Corrosion Research Research Articles

Progress in Corrosion and Protection Research in Offshore Petroleum Engineering

This paper summarizes the latest research progress on the corrosion of concrete structures in marine engineering and its protection technology. The article firstly emphasizes the influence of seawater on the performance of concrete engineering, and then discusses the application of composite corrosion inhibitors in the marine environment. The composite corrosion inhibitor significantly reduces the corrosion rate by simultaneously inhibiting the anodic and cathodic reactions and forming a protective hydrophobic film on the metal surface. The article describes in detail the classification of corrosion inhibitors, including adsorption or film-forming inhibitors with polar hydrophobic groups such as N, S, and -OH, as well as migratory corrosion inhibitors (MCIs) that diffuse through the pores of the concrete to the surface of the reinforcement bar to form a protective film. The article also discusses the performance evaluation criteria of corrosion inhibitors, including the electrochemical performance of saltwater impregnation, the performance of dry-wet cold-heat cycles, and the performance of resistance to Cl- penetration, etc., and lists the relevant national standards and test methods. Through a comprehensive analysis of relevant literature at home and abroad in recent years, the article points out that composite corrosion inhibitors show great potential in improving the durability of marine concrete structures, but the long-term stability and compatibility with different concrete types still need to be further studied. Future research should focus on developing more efficient and environmentally friendly corrosion inhibitors and expanding their application in marine engineering to meet the increasingly severe challenges of marine corrosion. At the same time, a comprehensive evaluation of the longevity, economy and environmental friendliness of corrosion inhibitors is also an important direction for future research.

Current Challenges in Corrosion Research

Corrosion is a degradation phenomenon with huge economic consequences and severe security implications [...]

Status and issues of high-temperature and high-pressure water corrosion research of fusion structural materials in Japanese DEMO reactor development

Abstract The activated corrosion product assessments of fusion structural materials are essential to designing components and evaluating workers’ radiation exposure. This paper first gives the R&D status of the high-temperature pressurized water corrosion study of reduced activation ferritic/martensitic steels and chromium–zirconium–copper (CuCrZr) alloys, which are the leading candidate materials of fusion reactor in-vessel components such as breeding blanket and divertor, which are utilized in high-temperature and high-pressure water, and the recent progress of corrosion test apparatus simulating the unique environment of a fusion reactor will also be presented.

EIS Investigation of a Single Pit on Cantor Alloy in Acidic Environment

High-entropy alloys (HEA) are an emerging class of materials with promising properties such as high strength and ductility, improved fatigue resistance, fracture toughness, and thermal stability. They show considerable potential for use as corrosion resistant alloys to support our infrastructure especially for use in extreme environments. In this work, we mainly focused on the typical Cantor alloy, which consists in a mixture of 5 elements CrMnFeCoNi in equimolar proportion. A huge amount of works has already been devoted to the study corrosion resistance of alloys in sulfuric acid [1] or in chloride containing solutions [2,3]. For the latter, the study of the pitting propagation remains challenging since this kind of corrosion initiates as a stochastic process.Electrochemical impedance spectroscopy (EIS) is intensively used as a tool for corrosion research and is well suited for the identification of complex mechanisms. However, data analysis remains difficult in the case of pitting studies, which can be described schematically as n anodic sites in parallel at different states of evolution. In this work we report on EIS analysis performed on a single pit (Fig. 1a) in order to describe the various step of its evolution as a function of time, but also as a function of various parameters such as the chloride ion concentration or the corrosion potential. Single pits were obtained by studying the breakdown of the passive film using the pumped-micropipette delivery/substrate collection (Pumped-MD/SC) mode of scanning electrochemical microscopy (SECM). A detailed mechanism is proposed to account for EIS results obtained on a single pit (Fig. 1b) in order to explain results on usuals EIS measurements.[1] J. Yang, J. Wu, C. Y. Zhang, S. D. Zhang, B. J. Yang, W. Emori et J. Q. Wang, « Effects of Mn on the electrochemical corrosion and passivation behavior of CoFeNiMnCr high-entropy alloy system in H2SO4 solution », Journal of Alloys and Compounds, 819, avril 2020, p. 152943, https://doi.org/10.1016/j.jallcom.2019.152943[2] Camila Boldrini Nascimento, Uyime Donatus, Carlos Triveño Ríos et Renato Altobelli Antunes, « Electronic properties of the passive films formed on CoCrFeNi and CoCrFeNiAl high entropy alloys in sodium chloride solution », Journal of Materials Research and Technology, 9, no 6, novembre 2020, p. 13879-92, https://doi.org/10.1016/j.jmrt.2020.10.002[3] Mengjiao Li, Qingjun Chen, Xia Cui, Xinyuan Peng et Guosheng Huang, « Evaluation of corrosion resistance of the single-phase light refractory high entropy alloy TiCrVNb0.5Al0.5 in chloride environment », Journal of Alloys and Compounds, 857, mars 2021, p. 158278, https://doi.org/10.1016/j.jallcom.2020.158278 Figure 1

Visualization and Analysis of Oil and Gas Pipeline Corrosion Research: A Bibliometric Data-Mining Approach

Visualization and Analysis of Oil and Gas Pipeline Corrosion Research: A Bibliometric Data-Mining Approach

Research Progress in Corrosion Behavior and Anti-Corrosion Methods of Steel Rebar in Concrete

The corrosion of steel rebars is a prevalent factor leading to the diminished durability of reinforced concrete structures, posing a significant challenge to the safety of structural engineering. To tackle this issue, extensive research has been conducted, yielding a variety of theoretical insights and remedial measures. This review paper offers an exhaustive analysis of the passivation processes and corrosion mechanisms affecting steel rebars in reinforced concrete. It identifies key factors such as chloride ion penetration and concrete carbonization that primarily influence rebar corrosion. Furthermore, this paper discusses a suite of strategies designed to enhance the longevity of reinforced concrete structures. These include improving the concrete protective layer’s quality and bolstering the rebars’ corrosion resistance. As corrosion testing is essential for evaluating steel rebars’ resistance, this paper also details natural and accelerated corrosion testing methods applicable to rebars in concrete environments. Additionally, this paper deeply presents an exploration of the use of X-ray computed tomography (X-CT) technology for analyzing the corrosion byproducts and the interface characteristics of steel bars. Recognizing the close relationship between steel bar corrosion research and microstructural properties, this paper highlights the pivotal role of X-CT in advancing this field of study. In conclusion, this paper synthesizes the current state of knowledge and provides a prospective outlook on future research directions on the corrosion of steel rebars within reinforced concrete structures.

Failure mode of passive film under electric field and chloride environment in concrete

Exploring the failure mode of passive film is the most fundamental issue for corrosion research and prevention of metals. In the actual service of reinforced concrete structures, steel rebars are typically exposed to a complex solution environment, characterized by electric fields, chloride ions, and fluctuating temperatures. Using scanning electron microscope, scanning electrochemical microscope, and a series of electrochemical tests, we present the damage mode of steel passive film in a simulated alkaline environment of concrete; and then establish a deductive diagram to illustrate it. Additionally, we use atomic force microscope, X-ray photoelectron spectroscopy and transmission electron microscope to explore the structural characteristics of passive film on an atomic scale, and confirm that specific ion channels serve as the pathway for chloride invasion. This study can enable a deeper understanding of the micro-mechanisms involved in steel depassivation and the initiation of corrosion electrochemical reaction.

Progress in Corrosion Research on Alternative Liquid Fuels

Progress in Corrosion Research on Alternative Liquid Fuels

A novel method for estimation of electrode kinetics parameters

PurposeThe purpose of this paper is to extract electrochemical reaction kinetics parameters, such as Tafel slope, exchange current density and equilibrium potential, which cannot be directly measured, this study aims to propose an improved particle swarm optimization (PSO) algorithm.Design/methodology/approachIn traditional PSO algorithms, each particle’s historical optimal solution is compared with the global optimal solution in each iteration step, and the optimal solution is replaced with a certain probability to achieve the goal of jumping out of the local optimum. However, this will to some extent undermine the (true) optimal solution. In view of this, this study has improved the traditional algorithm: at each iteration of each particle, the historical optimal solution is not compared with the global optimal solution. Instead, after all particles have iterated, the optimal solution is selected and compared with the global optimal solution and then the optimal solution is replaced with a certain probability. This to some extent protects the global optimal solution.FindingsThe polarization curve plotted by this equation is in good agreement with the experimental values, which demonstrates the reliability of this algorithm and provides a new method for measuring electrochemical parameters.Originality/valueThis study has improved the traditional method, which has high accuracy and can provide great support for corrosion research.

Transpassive Metal Dissolution vs. Oxygen Evolution Reaction: Implication for Alloy Stability and Electrocatalysis.

Multi-principal element alloys (MPEAs) are gaining interest in corrosion and electrocatalysis research due to their electrochemical stability across a broad pH range and the design flexibility they offer. Using the equimolar CrCoNi alloy, we observe significant metal dissolution in a corrosive electrolyte (0.1 M NaCl, pH 2) concurrently with the oxygen evolution reaction (OER) in the transpassive region, despite the absence of hysteresis in polarization curves or other obvious corrosion indicators. We present a characterization scheme to delineate the contribution of OER and alloy dissolution, using scanning electrochemical microscopy (SECM) for OER-onset detection, and quantitative chemical analysis with inductively coupled-mass spectrometry (ICP-MS) and ultraviolet visible light (UV/Vis) spectrometry to elucidate metal dissolution processes. In situ electrochemical atomic force microscopy (EC-AFM) revealed that the transpassive metal dissolution on CrCoNi is dominated by intergranular corrosion. These results have significant implications for the stability of MPEAs in corrosion systems, emphasizing the necessity of analytically determining metal ions released from MPEA electrodes into the electrolyte when evaluating Faradaic efficiencies of OER catalysts. The release of transition metal ions not only reduces the Faradaic efficiency of electrolyzers but may also cause poisoning and degradation of membranes in electrochemical reactors.

Transpassive Metallauflösung vs. Sauerstoffentwicklung: Auswirkungen auf Legierungsstabilität und Elektrokatalyse

AbstractMulti‐Hauptelement‐Legierungen (MPEAs) gewinnen in der Korrosions‐ und Elektrokatalyseforschung aufgrund ihrer elektrochemischen Stabilität über einen breiten pH‐Bereich und der Vielfalt der möglichen chemischen Zusammensetzungen zunehmend an Interesse. In unseren Untersuchungen mit der äquimolaren CrCoNi‐Legierung in einem sauren Elektrolyten (0.1 M NaCl, pH 2) beobachteten wir eine signifikante Metallauflösung, die mit der Sauerstoffentwicklungsreaktion (OER) im transpassiven Bereich einhergeht, obwohl in zyklischen Polarisationskurven keine Hysterese auftrat oder andere offensichtliche Korrosionsindikatoren vorlagen. In diesem Artikel wird ein Charakterisierungskonzept eingeführt, dass die Beiträge der OER und der Legierungsauflösung differenziert. Hierfür kommt die elektrochemische Rastermikroskopie (SECM) zum Nachweis des Beginns der OER und die quantitative chemische Analyse mit induktiv gekoppelter Massenspektrometrie (ICP‐MS) und UV/Vis‐Spektrometrie zur Aufklärung der Metallauflösungsprozesse zum Einsatz. Die elektrochemische In situ‐Atomkraftmikroskopie (EC‐AFM) zeigte, dass die intergranulare Korrosion der dominierende Mechanismus der transpassive Metallauflösung von CrCoNi ist. Diese Ergebnisse besitzen erhebliche Auswirkungen für die Beurteilung der Stabilität von MPEAs in Korrosionssystemen und der Stromausbeute von OER‐Katalysatoren auf der Basis von MPEAs. Die Daten unterstreichen die Notwendigkeit der analytischen Bestimmung von Metallionen, die von MPEA‐Elektroden freigesetzt werden. Die Freisetzung von Übergangsmetallionen verringert nicht nur die Stromausbeute von Elektrolyseuren, sondern kann zu einer Schädigung von Membranen in elektrochemischen Reaktoren führen.

X‐ray computed tomography study of microstructure weakening by high‐temperature hydrogen attack on refractories

AbstractX‐ray computed tomography (XRT) is a three‐dimensional (3D), non‐destructive, and reproducible investigation method capable of visualizing and examining internal and external structures of components independent of the material and geometry. In this work, XRT with its unique abilities complements conventionally utilized examination methods for the investigation of microstructure weakening induced by hydrogen corrosion and furthermore provides a new approach to corrosion research. The motivation for this is the current inevitable transformation to hydrogen‐based steel production. Refractories of the system Al2O3‐SiO2 are significant as lining materials. Two exemplary material types A and B, which differ mainly in their Al2O3:SiO2 ratio, are examined here using XRT. Identical samples of the two materials are measured, analyzed, and then compared before and after the hydrogen attack. In this context, hydrogen corrosion‐induced porosity and its spatial distribution and morphology are investigated. The results show that sample B has a higher resistance to hydrogen‐induced attack than sample A. Furthermore, the 3D representation revealed a differential porosity increase within the microstructure.

Corrosion mechanism and research progress of metal pipeline corrosion under magnetic field and SRB conditions: a review

Abstract Biocides are used to prevent microbiologically influenced corrosion (MIC), which damages and disables metal structures. However, biocides can make microorganisms resistant and contaminate the environment. Some studies have found that magnetic fields have an inhibitory effect on MIC, providing a new way of thinking for MIC control. In this paper, the current research status of MIC is discussed for typical anaerobic sulfate-reducing bacteria (SRB), the MIC of different metals in different environments is summarized, and the corrosion mechanism of SRB on metal structures, including cathodic depolarization and metabolite corrosion, is introduced. On this basis, the research progress of metal corrosion under magnetic field and microbial conditions in recent years is summarized, and discussed from three aspects, namely, electrochemical corrosion, SCC, and microbial corrosion, respectively. The corrosion process of microorganisms on metals in magnetic field is summarized, including biofilm theory, ion interference theory, free radical theory, and so on. Finally, the prevention and control of microbial corrosion by magnetic fields are prospected using the relevant mechanisms of magnetic field corrosion on metals.

Sebacate intercalated Ca[sbnd]Al layered double hydroxide pigments for corrosion protection of low carbon steel: Anion exchange and electrochemical properties

Sebacate (SB) molecules were incorporated into CaAl layered double hydroxides (CaAL-LDH) using a hydrothermal method. The resulting products underwent characterization through X-ray diffraction, infrared spectroscopy, and scanning electron microscopy. To investigate the release kinetics and thermodynamics of the corrosion inhibitor, total organic carbon analysis (TOC) was employed. A comparison was made with CaAl-LDH prepared without corrosion inhibitors, in which nitrates were the primary anions within the layered clay structure. An assessment of anion exchange between nitrates and chlorides was conducted using total nitrogen analysis (TN). The SB anion comprised approximately 49.2% of the total dried powder synthesized, with a maximum release efficiency of around 86.7% fitting a Langmuir model. For the evaluation of the corrosion inhibition effect on steel surfaces, electrochemical impedance spectroscopy, potentiodynamic polarization, and scanning vibrating electrode technique were employed. The corrosion inhibition impact was ascribed to the liberation of SB anions from the CaAl-LDH pigments, accompanied by alkalinization stemming from partial particle dissolution. Additionally, the incorporation of organic molecules notably enhanced the stability of pigments in aqueous solutions compared to similar ones hosting nitrates. These findings suggested that CaAl-LDH pigments have potential as nanocontainers for organic inhibitors, showing promising prospects in the field of corrosion research.

Applying microelectrodes to investigate aged ductile iron and copper coupon reactivity during free chlorine application

In drinking water distribution systems, including premise plumbing, dissolved oxygen (DO) and free chlorine (FC) are common oxidants and ductile iron (DI) and copper (Cu) are commonly used pipe materials. Microelectrodes as a tool have been applied in previous corrosion research and were used in this study to collect quantifiable data and understand DO and FC reactivity and pH changes at the water-metal interface. Using microelectrodes, pH, DO, and FC profiles from the bulk water to near and at the surface of aged DI (154–190 d) and Cu (2 d and 86–156 d) coupons were investigated during periods of flow and stagnation (30 min). Using the measured microelectrode profiles, oxidant fluxes and apparent surface reaction rate constants were calculated to elucidate differences between DO and FC reactivity with the coupons. Microelectrodes were successfully applied to measure pH, DO, and FC profiles from the bulk water to near aged DI and Cu coupon surfaces; Cu coupons aged quickly and exhibited less reactivity at 2 d with DO and FC than aged DI coupons did after 154–190 d; and for the aged DI coupon experiments, orthophosphate presence stabilized pH profiles where without orthophosphate pH fluctuations of greater than 2 pH units occurred from the bulk water to the DI coupon surface.

(Corrosion Division H. H. Uhlig Award) A Journey From Ice-Breakers to Biomedical Implants: Multifacets of Corrosion

Understanding of corrosion mechanisms enables safe, durable and sustainable application of metallic materials in various fields. The presentation will shortly summarize a personal selection of most important lessons learned in the last 30 years of corrosion research, and then highlights some recent developments for methodologies to study atmospheric and immersion corrosion by respirometry. The approach is based on monitoring the rate of cathodic reactions with help of different types of sensors; this enables a real-time, simultaneous quantification of the rate of the O2 reduction reaction (OER) and the H2 evolution reaction (HER). The respirometric setups can be coupled with electrochemistry, enlarging the corrosion cases to be studied from open-circuit conditions to potential-controlled systems. Examples will be presented, to illustrate the potential of these techniques to reveal insights on corrosion mechanisms of active (e.g. Mg and Zn) and passive metals and alloys (e.g. stainless steels). For passive metals and alloys, special focus in this presentation will be on transpassive dissolution. In essence, three processes can take place in this potential regime: metal dissolution, oxide film formation, and oxygen evolution from water oxidation. In this case, respirometric determination of the oxygen evolution reaction (ORR) helps to distinguish the current (charge) consumed for metal oxidation reactions vs. water oxidation. Most recent developments to enable high-resolution respirometric measurements – and hence to study corrosion in the passive state and its localized breakdown – will be presented.

Minimize Surface Change for Corrosion Study Using a Chronopotentiometric Approach Method in SECCM

In the realm of single-channel scanning electrochemical cell microscopy (SECCM), two primary methods are utilized for approaching the micropipette onto the substrate surface, specifically the chronoamperometric and chronopotentiometric methods. The chronoamperometric method is typically employed in corrosion studies utilizing SECCM, although it has been observed that negative approach potentials can influence subsequent microscale electrochemical measurements as a result of cathodic degradation of the metal oxide film. In this study, we investigated the practicality and stability of utilizing the chronopotentiometric approach method in SECCM-based corrosion research, and we found that the metal surface change during the approach process can be reduced by applying a 0 A approach signal, allowing for the acquisition of primitive electrochemical information of the surface.

Corrosion Behavior of Shot-Peened Ti6Al4V Alloy Produced via Pressure-Assisted Sintering

For the first time, the present study investigates the corrosion, surface, and subsurface properties of a shot-peened Ti6Al4V powder metallurgical alloy produced via pressure-assisted sintering. Shot peening yielded a fine-grained microstructure beneath the surface down to 100 microns, showing that it caused severe plastic deformation. XRD analysis revealed that the sizes of the crystallites in unpeened and shot-peened Ti6Al4V alloy samples were 48.59 nm and 27.26 nm, respectively, indicating a substantial reduction in crystallite size with shot peening. Cross-sectional hardness maps of shot-peened samples showed a work-hardened surface layer, indicating a ~17% increase in near-surface hardness relative to unpeened samples. Three-dimensional surface topographies showed that shot peening yielded uniform peaks and valleys, with a maximum peak height of 4.83 μm and depth of 6.56 μm. With shot peening, the corrosion potential shifted from −0.386 V to −0.175 V, showing that the passive layer developed faster and was more stable than the unpeened sample, improving corrosion resistance. As determined via XRD analysis, the increased grain refinement (i.e., the number of grain boundaries) and the subsequent accumulation of TiO2 and Al5Ti3V2 compounds through shot peening also suggested the effective formation of a protective passive layer. As demonstrated via electrochemical impedance spectroscopy, the formation of this passive film improved the corrosion resistance of the alloy. The findings will likely advance surface engineering and corrosion research, enabling safer and more productive shot peening in corrosion-critical applications.

High‐throughput experimental techniques for corrosion research: A review

AbstractHigh‐throughput experimental techniques can accelerate and economize corrosion evaluation, and thus, have great potential in the development of new materials for corrosion protection such as corrosion‐resistant metals, corrosion inhibitors, and anticorrosion coatings. This concise review highlights high‐throughput experimental techniques that have been recently applied for corrosion research, including (i) the high‐throughput preparation of metal samples in the form of thin films or bulk materials, (ii) high‐throughput experiments based on corrosive solutions with independent or gradient parameters, (iii) high‐throughput evaluation of changes in physicochemical properties, and (iv) high‐throughput corrosion evaluation by electrochemical methods. To advance automated and intelligent corrosion research, future directions for the development of the high‐throughput corrosion experimental and characterization techniques are also discussed.

Performance of Disposable Cu/CuSO4 Reference Electrode in Reinforced Concrete Corrosion Analysis

The investigation of reference electrode performance for corrosion analysis has been widely conducted over the last decade. The need for a disposable and reliable reference electrode is a specific need for corrosion investigation. This research investigated the effectiveness of liquid-based and solid-state reference electrodes, which are disposable and provide reliable performance. The electrode was prepared with low-cost material preparation (disposable usage) within a Copper-Copper Sulphate (CCS) liquid-based and solid-state electrodes. The potential stability was already tested for dependability by measuring the Open Circuit Potential (OCP) on the rebar concrete specimen. The behaviour of solid-state reference and liquid-based reference electrodes in terms of polarization was studied in a corroded environment. Real-time potential data was also obtained for the corrosion rate investigation. The result shows the consistency performance of (OCP) value during corrosion measurement. The deviation of the maximum to a minimum potential value less than 0.02 V, verifies that the liquid-based copper (Cu) electrode and solid-state copper (Cu) electrodes are reliable, adaptable, and disposable for reinforced concrete corrosion measurement. In terms of corroded rebar potential measurement, the real-time polarization measurement result shows that the high-risk corroding occurred on the embedded rebar and was validated by directly visualizing the rebar concrete specimen. Therefore, the results obtained allow us to conclude that the disposable of both reference electrodes shows their stability and significantly reduces the reinforced concrete corrosion research cost.