal and oxides layers in addition to corrosion products delamination and internal cracking. Then, the use of A516 Gr70 carbon steel is rejected for a long term design under solar salts containing chlorides content in the range 1.2–3% by weight being necessary a higher corrosion resistant materials selection. An improved materials selection focused on higher corrosion resistance alloys is discussed.

Corrosion Performance of Steel Coated with Different Duplex Systems and Exposed to Salt Spray and Continuous Immersion Tests

Fil: Di Sarli, Alejandro Ramon. Consejo Nacional de Investigaciones Cientificas y Tecnicas. Centro Cientifico Tecnologico la Plata. Centro de Investigacion y Desarrollo En Tecnologia de Pinturas (i); Argentina. Provincia de Buenos Aires. Gobernacion. Comision de Investigaciones Cientificas; Argentina

Nanostructure Formations and Improvement in Corrosion Resistance of Steels by Means of Pulsed Electron Beam Surface Treatment

The corrosion of steels has long been the topic for materials scientists. It is established that surface treatment is an efficient way to improve the corrosion resistance of steels without changing the bulk properties and with low costs. In the present paper, different kinds of surface treatment techniques for steels are briefly reviewed. In particular, the surface modification involving nanostructure formations of steels by using a low energy high pulsed electron beam (LEHCPEB) treatment is lightened in the case of an AISI 316L stainless steel and D2 steel. The overall results demonstrate the high potential of the LEHCPEB technique for improving the corrosion performance of steels.

Hybrid nano/micro-particles for Increased Steel Corrosion Resistance: Particles’ Alterations with pH Change and Steel Behavior in Cement Extract and Mortar

ABSTRACTHybrid nano/micro particles were investigated for their possibility to re-structure within local pH alterations, release certain active substance and further contribute to increased steel corrosion resistance. Two aspects with regard to corrosion control and self-healing in cement-based materials are discussed: the first aspect deals with the electrochemical performance of low carbon steel electrodes (St37) in model alkaline solutions (cement extract) in the presence of 4.9.10-4 g/l hybrid particles i.e. cement extract, containing PDADMAC (poly (diallyl, dimethyl ammonium chloride) / PAA (Poly (acrylic acid)/ PDADMAC over a CaO core. The second aspect refers to the performance of reinforcing steel (FeB500 HKN) in mortar specimens, containing hybrid particles in the mixing water in concentration of 3.6×10-4 wt. % per mortar weight. The main objective was to determine if these hybrids will lead to increased corrosion resistance of the steel surface layers, generally formed in the hereby investigated environmental medium (both liquid i.e. cement extract and solid i.e. mortar). Further, it was expected that when chlorides are involved, as corrosion accelerating factor, the presence of hybrid particles will delay corrosion initiation and will therefore lead to increased corrosion resistance. The results denote for indeed superior corrosion performance of steel in chloride-free and chloride containing medium, when hybrid particles are involved. The responsible mechanisms are related to increased barrier effects of the formed layer and self-repair upon morphological alterations of the hybrid particles, “nucleation sites effects” and/or Ca-core “release” on locally active (anodic) areas on the steel surface.

Accelerating Standard Test Method for Assessing Corrosion of Steel in Concrete

This article describes how the time required to quantitatively assess the corrosion performance of steel embedded in concrete can limit the introduction of new materials and systems into the market to extend the life of reinforced concrete structures that have been exposed to corrosive environments. Many state and federal highway agencies, public utilities and infrastructure developers are aggressively pursuing corrosion protection methods for reinforced concrete structures. New test methods that can quickly provide quantitative results for assessing corrosion resistance are needed. Results from a research program that assessed the influence of exposure environment on the time to corrosion of steel embedded in concrete following the ASTM G109 test procedures are presented in the article. The results indicate that the modified test can provide quantitative results for reinforced concrete specimens containing different materials and that increasing the temperature and humidity reduces the time to initiation of corrosion. However, the reduction in time is not significant for specimens containing materials that resist corrosion, and increasing the temperature and humidity is not sufficient to generate results over reasonable durations.

Steel corrosion resistance in model solutions, containing waste materials

This work reports on the corrosion resistance of low-carbon steel in alkaline model solutions, i.e. “red mud” (RM) containing extracts of Ordinary Portland Cement (OPC) and Blast Furnace Slag (BFS) cement. The objective was to define the steel electrochemical behavior and the properties (morphology and composition) of the product layer that forms on the steel surface within treatment in chloride-free and chloride-containing model solutions. The motivation for this research is related to several aspects, mainly to exploring the possibility for achieving superior corrosion performance of steel in cement-based systems by using (combination of) waste materials. The study reveals that RM has a distinctive positive effect on the corrosion performance of steel, especially in chloride containing environment. The presence of RM in both OPC and BFS solutions (with and without NaCl) favors steel passivation and results in an increased corrosion resistance. The positive effect of RM is especially pronounced for steel, exposed to BFS solutions. The observed behavior is attributed to the presence of Fe 2O 3 and Al 2O 3 (from RM and BFS). The presence of Fe 3+ stabilizes the passive layer. Additionally, the adhered red mud particles act as adsorption sites for Ca 2+, resulting in a product layer with higher corrosion resistance. Further, the RM particles with regard to their Al 2O 3 content enhance steel passivity and increase the chloride threshold for corrosion initiation and/or propagation.

The Influence of Admixed Polymeric Vesicles on Corrosion Performance of Steel in Simulated Pore Solution and/or Reinforced Mortar

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Electrochemical Performance of Low-Carbon Steel in Alkaline Model Solutions Containing Hybrid Aggregates

This work reports on the electrochemical performance of low-carbon steel electrodes in model alkaline solutions in the presence of 4.9.10-4 g/l hybrid aggregates i.e. cement extract, containing PDADMAC (poly (diallyl, dimethyl ammonium chloride) / PAA (Poly (acrylic acid)/ PDADMAC over a CaO core. The main objective was to determine if the addition of hybrid aggregates will lead to increased corrosion resistance of the steel surface layers, generally formed in the hereby investigated environmental medium. Further, it was expected that when chlorides are involved, as corrosion accelerating factor, the presence of hybrid aggregates will delay corrosion initiation and therefore lead to increased corrosion resistance. This investigation forms part of a novel approach to control steel corrosion in reinforced concrete, using self-healing mechanisms. The results from this study denote for indeed superior corrosion performance of steel in chloride-free and chloride containing alkaline solution, when hybrid aggregates are involved. The mechanisms are related to increased barrier effects of the formed layer and CaO release from the core of the aggregates.