Improved Corrosion Resistance Research Articles

Hierarchically Electrodeposited Nickel/Graphene Coatings for Improved Corrosion Resistance of Ni Foam Flow Field in PEMFC

Hierarchically Electrodeposited Nickel/Graphene Coatings for Improved Corrosion Resistance of Ni Foam Flow Field in PEMFC

Research Progress on the Relationship Between Microstructure and Properties of AISI 321 Stainless Steel

AISI 321 stainless steel is widely used in chemical pipelines and nuclear power, prompting research on its high-temperature performance and corrosion resistance. This review focuses on the effects of alloy elements, second-phase particle formation, and heat treatment processes on the microstructure and properties of AISI 321 stainless steel. Fine tuning of alloying elements can affect the mode and effect of dynamic recrystallization, altering the high-temperature flow deformation of AISI 321 stainless steel. In order to achieve phase equilibrium, the relationship between corrosion resistance and high-temperature creep behavior and high-temperature mechanical behavior in the presence of second-phase particles was also analyzed. This review outlines the basic heat treatment procedures for improving material properties, providing a new perspective for solution treatment and improving corrosion resistance. In addition, the latest research progress on other factors affecting the high-temperature performance of AISI 321, such as coatings, was briefly introduced.

Nanotube formation and coating of hydroxyapatite-polyvinyl alcohol-collagen composite on Ti-6Al-4V metal alloy

Abstract Ti-6Al-4V metal is widely used as an implantable material due to its biocompatibility and corrosion resistance; however, it has low bioactive properties. The formation of nanotubes and a hydroxyapatite-polyvinyl alcohol-collagen composite coating on Ti-6Al-4V metal aims to enhance its biocompatibility and bioactivity. The nanotube oxide layer Ti-6Al-4V was formed by the anodization method. The composite’s infrared spectrum showed characteristic absorption bands from Hydroxyapatite (HAp), polyvinyl alcohol, and collagen. The composite-coated Ti-6Al-4V metal, both non-nanotube, and nanotube, showed a typical diffraction pattern of HAp and titanium element. The electron microscope image showed the uniform granular form of HAp. The corrosion test results showed that composite-coated nanotube Ti-6Al-4V metal could not improve corrosion resistance. It is also relevant to the in vitro test in a lactate ringer solution that showed the higher Ca2+ ion of nanotube Ti-6Al-4V metal than that of non-nanotube Ti-6Al-4V metal.

Improving electrochemical corrosion resistance of AISI 304 using tungsten carbide-cobalt/silicon carbide high-velocity oxygen fuel coatings

This study offers an in-depth analysis of the electrochemical corrosion behaviour of tungsten carbide-cobalt/silicon carbide coatings on AISI 304 stainless steel, applied using high-velocity oxygen fuel spraying. The coatings were produced with varying silicon carbide concentrations (25%, 40%, 60% and 75%) to evaluate their effectiveness in enhancing corrosion resistance. Microstructural analyses were conducted using SEM and EDS, while corrosion behaviour was assessed through open-circuit potential and Tafel tests in a NaCl solution. The findings indicate that increasing the silicon carbide content increases surface roughness and coating thickness. Additionally, the corrosion results revealed that coatings with higher silicon carbide concentrations exhibited more negative potential values, indicating improved corrosion resistance due to passivation effects.

Experimental and numerical studies on corrosion-resistant aluminium foam sandwich panel subject to low-velocity impact

Aluminium foam sandwich panels (AFSPs) have a high impact resistance and are suitable for a wide range of engineering applications. To improve corrosion resistance, this paper proposes an anti-corrosion sandwich panel with stainless steel as the upper sheet. Drop hammer impact tests were performed on a total of ten AFSPs to investigate their dynamic response and failure patterns. To assess the deformation performance of AFSPs, a laser displacement meter was used to obtain the bottom centre displacement. The effects of the impact energy and the thickness of each component of AFSPs on the peak impact force and deformation performance were studied. Test results showed that the thickness of each component had notable effects on the impactor and bottom displacements. In addition, the effect of the unit mass of the components in AFSPs on decreasing the bottom displacement was discussed. Compared to increasing the aluminium foam and lower sheet thicknesses, increasing the upper sheet thickness was more effective in decreasing the bottom displacement. A finite element model of AFSPs was developed to conduct parameter analysis, indicating that impactors with larger diameters resulted in higher peak forces and reduced deformation of AFSPs.

Investigation of phase transformation and mechanical properties of silicon addition on AlCrFeMnNi high entropy alloys

Abstract This paper examines the impact of silicon in the AlCrFeMnNi high-entropy alloy system, focusing on both its microstructural and mechanical properties. Alloys with varying silicon content (x = 0, 0.3, 0.6, 0.9 atomic ratio) were synthesized using vacuum arc melting. The phase formation of these high-entropy alloys was analyzed using X-ray diffraction to comprehend the alloying process behaviour. The findings revealed that the solidification of the AlCrFeMnNi alloy occurred in dendritically, with dendrite cores containing Cr, Fe, and Ni, while interdendritic regions were enriched in Al and Ni after adding Silicon. Increasing the silicon content from 0 to 0.9 led to significant improvements in microhardness and wear resistance. This improvement is attributed to the reinforcement of grain boundaries provided by silicon. The formation of an Al and Ni rich B2 phase is crucial in resisting dislocation motion and preventing further deformation. Additionally, the addition of silicon led to improved corrosion resistance, as demonstrated by potentiodynamic polarization measurements. However, a trade-off was observed between compressive strength and ductility: compressive strength increased with higher silicon concentrations, but at the expense of ductility.

A significant improvement in corrosion resistance and biocompatibility in ZrNbTiCrCu high-entropy films induced by the precipitation of Cu

Utilizing nanotechnology and composites to create a protective film on titanium alloy is an effective means of achieving the desired high performance. Self-assembly of nanocomposite structures offers a promising route to forming high entropy alloy films (HEAFs), but controlled preparation remains challenging. This work used magnetron sputtering through adjusting preparation parameters to prepare ZrNbTiCrCu HEAFs, achieving a significant improvement in corrosion resistance and biocompatibility induced by the precipitation of Cu. According to the electrochemical corrosion test, without obvious corrosion pits on the surface of S2 after corrosion, a passivation film composed of bimetallic oxide CuCrO2 formed on the film surface, indicating that ZrNbTiCrCu HEAFs have remarkable corrosion resistance performance. In the cytocompatibility experiment, the cell viability of HEAFs reached over 95 % due to the precipitation of Cu, suggesting their excellent biocompatibility. In addition, ZrNbTiCrCu HEAFs exhibit outstanding antibacterial ability, especially when the sputtering current is 0.6 A, and the in vitro antibacterial rate of the sample against Escherichia coli is close to 99 %.

Study on the mechanism of aluminum melt corrosion of Fe-SG series metals

This paper investigates the corrosion behavior of Fe-SG series metals with different graphite nodule counts to molten Al by using the ultrasonic vibration hot-dip aluminum experimental method. Fe-SG series metals to aluminum melt exhibited a much better corrosion resistance compared to H13 tool steel. As the graphite nodule count increases, the hot melting loss rate of Fe-SG series metals gradually decreases, indicating an improvement in corrosion resistance to aluminum melt. Scanning and EDS analysis of the samples after hot-dip aluminum testing revealed that the thickness of the product layer increased progressively with the extension of hot-dip aluminum time. Through the analysis of the structure and composition of the product layer, it was found that the corrosion products in H13 steel were composed of Fe2Al5 and FeAl3. In addition to the two phases, the product layer of the Fe-SG series metals also contained granularly distributed Fe-Al-Si intermetallic compounds within the Fe2Al5 phase. This resulted in a better corrosion resistance to aluminum melt.

Simultaneous improvement of wear and corrosion resistance of microarc oxidation coatings on ZK61 Mg alloy by doping with ZrO2 nanoparticles

Simultaneous improvement of wear and corrosion resistance of microarc oxidation coatings on ZK61 Mg alloy by doping with ZrO2 nanoparticles

One-step electrodeposition of reduced graphene oxide-amorphous carbon composite coatings for proton exchange membrane fuel cell bipolar plates

In this paper, a convenient electrodeposition method is proposed to directly fabricate a reduced graphene oxide-amorphous carbon composite coating (rGO-ACC) on a 316L stainless steel substrate. The rGO-ACC coating is achieved through a one-step reduction by utilizing a choline chloride-ethylene glycol deep eutectic solvent (DES) with the dispersion of graphene oxide. The analysis results from SEM, Raman and XPS reveal that the obtained rGO-ACC coating, with layered wrinkle morphology, uniformly covers and covalently bonds to 316L stainless steel substrate. Potentiodynamic and potentiostatic polarization tests showed that the corrosion current densities of rGO-ACC coated 316L stainless steel were of the order of 10-7 A cm−2 in simulated proton exchange membrane fuel cells (PEMFC) working environment, indicating a significant improvement of corrosion resistance of 316L and an excellent electrochemical stability. Meanwhile, compared with the naked 316L steel, the interfacial contact resistance (ICR) of the coated stainless steel is significantly reduced due to the outstanding electrical conductivity of the coated rGO. The results manifested that deposited rGO-ACC on steel surface may be a highly promising modification method for PEMFC metal bipolar plates.

Effect of texture, grain boundary constitution, and molybdenum partitioning on corrosion and hydrogen permeation behavior of pulse electrodeposited Ni-Mo coatings

Microstructural evolution, electrochemical corrosion and hydrogen permeation in pulse electrodeposited Ni-Mo coatings (2, 4, 8, and 11wt% Mo) were investigated. Electrochemical impedance spectroscopy and potentiodynamic polarization measurements revealed improved corrosion resistance at an optimum Mo content. The corrosion current density icorr and polarization resistance Rp values obtained were 13.8 μA/cm2 and 1745 Ωcm2 respectively for pure Ni coating while the icorr and Rp values obtained were 1.7 μA/cm2 and 5406 Ωcm2 respectively for Ni-4wt% Mo coating. Further, increase in the Mo content beyond 4 wt% increased the corrosion rate. Nevertheless, corrosion resistance of Ni-Mo coatings was found to be higher than the pure Ni coating. Ni-Mo coatings contained relatively Mo-enriched clusters in a solid solution matrix. The highest corrosion resistance of Ni-4wt% Mo coating was due to lower energy (001) and (111) textures, lower energy grain boundary constitution, and low coating strain. In Ni-4wt% Mo coating, Mo-enriched Ni-Mo nanoclusters inhibited hydrogen passage by providing a torturous path. In contrast, a high fraction of high-angle grain boundaries (compared to pure Ni coating) facilitated hydrogen permeation leading to a similar extent of hydrogen permeation through pure Ni and Ni-4wt% Mo coatings.

Advancing biodegradable Mg-Gd-Y alloy for cardiovascular stent applications

The implants of percutaneous coronary intervention are making progress to periodic degradation and the reduction of complications. Thus, magnesium alloys have emerged as excellent candidate materials for preparing cardiovascular stents due to their excellent biodegradability and biocompatibility. This study investigates the effect of Gd content on the mechanical properties and corrosion behavior of Mg-xGd-5Y alloys. The results indicate that Gd dissolved in the Mg matrix, enhancing ultimate tensile strength (UTS of 344MPa) through a solid solution-strengthening effect and activating Prismatic <a> slip systems to enhance elongation (EL of 15.7%). The Pilling-Bedworth ratio (PBR) of Mg-xGd-5Y alloys was analyzed after being immersed in Hank's Balanced Salt Solution for 24h, with Mg-10Gd-5Y exhibiting a PBR value of 1.1. Furthermore, the product film of Mg-xGd-5Y alloys, mainly oxides and carbonates, effectively improved corrosion resistance. Mg-xGd-Y alloys with low Gd content (Gd≤10wt.%) demonstrated good cell compatibility with L929 cells (relative growth rate≥75%). These results suggest that Mg-xGd-5Y alloys (Gd≤10wt.%) have significant potential for cardiovascular stent application.

A novel fine-grained TiZrCu alloy tailored for marine environment with high microbial corrosion-resistance

Titanium alloys, usually known as non-corrodible material, are susceptible to microbiologically influenced corrosion (MIC) in marine environment. While titanium-zirconium (TiZr) alloys have been extensively studied in medical applications, the influence of microorganisms, especially marine microorganisms, on their corrosion behavior has not been explored. In this work, a TiZrCu alloy with a combination of excellent mechanical, anti-corrosion, and antibacterial properties was developed by optimizing the Cu content and grain refinement. Its MIC and antibacterial mechanisms against Pseudomonas aeruginosa, a representative marine microorganism, were systematically investigated. 5.5 wt% was determined as the optimal copper content. The fine-grained Ti-15Zr-5.5Cu (TZC-5.5FG) alloy maintained high MIC resistance, exhibiting a corrosion current of 5.7 ± 0.1 nA/cm2 and an antibacterial rate of 91.8 % against P. aeruginosa. The mechanism of improved corrosion resistance was attributed to the denser passive film with high TiO2 content and the lower surface potential difference ΔE. The release of Cu2+ ions, ΔE, and the generation of ROS are three major factors that contribute to the antibacterial performance of TiZrCu alloys. Compared to other available marine metals, TZC-5.5FG alloy exhibited superior comprehensive performance, including excellent mechanical properties and anti-MIC capacity, which make it a promising material for load-bearing applications in marine environment.

Zn-Mn composite coating codeposited with two-dimensional carbon nanoplatelets for improving corrosion resistance

Zn-Mn composite coating codeposited with two-dimensional carbon nanoplatelets for improving corrosion resistance

Corrosion resistance in LNG plant design: Engineering lessons for future energy projects

Corrosion resistance is a critical consideration in the design and operation of liquefied natural gas (LNG) plants, where harsh environmental conditions and aggressive chemicals can significantly impact asset integrity and safety. This paper explores engineering lessons learned from past LNG projects, emphasizing the importance of corrosion management strategies to enhance the longevity and reliability of energy infrastructure. The study highlights key factors contributing to corrosion in LNG facilities, including materials selection, environmental exposure, and operational practices. By employing advanced materials such as corrosion-resistant alloys and coatings, engineers can mitigate corrosion risks, leading to reduced maintenance costs and extended equipment lifespan. The paper examines successful case studies where proactive corrosion management has been implemented, showcasing innovative engineering solutions such as cathodic protection, corrosion monitoring systems, and design modifications that enhance resistance to corrosion-related failures. Furthermore, it addresses the role of regular inspections, predictive maintenance, and risk-based approaches in identifying potential corrosion issues before they escalate into significant problems. As LNG plants continue to proliferate globally, the integration of corrosion resistance into design and operational frameworks becomes increasingly vital. This paper also discusses emerging technologies and materials that hold promise for improving corrosion resistance, including nanotechnology and smart coatings that provide real-time monitoring capabilities. By learning from past projects and embracing a proactive approach to corrosion management, future energy projects can enhance safety, reduce operational risks, and achieve greater sustainability in their operations. Ultimately, the lessons derived from this research will contribute to developing best practices for designing and operating LNG plants and other energy facilities, ensuring that they meet the challenges of a rapidly evolving energy landscape.

Ceramic matrix composites for corrosion-resistant next-generation nuclear reactor systems: A conceptual review of enhancements in durability against molten salt attack

Ceramic matrix composites (CMCs) are emerging as a key material class for enhancing corrosion resistance in next-generation nuclear reactor systems, particularly in high-temperature molten salt environments. These environments, critical for advanced nuclear reactors such as molten salt reactors (MSRs), present severe challenges, including aggressive chemical attacks that degrade traditional structural materials over time. This conceptual review explores the development and application of CMCs to improve the durability and corrosion resistance of nuclear reactors exposed to molten salt attacks. CMCs, which consist of ceramic fibers embedded in a ceramic matrix, offer significant advantages, such as high thermal stability, mechanical strength, and improved corrosion resistance compared to conventional materials. This review examines how CMCs can be tailored to withstand harsh operational conditions, with a focus on the selection of ceramic phases, fiber-matrix interactions, and innovative fabrication techniques that enhance their protective capabilities. Key challenges addressed include the optimization of composite design to resist molten salt corrosion, the effects of temperature on the material properties, and the long-term stability of CMCs under extreme conditions. Advances in surface treatments, coatings, and the development of hybrid CMC systems are also discussed, highlighting their potential to further enhance durability. The review outlines the use of advanced characterization techniques, such as high-temperature corrosion testing and in situ microscopy, to evaluate CMC performance in molten salt environments. Additionally, it identifies knowledge gaps in current research, emphasizing the need for long-term studies on CMC behavior under realistic reactor conditions. This review concludes by proposing future research directions and technological advancements required to integrate CMCs into next-generation nuclear reactor designs, aiming to improve system reliability and operational safety.

Self-healing efficiency of ceria-doped Zn-Co coatings: Insights into particle-free versus biphasic plating baths

Achieving the superior properties of nanocomposite materials involves addressing several challenges, particularly the agglomeration of nanoparticles in the plating bath. This study focuses on the electrodeposition and characterization of Zn-Co-CeO2 composite coatings using a particle-free plating bath, which is an effective strategy to mitigate agglo¬meration. For comparison, the composite coatings were also deposited from a traditional biphasic plating solution. The coatings were deposited galvanostatically, at various current densities. Scanning electron microscopy revealed that using a particles free plating solution in conjunction with lower current densities enhanced the compactness and the overall quality of the coatings. Lower current densities favoured the codeposition of particles, as indicated by energy-dispersive X-ray spectroscopy results. Notably, the coatings produced from the particle-free bath exhibited significantly improved corrosion resistance and durability in chloride-rich environments, attributed to their self-healing properties, as shown by electrochemical impedance spectroscopy.

Corrosion resistance and biocompatibility of carbon ion implanted AZ31B magnesium alloy

The poor corrosion resistance of magnesium limits its clinical applications. Accordingly, in the present study, carbon ions were incorporated into a AZ31b magnesium alloy surface via carbon plasma immersion ion-implantation to improve its corrosion resistance and biocompatibility. The surface morphology and properties of the modified alloy were evaluated by field-emission scanning electron microscopy, water contact angle measurement, Raman scattering, X-ray photoelectron spectroscopy, and energy dispersive X-ray spectroscopy. Furthermore, compositional depth profiles were obtained by glow discharge optical emission spectroscopy, revealing a Gaussian-like distribution of carbon concentration. Electrochemical and hydrogen-evolution analysis demonstrated the successfully improved corrosion resistance of the AZ31b Mg alloy, while its biocompatibility was demonstrated by MTT and cell-adherence assays.

Synthesis, structure characterization, and corrosion properties of duplex electroless Ni-P/Ni-B and Ni-P/Ni-B-W coatings on mild steel

This study investigates the formation of duplex electroless Ni-P/Ni-B and Ni-P/Ni-B-W alloys through electroless plating process coatings on mild steel using hypophosphite and sodium borohydride as a reducing agent, employing heat-treated. Electroless plating is affordable and suitable for coating convoluted structures. Duplex electroless on mild steel was characterized by X-ray diffraction (XRD), Energy-dispersive X-ray spectrometry (EDS), scanning electron microscopy (SEM) were used to examine the surface and cross-sectional morphologies of the duplex coating, and finally study electrochemical corrosion properties. The analysis reveals that duplex coating yields a thicker, more homogeneous coating with a characteristic cauliflower morphology and spherical nodular structures. The coating was initially amorphous, but finally crystallized when heated to 400 °C. More corrosion resistance was found in the Ni-P/Ni-B and Ni-P/Ni-B-W layers when Ni-B served as the outer covering. This study focuses on the important effects of varying tungsten concentrations and heat treatment on the corrosion resistance, surface quality, and microstructural characteristics of duplex coatings. Showed improved corrosion resistance when exposed to 0.5 g/L of Na2WO4.

Nano Material Innovation in Enhancing Corrosion Resistance of Offshore Structures

Offshore structures are constantly exposed to the corrosive marine environment, causing significant material degradation and potentially jeopardizing structural integrity. This research explores recent innovations in nanomaterial technology to improve the corrosion resistance of offshore structures. The main focus is given to the development of nano-composite coatings incorporating metal oxide nanoparticles and carbon nanotubes. An electrophoretic deposition method was used to apply the coatings on steel substrates, followed by characterization using scanning electron microscopy (SEM) and electrochemical impedance spectroscopy (EIS). Results showed a significant improvement in corrosion resistance, with the nano-composite coatings exhibiting a reduction in corrosion rate of up to 85% compared to conventional coatings. In addition, these coatings exhibited superior adhesion and abrasion resistance in simulated extreme marine conditions. These findings highlight the great potential of nanomaterials in extending the service life and improving the reliability of offshore structures, with important implications for the oil and gas and offshore renewable energy industries.