Corrosion Phenomena Research Articles

Anti-Corrosion and Wave-Absorbing Properties of Epoxy-Based Coatings on Q235 Steel

Carbon nanotube/epoxy resin (CNE) coatings and carbon nanotube/carboxy iron powder/epoxy resin (CIE) coatings were applied on the surface of Q235 steel, and their corrosion, absorption properties and other characteristics were measured in this work. The results indicate that the average thickness of a single application was approximately 400 μm, and the surface of the CNE coating was still smooth and intact after a 3000 h copper ion accelerated salt spray test without bubbles, falling off or other corrosion phenomena. The same was true for 28 days of full immersion in solutions of 10% hydrochloric acid (HCl) and 10% sodium hydroxide (NaOH) of the coating. The electrochemical testing exhibited the corrosion current of the CNE coating as being markedly lower than that of Q235 steel, with a protection efficiency of 81.68% for the Q235 steel. The CNE-0.6 coating had the maximum corrosion voltage (−0.390 V), and the CNE-0.3 coating had the minimum corrosion current of 2.07 × 10−6 A·cm2. The adhesion between the coating and Q235 could reach level 0, and the tensile strength of the coating was up to 18.75 MPa. The coating was observed to remain intact and free from detachment upon undergoing a drop test from a height of 50 cm. In addition, the CIE-0.6 coating exhibited an effective absorption band of 9.1 GHz, covering the range from 8.2 to 13.7 GHz, and it achieved a maximum reflection loss of −15.1 dB at a frequency of 8.6 GHz.

Integrating Flow Field Dynamics and Chemical Atmosphere Predictions for Enhanced Sulfur Corrosion Risk Assessment in Power Boilers.

In this work, we attempt to explain the phenomenon of sulfur corrosion of power boiler water walls under the conditions of large fluctuations in carbon monoxide concentrations. To assess the conditions required for corrosion formation, a criterion based on the chemical and flow field parameters of the flue gas is proposed. The formulated sulfur corrosion criterion is based on the mixture fraction variance and the turbulence time scale. Numerical modeling of coal combustion in a 250 MW power boiler is performed using ANSYS. Two cases of combustion in a boiler are analyzed, with the first simulating the boiler operated using classic high-swirl burners and the second one accounting for boiler operation with modified low-swirl burners. Calculations of pulverized coal combustion are performed using the standard k-ε turbulence model and the combustion described by the mixture fraction. The simulation results reveal that the low-swirl burner is characterized by higher values of the mixture fraction variance and a higher frequency of fluctuation of the velocity field, which is strongly related to an increased corrosion rate. The study outcomes show the validity of using the criterion of the mixture fraction variance and velocity field fluctuations to determine the areas at risk of sulfur corrosion.

Machine Learning–Assisted Risk Assessment of Pitting Corrosion Susceptibility of AA1050 in Ethanol‐Containing Fuels

ABSTRACTThe ability to assess the risk of corrosion of metallic structures in particular environments holds considerable significance in the field of automotive industry. In recent years, machine learning has evolved into a crucial tool to evaluate the complex and multidimensional corrosion phenomena. In this paper, the special case of non‐aqueous alcoholate pitting corrosion of AA1050 in ethanol‐blended fuels with water and chloride contamination is examined via supervised machine learning techniques in order to distinguish between safe and unsafe conditions. The data space was created by conducting dedicated experiments with varying ethanol–fuel–water ratios, temperatures, and surface preparations. The classifier's performance rating of 0.87 (balanced accuracy) indicates an outstanding predictive ability and highlights the model's usefulness as decision support for subsequent experiments.

Study on superhydrophobicity and corrosion resistance of the micro-nano structure prepared by femtosecond laser

The wettability as well as the corrosion resistance of metal is closely related to the surface microstructure. A surface structure with micro protrusion and nano ripple was designed and constructed on 316L stainless steel by femtosecond pulse laser. Superhydrophobic surfaces with a great contact angle over 150° were obtained by surface modifications of heat treatment or fluorination treatment. The corrosion resistance of the superhydrophobic micro-nano structured surfaces was studied through electrochemical testing. The result of polarization curve revealed that the superhydrophobic micro-nano structured surfaces possessed a higher corrosion potential, signifying the susceptibility to corrosion was reduced. Besides, the results of impedance indicated that the superhydrophobic micro-nano structured surfaces exhibited greater total resistance when compared to the original surface, demonstrating the corrosion resistance was enhanced. According to the results, the superhydrophobic surface, characterized by its micro-nanostructure, facilitates the formation of a protective gas film. Additionally, the intricate micro-nano rough structure, in conjunction with the gas film, effectively shields the underlying surface from infiltrative processes, thereby mitigating the potential exacerbation of corrosion phenomena.

Effect of Temperature and Oxygen Concentration on Corrosion of J55 Steel in an O2/CO2 Environment

ABSTRACTThe corrosion product competition and transformation process of J55 under an O2/CO2 environment in the temperature range of 50–350°C and 0–1 MPa oxygen partial pressure range, respectively, were studied using electrochemical and surface analysis techniques as well as thermodynamic calculations to determine its corrosion rate change law and pitting corrosion phenomenon. This study demonstrates that the uniform corrosion rate of J55 with increasing temperature shows a trend of first increasing, then decreasing, and finally increasing. The transformation of its corrosion products, from FeCO3 into Fe3O4, is consistent with the altering corrosion rate law with increasing temperatures. J55 corrodes faster at 350°C as the O2 partial pressure increases. When the O2 partial pressure is low, the predominant kind of corrosion product that is obtained is FeCO3; when the O2 partial pressure exceeds 0.2 MPa, all corrosion products are transformed into iron oxides. As the oxygen partial pressure increases, J55's corrosion product film becomes increasingly less protective of the substrate, making the substance more vulnerable to corrosion reactions.

Corrosion Mechanism of a high corrosion-resistance Zn-Al-Mg coating in typical extremely harsh marine and cold environments

The corrosion mechanism of a high corrosion-resistant Zn-Al-Mg coating exposed to typical extremely harsh environments in Wanning and Mohe was investigated. The findings revealed that the corrosion behavior of Zn-Al-Mg coating is significantly influenced by environmental conditions, exhibiting varying rates and processes in high-temperature marine and extremely cold urban environments, which lead to distinct corrosion patterns and pit morphologies over time. In the marine atmosphere of Wanning, characterized by high temperature and humidity, corrosion preferentially occurs in the eutectic phase and extends towards the interior of the coating along the eutectic phase near the zinc-rich phase. The corrosion rate on the skyward side is smaller than that on the field-facing side, and this difference between the two sides initially decreases and later increases. However, in the urban atmosphere of Mohe, with extremely low temperatures, the phenomenon of localized corrosion is more pronounced. Corrosion pits tend to form in the eutectic phase near the zinc-rich phase, with their shapes gradually transitioning from sharp to shallow. After 6 and 12 months of exposure, the corrosion rate on the skyward side is smaller than that on the field-facing side, and after 24 months of exposure, both sides exhibit similar corrosion rates.

Comparison of crevice corrosion of P110S and HP-13Cr in extremely aggressive environment containing CO2 and H2S

The crevice corrosion of P110S steel and HP-13Cr stainless steel (SS) in different simulated oil and gas environments was investigated using a modified crevice corrosion apparatus, surface analysis techniques and weight-loss method. In addition, the corrosion behavior of the two different pipeline steels was explained using the dissolution-ionization-diffusion-deposition (DIDD) model in combination with passive dissolution model and metastable pitting model. The results indicate that there is no crevice corrosion phenomenon in P110S steel, and there is no coupling effect between H2S and CO2. P110S steel experienced crevice corrosion at the beginning of the experiment, but later the corrosion products inside the crevice began to thicken, and the states inside and outside the crevice gradually converged. Moreover, significant crevice corrosion was observed for HP-13Cr SS, and CO2 and H2S had a coupling effect. The crevice corrosion phenomenon can be explained by metastable pitting model.

Identification of corrosion nature using acoustic emission in representative scale samples

Monitoring corrosion is critically important across numerous applications, given its occurrence in key industrial sectors such as energy production, transportation, and civil engineering to prevent leaks and failures. Especially, determining the exact nature of corrosion phenomena could help planning specific maintenance operations, reducing costs and risks. Machine Learning methods have demonstrated capacities to discriminate corrosion phenomenona. An important step to create precise Machine Learning models is the quality of training datasets. With this goal in mind, this paper presents experiments performed on different metallic samples to create specific corrosion forms, respectively pitting and uniform corrosion to train a supervised model. This model is evaluated on 316L steel samples prone to endure both pitting and uniform corrosion. The usage of supervised learning is then discussed compared to other methods.

Stray current affected zone in electrochemical jet machining

The stray current affected zone (SCAZ) in electrochemical jet machining (EJM) poses a significant and often unavoidable challenge. This study offers an in-depth analysis of the morphological characteristics and formation mechanisms of SCAZ in EJM through a combination of machining experiments and surface characterization. By investigating various workpiece materials and electrolytes, we identify that stray corrosion phenomena are highly dependent on the specific material-electrolyte combinations used. Although applying ultra-short pulses of 750 ns enhances shape accuracy, it does not fully prevent pitting corrosion. Conversely, the bipolar pulse technique effectively reduces pitting, though stray oxidation remains an issue. As a result, post-finishing processes are crucial. Notably, plasma electrolytic polishing is demonstrated to be highly effective in removing stray oxidation, achieving a glossy surface on SUS304 in just 3 s while maintaining dimensional accuracy.

Synthesis of a new quaternary ammonium salt for efficient inhibition of mild steel corrosion in 15 % HCl: Experimental and theoretical studies

The corrosion phenomenon and its economic impacts can hardly be ignored in any application. This study synthesized a quaternary ammonium salt (3) containing hydrophobic dodecyl and electron-rich diallylbenzyl amine moieties to be used in 15 % HCl as a corrosion inhibitor of mild steel. Several techniques, such as 1H and 13C NMR, IR, TGA, and elemental analysis, have been used to characterize inhibitor 3. Popular corrosion measurement techniques, namely weight loss, potentiodynamic polarization techniques, and electrochemical impedance spectroscopy, have been used to determine the efficiency of inhibitor 3. At 303 K and a moderately low concentration of 50 ppm, the quaternary ammonium salt-based inhibitor demonstrated a maximum efficiency of ≈95.0 %. At elevated temperatures of 313, 323, and 333 K, the inhibition efficacy values were recorded as 91.3, 82.8, and 75.0 %, respectively. Adsorption isotherm study revealed that the adsorption of inhibitor 3 followed Langmuir adsorption isotherm. The value of ΔGads° was found to be – 40.19 kJ mol−1, indicating that inhibitor 3 became adsorbed via a mixed physi-chemisorption mechanism. A very high adsorption constant (Kads) of 1.53 × 105 L mol−1 suggested strong adsorption of inhibitor 3. The difference in activation energy (Ea) value of 42.4 kJ mol−1 between the control and the inhibited solution indicated an efficient adsorption of inhibitor 3. The ability of inhibitor 3 to retard both anodic and cathodic half-cell reactions was proved via open circuit potential and Tafel curves studies. Detailed discussions on the change in corrosion current densities (icorr), polarization (Rp) and charge transfer (Rct) resistances have been offered to discuss the inhibition efficiency. Water contact angle measurement showed a drastic increase in mild steel surface hydrophobicity following inhibitor 3 adsorption. SEM-EDX and XPS studies confirmed the definitive presence of inhibitor 3 on the mild steel surface. Density functional theory (DFT) studies revealed the frontier molecular orbitals with which the metal surface interacts. A detailed corrosion inhibition mechanism has been offered in the context of adsorption isotherm and DFT studies.

Composite fluorescence probe towards a smart coating for early corrosion detection of carbon steel

Herein, a composite fluorescent probe was developed as a smart indicator in acrylic resin-based coatings for the early detection of steel corrosion. The Fe3+-sensitive Rhodamine B derivative probe (Rxbxja) was synthesized, and the SiO2 nanoparticle-supported probe S-Rxbxja was prepared through the hydrolysis of tetraethyl orthosilicate (TEOS). The successful synthesis of S-Rxbxja was confirmed using a variety of techniques i.e. SEM and FTIR. A fluorescence microscope was utilized to assess the self-reporting performance of coatings. EIS and seawater immersion tests were employed to evaluate the corrosion resistance of the coating. The fluorescence test results revealed the absence of premature fluorescence in the composite coating, owing to the exceptional compatibility between S-Rxbxja and the coating. The scratched area in the 0.5 wt% sensor-doped coatings exhibited fluorescent and colorimetric dual-channel signals after soaking in 3.5 wt% NaCl solution for 2 h before any visible corrosion phenomenon. The EIS results demonstrated that the |Z|0.01Hz value of composite coating maintained 107 Ω cm2 even after being immersed in a 3.5 wt% NaCl solution for 7 days, indicating the excellent anti-corrosion properties of the S-Rxbxja coating. Moreover, mechanical property tests showed that the S-Rxbxja coating had excellent mechanical properties due to the introduction of SiO2 nanoparticles.

CAVITATION EROSION IN FRANCIS TURBINES

The phenomenon of secondary flow is a global problem that causes cavitation erosion in hydraulic equipment. Cavitation is a phenomenon of localised corrosion of the metal surface leading to instability and highly uneven flow behaviour with a consequent excessive noise, vibration, and decreased efficiency in Francis, Kaplan, and other turbines. Both Kaplan and Francis turbines are reaction turbines. Francis turbines (FT) are used worldwide due to their relatively compact design, high efficiency, and operation underwater at heights ranging from 100 to 300 m with an efficiency ranging from 90% to 95%. The article analyses the latest relevant research conducted by various researchers on different turbine components. The analysis shows that this type of erosion depends on flow characteristics, surface, and properties of the material eroding. Tools for design optimisation, cavitation erosion, and well-conducted experiments will provide results for identifying and reducing erosion. Although some researchers conducted experimental work to study the effect of cavitation erosion, literature on computational fluid dynamics (CFD) is very scarce. Over the past two decades, experts have been applying CFD methods to detect cavitation by examining areas where the pressure is below the vapour pressure with a single-phase model. Most studies do not consider the impact of cavitation bubbles on the flow field. However, these methods cannot provide detailed information, such as the impact of cavitation on efficiency or a more accurate prediction of the cavitation bubble size. Some researchers use cavitation inducers and some of the latest visualisation methods as experimental tools to study cavitation phenomena. In the last decade, a numerical methodology has been widely used in research and experiments, yielding significant results. Studying cavitation erosion in hydroelectric turbine systems presents a complex challenge for future research. Many parameters and features still require further investigation. All the discussed studies have established that cavitation phenomena require state-of-the-art equipment for their detection and visualisation. Moreover, more work is necessary for the numerical assessment of cavitation. Keywords: hydroelectric turbine, cavitation erosion, computational fluid dynamics.

The effect of graphene solution on mixed powder electrical discharge milling of Ti6Al4V

Abstract Ti6Al4V is the most widely used materials in aerospace, medical, nuclear power and other fields. However, due to its unique properties such as low thermal conductivity, titanium alloy poses challenges in machining processes. Electrical discharge milling (EDM) is a machining method that utilizes the electrical corrosion phenomenon of pulsed spark discharge between two electrodes to remove materials, which is highly suitable for the machining of Ti6Al4V. This paper investigates a mixed powder EDM approach for titanium alloy using a graphene solution medium known for its green and sustainable characteristics. Compared to conventional deionized water medium processing which without powder particles, the material removal rate can be increased by 50%, the surface hardness after processing was 2.5 times higher than that of the substrate, the electrode wear rate could be reduced by 40%, the surface roughness values were reduced by more than 20%. Besides that, the micro-cracks and micro-pores on the workpiece surface can be significantly reduced. Subsequently, single factor experiments and orthogonal experiments were conducted using material removal rate, electrode wear rate, and surface roughness as process indicators. The influence of processing parameters on process indicators was investigated based on optimal selection method and analysis of variance (ANOVA). Finally, the optimized parameters in graphene solution mixed powder EDM for Ti6Al4V were obtained. When using the process combination A3B3C1D2, the maximum MRR can be obtained.

Multifunctional zinc-nickel alloy enabling high-performance aqueous zinc ion batteries

Aqueous zinc ion batteries are considered to be the new type of secondary batteries that have the potential to replace lithium-ion batteries as the most widely used in the future due to their green environment, high specific capacity and abundant zinc resources. However, due to the contact between the zinc anode and electrolyte, the generation of by-products and corrosion phenomena are not completely avoided, which can easily lead to problems such as short cycle life and poor electrochemical performance of the battery. In this study, uniform zinc-nickel alloy (ZnNi) was prepared by melting method. The element nickel has excellent corrosion resistance and is widely used to improve the corrosion resistance of metal alloys, so the introduction of nickel effectively enhances the corrosion resistance of ZnNi alloys. In addition, metallic nickel shows strong attraction to Zn2+, which can promote the uniform distribution and deposition of Zn2+ and inhibit the dendrites growth to prolong the battery life. Notably, the ZnNi-assembled symmetric cell exhibited excellent cycling performance compared with the Zn//Zn cell (100 h), with a cycle life of up to 1000 h at 2 mA cm−2. In addition, the capacity retention rate of the ZnNi//MnO2 full cell was still as high as 90.6 % after 1000 cycles. The preparation of the ZnNi alloy anode may provide a new idea for future alloying strategies.

Effect of Crevice Size on Crevice Corrosion of N80 Carbon Steel in CO2-Saturated NaCl-HAc Solution.

The effect of crevice size on the crevice corrosion of N80 carbon steel was investigated by electrochemical measurements and surface analysis in a CO2-saturated NaCl-HAc solution. The N80 carbon steel exhibits a high susceptibility to crevice corrosion in this environment, which can be initiated immediately without an induction period for specimens with crevice sizes of 100 μm, 300 μm, and 500 μm. Typically, crevice solutions become more acidic during crevice corrosion; however, in this study, the crevice solution became alkaline, resulting in galvanic corrosion between the inner and outer steel surfaces and leading to severe crevice corrosion. The pH levels of the crevice solution for specimens with 100 μm and 300 μm crevice sizes are similar, but both are notably higher than that of the specimen with a 500 μm crevice size. As a result, there is no significant difference in the crevice corrosion phenomenon between specimens with 100 μm and 300 μm crevice sizes, but it is more severe than in the specimen with a 500 μm crevice size.

Failure analysis of a C-type bourdon tube

This paper presents the failure analysis of a C-type Bourdon tube made of AISI 316L stainless steel, which was part of a pressure gauge. For the study, chemical composition and microstructure of the Bourdon tube were determined. Additionally, electrochemical attack with oxalic acid was used to asses if the microstructure was suspected of sensitization in samples taken near to and away from the failure. Finally, fractographic analysis of the failed Bourdon tube was accomplished by scanning electron microscopy. The results showed that the failure was due to an intergranular corrosion phenomenon that embrittled the material in the area close to the welding between the Bourdon tube and the joint.

Developing Methods to Interrogate Nanomaterials in Action for Electrochemical Energy Conversion Reactions

We are observing unprecedented growth in electrified processes at industrial scales for the production of fuels and chemicals. This includes the production of hydrogen, carbon-based molecules (e.g. CO, ethylene), and ammonia, among others. Nevertheless, a number of technical challenges remain in order to meet cost targets for these technologies to scale. Understanding nanomaterials under reaction conditions is essential to designing and developing systems with improved performance and durability, addressing key needs. This paper will describe efforts to understand electrified interfaces at the nanoscale, ranging from fundamental systems to applied systems, and doing so under relevant operating regimes. Methods include X-ray techniques to observe the chemical dynamics of catalysts, vibrational spectroscopy and neutron reflectometry to monitor electrified interfaces at the nanoscale, microscopy to observe mass transport and crystallization within porous media, and inductively coupled plasma mass spectrometry to quantitatively measure corrosion phenomena. The development and implementation of these in-situ/operando techniques are providing the insights needed to advance these emerging technologies towards more widespread commercialization.

Performance of a Ship-Based Cupronickel Alloy in Exposure Conditions of Arabian Seawater-A Comparative Study.

Cupronickel-based alloys are widely known for their excellent resistance against aqueous corrosion, however, they can be susceptible to corrosion at accelerated rates and premature failure when exposed to a polluted or brackish seawater medium, even for short-term exposure durations. This unfamiliar corrosion behavior may be a result of the formation of an unprotected corrosion film during the early exposure durations. The paper investigates the corrosion phenomenon in cupronickel 90/10 alloy, by exposing the coupons in two different seawater compositions in the Arabian Sea region. Corrosion losses were investigated on the experimental coupons in a submerged position, for a maximum exposure duration of 150 days, using the conventional weight loss method and a new dimensional metrology-based measurement technique. Additionally, in this research the tubes of a marine heat exchanger having similar material that failed prematurely during operation in the Arabian Sea were also investigated for corrosion losses, followed by the characterization of the corrosion deposits using following analytical techniques: SEM, EDS, XRD and Raman Scattering. The experimental results showed significantly higher corrosion losses on coupons exposed to seawater site rich in pollutants and nutrients including dissolved inorganic nitrogenous compounds, compared to those subjected to a natural seawater solution in corrosion tanks maintained in a controlled environment.

Electrochemical Characteristics and Corrosion Mechanisms of High-Strength Corrosion-Resistant Steel Reinforcement under Simulated Service Conditions

Long-term steel reinforcement corrosion greatly impacts reinforced concrete structures, particularly in marine and coastal settings. Concrete failure leads to human casualties, requiring extensive demolition and maintenance, which represents an inefficient use of energy and resources. This study utilizes microscopic observation, atomic force microscopy (SKPM), electrochemical experiments, and XPS analysis to investigate the corrosion behavior of 500CE and 500E under identical conditions. We compared 500E with 500CE, supplemented with 0.94% Cr, 0.46% Mo, 0.37% Ni, and 0.51% Cu through alloying element regulation to obtain a finer ferrite grain and lower pearlitic content. The results indicate that 500CE maintains a stable potential, whereas 500E exhibits larger grain sizes and significant surface potential fluctuations, which may predispose it to corrosion. In addition, despite its more uniform microstructure and stable electrochemical activity, 500E shows inferior corrosion resistance under prolonged exposure. The electrochemical corrosion rate of 500CE in both the pristine and passivated states and for various passivation durations is slower than that of 500E, indicating superior corrosion performance. Notably, there is a significant increase in the corrosion rate of 500E after 144 h of exposure. This study provides valuable insights into the chloride corrosion phenomena of low-alloy corrosion-resistant steel reinforcement in service, potentially enhancing the longevity of reinforced concrete structures.

Deep Intergranular Fluoride Attack by High-Temperature Corrosion on Alloy 625 by LiF in Air at 600 °C

In most chemical and high-temperature processes, metals are exposed to temperature gradients which, in turn, affect the extent of corrosion phenomena. In this study, a long, continuous strip of alloy 625 was exposed to lithium fluoride in a temperature range of 50–600 °C, air environment. The hottest section of this strip was analyzed as a coupon and compared with two other coupons which were exposed isothermally. One of the isothermal exposures was carried out in a tube furnace, and the other one was in a vertical furnace. Oxygen had three different kinds of access to these three coupons, which, in turn, affected the corrosion process. In order to limit the access of oxygen, a long column of lithium fluoride was used in a vertical furnace. The results of the isothermal exposure showed that more access of oxygen in a horizontal tube furnace facilitated the fluoride ingress to a great extent. However, a long sample exposed to a temperature gradient suffered more corrosion attack than the isothermal coupon, under the same LiF load in the vertical furnace. This was associated with the reduction of oxygen at a larger cathode area reaching into colder regions in Inconel 625 strip. Increased oxygen reduction also increases the efficiency of an inner anode at the hottest section, causing the observed rapid intergranular fluoride uptake. The study proposes a mechanism explaining these observations.