Corrosion Resistance Of Steel Research Articles

Corrosion behaviour of oxide film formed on carbon steel in high temperature alkaline water in the presence of zinc and magnesium ions

ABSTRACT Magnetite films on carbon steel are known to reduce corrosion in high temperature aqueous medium. The magnetite films were modified in-situ by introducing Zn and Mg in autoclave by hydrothermal process at 250°C. The film developed in the presence of Zn were thinner with particle size 150 nm after 240 h exposure compared to that developed in the presence of Mg with particle size 223 nm. The depth distribution of Zn and Mg monitored by Rutherford backscattering spectrometry showed that Mg was present more at the top surface, whereas Zn were almost uniform across the depth of the film. Contact angle measurements and electrochemical studies of coated specimens showed an increased corrosion resistance in presence of Zn and Mg in comparison to known passive magnetite layer formed in their absence. It was shown that Zn is a better candidate for corrosion resistance of carbon steel in high temperature aqueous medium.

Corrosion resistance of Aluminium steel in 1N Sodium Hydroxide solution by an aqueous extract of Thespesia populnea plant leaves

Corrosion resistance effect of aluminium steel in 1N sodium hydroxide by an aqueous extract of Thespesia populnea plant leaves has been investigated by mass loss method. It is observed that as the concentration of the inhibitor increases, the inhibition efficiency increases. The mechanistic aspects of corrosion resistance have been studied by potentiodynamic polarization technique and electrochemical impedance spectroscopy. A maximum inhibition efficiency of 78.70% is achieved by this inhibitor system. Potentiodynamic polarization technique reveals that the inhibitor system functions as a mixed type of inhibitor, controlling anodic and cathodic reactions. It is noted that in the presence of inhibitor, linear polarization resistance value increases and corrosion current decreases. Electrochemical impedance studies reveal that a protective film is formed on the Al steel surface, since in the presence of inhibitor system, the charge transfer resistance value increases and double layer capacitance value decreases. This is due to adsorption of the molecules of the active ingredients of the extract on the Al steel surface. The inhibition efficiency increases due to adsorption of hetero atoms present in TP plant leaves extract on the Al steel surface. The maximum inhibition efficiency and the lower corrosion rate are obtained at high concentration 1200 ppm for TP plant leaves extract. By further increase in inhibitor concentration above 1200 ppm, the inhibition efficiency and corrosion rate almost remained constant. So, the 1200 ppm concentration is fixed as the maximum inhibition for the investigative aqueous extract of plant leaves as corrosion inhibitor. This concentration corresponds to the attainment of a saturation value in surface coverage of Al steel. The protective film formed over the Al steel surface has been characterized by Fourier Transform infra-red spectroscopy. The surface morphology of the protective film of carbon steel immersed in sodium hydroxide in the absence and presence of inhibitor has been studied by Scanning electron microscopy. The outcome of the study can be used in pickling industry wherein sodium hydroxide is used to remove the rust on the Al steel surface.

Development of Self-Passivating, High-Strength Ferritic Alloys for Concentrating Solar Power (CSP) and Thermal Energy Storage (TES) Applications

Concentrating solar power (CSP) and thermal energy storage (TES) based on molten salts still lacks economic feasibility, with the material investment costs being a major drawback. Ferritic stainless steels are a comparatively cheap class of materials that could significantly contribute to cost reductions. The addition of aluminum to ferritic steel can result in self-passivation by forming a compact Al2O3 top layer, which exhibits significantly higher corrosion resistance to solar salt compared to the Cr2O3 surface layers typically formed on expensive structural alloys for CSP and TES, such as austenitic stainless steels and Ni-base super alloys. However, to date, no ferritic stainless steel combining Al2O3 formation and sufficient structural strength is available. For this reason, cyclic salt corrosion tests under flowing synthetic air were carried out on seven Laves phase-forming, ferritic model alloys (17Cr2-14Al0.6-1Nb2.6-4W0.25Si), using “solar salt” (60 wt. % NaNO3 and 40 wt. % KNO3). The Al content was varied to investigate the influence on the precipitation of the mechanically strengthening Laves phase, as well as the impact on the formation of the Al-oxide top layer. The W and Nb contents of the alloys were increased to examine their influence on the precipitation of the Laves phase. The salt corrosion experiments demonstrated that simultaneous self-passivation against a molten salt attack and mechanical strengthening by precipitation of fine Laves phase particles is possible in novel ferritic HiperFerSCR (salt corrosion-resistant) steel. Microstructural examination unveiled the formation of a compact, continuous Al2O3 layer on the surface of the model alloys with Al contents of 5 wt. % and higher. Furthermore, a stable distribution of fine, strengthening Laves phase precipitates was achieved in the metal matrix, resulting in a combination of molten salt corrosion resistance and potentially high mechanical strength by a combination of solid solution and precipitation strengthening. These results show that high-strength ferritic alloys are suitable for use in CSP applications.

Corrosion performance of NV E690 steel and 316L stainless steel coating fabricated by underwater direct metal deposition

The corrosion resistance of NV E690 steel and 316L stainless steel (SS316L) coatings fabricated by underwater laser direct metal deposition (UDMD) was investigated. The corrosion resistance of the as-deposited NV E690 was improved by coating SS316L layers. The dilution effect coupling with macro-segregations (peninsula, island, and banded zone) deteriorated the corrosion resistance by forming preferential dissolution and crevice-shaped corrosion when depositing monolayer SS316L coating. While the above-mentioned drawbacks were alleviated when depositing bilayer SS316L coatings, thereby leading to higher corrosion resistance by forming a compact passive film.

Rapid formation of titanium nitride coating by atmospheric-controlled induction-heating fine particle peening and investigation of its wear and corrosion resistance

To create a coating of titanium nitride, atmospheric-controlled induction-heating fine particle peening using fine particles of pure titanium was conducted for low-alloy steel in a nitrogen atmosphere, and the surface characteristics of the treated specimens were investigated. The formation of hard titanium nitride coatings with a thickness of 100–200 μm was achieved by peening at 1373 K for 10 s and subsequent heating at 1373 K for 120 s. Titanium particles adhered to the treated surfaces during peening at the high temperature, which reacted with nitrogen in the atmosphere during the heating after peening. Ball-on-disk wear tests were conducted to examine the wear resistance of the specimens, and it was found that the created coating by AIH-FPP improved the wear resistance of low-alloy steel owing to its high hardness. The improvement was more significant at high testing temperatures because the high testing temperature and frictional heat caused oxygen in the air to react with titanium in the coating during the wear test. Immersion of the specimens into sodium chloride solution was also conducted to investigate the corrosion resistance, which revealed that the coating created improved corrosion resistance of low-alloy steel.

Clarifying the effect of Cu element on the corrosion properties of Ni-Mo low alloy steel in marine environment

Corrosion kinetics and rust layer protectiveness were combined to explore the effect of Cu content on the corrosion resistance of Ni-Mo low alloy steel in a simulated tropical marine atmospheric environment. The difference between the inner and outer rust layer protectiveness was discovered from the phase composition and distribution results and the evolution of electrochemical property. The synergistic effect of Cu with Ni and Mo on optimizing the rust layer protectiveness was revealed based on the formation and function of the appositional enrichment region (AER) inside the rust layer.

Investigation of the change in wettability properties and corrosion behavior of AISI 304 after laser surface texturing

Stainless steel is a widely used material in industry, architecture, and medical instruments. However, after various thermal processing of stainless steels, chromium carbides can be formed, which locally depletes the chromium available to form a passive film and reduces the corrosion performance. Laser surface treatment can change the surface chemistry of the steel and improve some electrochemical characteristics. However, these characteristics are influenced by the laser power, pulse width, distance between the lines, scanning speed, etc., which all change the surface chemistry and characteristics of laser surface texturing. Simultaneously, the ability to repel liquids that cause corrosion actions could combine to enhance corrosion performance. Since the wettability of a solid surface depends both on its topography and chemical nature, the micro structuring of an austenitic steel surface is an effective way of fabricating hydrophobic or super hydrophobic corrosion-resistant surfaces. For this reason, this study discusses the effect of laser power in the impact zone and the distance between raster lines on the microstructure, wettability, and corrosion resistance of austenitic steel (AISI 304) when exposed to nanosecond fiber laser radiation. The results indicate that parameter-controlled micro structuring can be used to form both hydrophilic and hydrophobic surfaces with different electrochemical performances.

Effect of surfactant concentration in modifying solution on corrosion properties of the coatings based on vinyltrimethoxysilane (VTMS) and poly(3,4-ethylenedioxythiophene) (PEDOT)

This paper presents an analysis of the structure and physicochemical properties of coatings based on an organofunctional silane (VTMS), a conductive polymer (PEDOT), and a surfactant (polyoxyethylene glycol monolauryl ether BRIJ).The coatings were deposited on X20Cr13 stainless steel and glassy carbon specimens using sol-gel immersion. The obtained coatings were characterised in terms of topography, microstructure, roughness, adhesion to the steel substrate, thickness, and corrosion resistance. Corrosion tests were conducted in sulfate environments with pH = 2 without or with the addition of Cl- ions.The use of different surfactant concentrations in the modifying solution is intended to improve the deposition efficiency and increase the degree of dispersion of silane and conducting polymer.The tested coatings were found to slow down the corrosion of the steel substrate, thus effectively protecting it from this phenomenon. The use of a surfactant compound is intended to increase the degree of dispersion of silane and polymer in the modifying solution to improve deposition efficiency.Test carried out in corrosive media have shown that the coatings proposed in the above work, based on VTMS silane, PEDOT polymer and BRIJ surfactant, significantly increase the corrosion resistance of the tested materials, which confirms their effectiveness and possibility of application in various industries.The novelty of this paper is the use of silane (VTMS), polymer (PEDOT) and surfactant (BRIJ) as components of the anticorrosion coating.

Compressive performance of SWSSC-filled CFRP-stainless steel composite tube columns

The structure of concrete confined by carbon fiber-reinforced polymer (CFRP) and stainless steel tubes was investigated. The columns, which take advantage of the ductility and corrosion resistance of stainless steel, are composed of stainless steel tube, core seawater and sea sand concrete (SWSSC) and outer FRP. Forty circular SWSSC-filled FRP-stainless steel composite tube columns (SCFSSCTs) were manufactured and subjected to axial compression tests. After fracturing of the FRP, the failure modes of the specimens mainly showed extrusion expansion, with a small amount of shear failure. The increase in the thickness of the stainless steel and the number of FRP layers resulted in a significant improvement in the load capacity and deformation capacity of the structure, which was more evident in the specimens with higher steel contents. With the increase in the number of FRP layers, the increases in ultimate stress and ultimate strain were 40.4% − 130.0% and 118.6% − 282.4%, respectively, compared with the column with single stainless steel confinement. The stress–strain curves for the SCFSSCTs were similar to those of structures reinforced by FRP and carbon steel and were divided into four stages. Models were proposed to predict the full axial stress–strain curves of SCFSSCTs, including the ultimate point and the peak point.

ЧИСЛЕННОЕ МОДЕЛИРОВАНИЕ ТЕЧЕНИЯ ПОТОКОВ МОТОРНОГО ТОПЛИВА В УЛЬТРАЗВУКОВОЙ КАМЕРЕ АКТИВАТОРА

To improve the quality of motor fuel, fuel activators with overlapping fields of different physical nature are used. The fuel activator with ultrasonic treatment is considered. The operation of the camera is carried out on the principle of a liquid whistle. The main working element of the ultrasonic is a plate made of corrosion-resistant steel and with a polished surface and a nozzle. The nozzle is positioned so that the flowing jet of motor fuel is symmetrically dissected by the plate. At the intersection of the motor fuel flow, the plate is excited and oscillates at one of the natural frequencies. It plays the role of a mechanical resonator, controls the operation of the system and emits sound. When ultrasonic vibrations are introduced, a secondary phenomenon occurs – cavitation, which affects the course of the processing process and the quality of the final product. Numerical simulation of the flow of motor fuel flows is presented in order to determine the parameters of the radiating surface and the operating pressure at which cavitation will occur. It is established that there are areas with a local decrease in pressure in the fluid flow and an increase in acoustic power, which is a sign of acoustic hydrodynamic cavitation. To create cavitation, the parameters of the plate are set: the thickness of the plate is 1-3 mm, the sharpening angle is 30-40 °, the ratio of the width of the plate to its length is 1 to 2, the distance to the nozzle is 0-0.1 mm, the applied pressure is at least 2 atm. To create an ultrasonic hydrodynamic acoustic developed cavitation, it is necessary to increase the difference in the applied pressure, for example, for a stationary activator, or increase the number of radiating surfaces (plates) or install reflectors (for a built-in activator).

A Review of Trends in Corrosion-Resistant Structural Steels Research-From Theoretical Simulation to Data-Driven Directions.

This paper provides a review of models commonly used over the years in the study of microscopic models of material corrosion mechanisms, data mining methods and the corrosion-resistant performance control of structural steels. The virtual process of material corrosion is combined with experimental data to reflect the microscopic mechanism of material corrosion from a nano-scale to macro-scale, respectively. Data mining methods focus on predicting and modeling the corrosion rate and corrosion life of materials. Data-driven control of the corrosion resistance of structural steels is achieved through micro-alloying and organization structure control technology. Corrosion modeling has been used to assess the effects of alloying elements, grain size and organization purity on corrosion resistance, and to determine the contents of alloying elements.

Reinforced corrosion resistance of mild steel in acidic medium by bis(2-acetylpyridine)dithiosemicarbazone (DTSc): electrochemical, surface and spectroscopic studies

Reinforced corrosion resistance of mild steel in acidic medium by bis(2-acetylpyridine)dithiosemicarbazone (DTSc): electrochemical, surface and spectroscopic studies

Electrochemical Corrosion Behavior of Passivated Precipitation Hardening Stainless Steels for Aerospace Applications

Precipitation-hardening (PH) stainless steels (SS) are widely used in various aerospace applications. These steels exhibit good mechanical and corrosion resistance. The electrochemical behavior of 15-5PH, 17-4PH, Custom450 and AM 350 stainless steels passivated with citric and nitric acid baths for 60 and 90 min at 25 and 49 °C were evaluated in 5 wt.% sodium chloride (NaCl) and 1 wt.% sulfuric acid (H2SO4) solutions. The electrochemical behavior was studied with potentiodynamic polarization curves (PPC) according to the ASTM G5-13 standard. The results indicated that there are two characteristic mechanisms that are present in the potentiodynamic polarization curves. When the PHSS is immersed in an H2SO4 solution, there is a secondary passivation, and in the NaCl solution, there is a pseudo-passivation (not stable passivation film). The current densities in the NaCl solution were between 10−4 and 10−5 mA/cm2, while those of H2SO4 were recorded around 10−2 and 10−3 mA/cm2. Citric acid does work as a passivating solution, and in some cases, the corrosion resistance of the stainless steel was comparable to that of nitric acid.

Effect of Ca and Sb on the Corrosion Resistance of E690 Steel in Marine Atmosphere Environment

This study investigates the impact of Ca and Sb elements on the corrosion resistance of E690 steel in a simulated marine environment. Electrochemical testing and dry/wet cyclic corrosion testing were conducted on prepared E690 steel specimens. The eroded specimens’ microstructure was observed under a scanning electron microscope, and the inclusion morphology was analyzed using an energy-dispersive spectrometer (EDS). The simulating liquid was designed to emulate the severe marine atmospheric environment in Xisha. Results showed that the addition of Ca and Sb elements effectively enhances the corrosion resistance of E690 steel in the simulated marine environment. The corrosion rates of E690 steel specimens with Ca and Sb additions were lower than those without, and the corrosion morphology was more uniform. These findings suggest that the addition of Ca and Sb elements can improve the corrosion resistance of E690 steel in simulated marine environments and have potential for use in marine engineering applications.

Passivation Effect of the Chlorinated Paraffin Added in the Cutting Fluid on the Surface Corrosion Resistance of the Stainless Steel.

Cutting fluids are the most effective method to lower the cutting temperature and decrease the cutting tool wear. At the same time, the cutting fluids influence the corrosion resistance property of the machined surface. In this study, chlorinated paraffin (CP), which is a common additive in the cutting fluid, was selected as the research objective to study its corrosion resistance property. The passivation effect of CP with different concentrations on the machined surface of stainless steel was studied. Electrochemical measurements and surface morphology investigation were used to characterize the passivation effect of CP with different concentrations. The test results showed that the corrosion resistance of stainless steel in the cutting fluid was enhanced with the increase in CP additive. This reason is that the charge transfer resistance increases and the corrosion current density decreases with the increase in CP additive. The X-ray photoelectron spectroscopy (XPS) results show that the proportion of metal oxides on the processed surface of the stainless steel sample was increased from 20.4% to 22.0%, 32.9%, 26.6%, and 31.1% after adding 1 mL, 2 mL, 4 mL and 6 mL CP in the cutting fluid with a total volume of 500 mL, respectively. The oxidation reaction between CP and the stainless steel sample resulted in an increase in metal oxides proportion, which prevented the stainless steel sample from corrosion in cutting fluid.

MATHEMATICAL MODELING OF THE CORROSION BEHAVIOR OF AUSTENITIC STEELS IN CHLORIDE-CONTAINING ENVIRONMENTS DURING THE OPERATION OF PLATE HEAT EXCHANGERS

Purpose. It consists in the development of mathematical models that describe the dependence of the critical pitting temperatures of AISI 304, 08X18N10, AISI 321, 12X18N10T steels in model circulating waters with pH 4...8 and chloride concentration from 350 to 600 mg/l.
 Research methods. The developed mathematical models are based on linear square regression and a neural network of direct signal propagation for a reduced set of features.
 Results. It was established that the critical pitting temperatures of the studied austenitic chrome-nickel steels increase with an increase in the pH of the circulating water, the number of oxides up to 3.95 μm in size, the average distance between titanium nitrides, the Cr content and a decrease in the concentration of chlorides in the circulating water, the average distance between oxides, and the austenite average grain diameter.
 Scientific novelty. Based on the established relationships between the critical pitting temperatures of corrosion-resistant steels AISI 304, 08Х18Н10, AISI 321, 12Х18Н10Т, their chemical composition within the standard and structural heterogeneity, the mechanisms of their influence on the pitting resistance of these structural materials in circulating chloride-containing waters have been developed. It was established that metastable pitting is formed in a solid solution of austenite of steels around oxides with a size of 1,98...3,95 microns and repassivates before reaching critical dimensions of about 5 microns, which contributes to the growth of their pitting resistance in reversible chloride-containing environments.
 Practical value. The developed mathematical models are proposed to be used for the selection of optimal melts of austenitic chrome-nickel steels for the production of heat exchangers and prediction of their pitting resistance during their operation in circulating waters. The processes contributing to the perforation of heat transfer elements of heat exchangers during their operation have been identified.

The corrosion response of the heterogeneous nitriding structure originated from the laser additive manufactured steel

Corrosion of the laser additive manufactured (LAM) steel attracts increasing attentions. In this work, plasma nitriding was carried out to improve the strength and corrosion resistance of LAM 18Ni300 maraging steel at the same time. Nitriding of the as-fabricated sample obtains a heterogeneous nitriding structure with typical LAM dendrite boundaries. Nanosized N-rich grains and associated N-depleted grains were found along the LAM dendrite boundaries, which are beneficial for pitting resistance. Moreover, the corrosion reaction of the nitrided surface is confirmed as γ′/γ + O → MeO(N) + Me+, (Me = Fe, Co, Ni, Mo).

Effects of external loads on microstructure and properties of P92 steel

During the metal-solid phase transition, the mechanical properties of metal materials are affected by the nucleation rate and growth rate of grain. In this work, external loads (200 N, 400 N, 600 N, and 800 N) were applied to P92 steel during the heat treatment process in an attempt to improve and optimize the microstructure and mechanical properties of P92 steel. The effects of different external loads on the morphology, corrosion resistance, microhardness, and mechanical properties of P92 steel were investigated by using optical microscopy, microhardness testing, electrochemical testing, tensile strength measurements, and semi-automatic impact tester. The results show that the grain growth rate of P92 steel was moderate under an external load of 600 N; the grain distribution was uniform and orderly whereas the microhardness and corrosion resistance of the sample reached the optimum value (528 Hv). The tensile strength, yield strength, and elongation of the sample were 786 MPa, 525 MPa, and 37.8 %, respectively. However, the impact power of the P92 steel under an external load of 200 N was the minimum, and its average value was 132 J. The results depict that the external load can improve the mechanical properties of P92 steel.

Study on Corrosion Behavior and Mechanism of Ultrahigh-Strength Hot-Stamping Steel Based on Traditional and Compact Strip-Production Processes.

Hot-stamping steel is a type of high-strength steel that is mainly used in key safety components such as the front and rear bumpers, A-pillars, and B-pillars of vehicles. There are two methods of producing hot-stamping steel, i.e., the traditional process and the near net shape of compact strip production (CSP) process. To assess the potential risks of producing hot-stamping steel using CSP, the microstructure and mechanical properties, and especially the corrosion behavior were focused on between the traditional and CSP processes. The original microstructure of hot-stamping steel produced by the traditional process and the CSP process is different. After quenching, the microstructures transform into full martensite, and their mechanical properties meet the 1500 MPa grade. Corrosion tests showed that the faster the quenching speeds, the smaller the corrosion rate of the steel. The corrosion current density changes from 15 to 8.6 μA·cm-2. The corrosion resistance of hot-stamping steel produced by the CSP process is slightly better than that of traditional processes, mainly since the inclusion size and distribution density of CSP-produced steel were both smaller than those of the traditional process. The reduction of inclusions reduces the number of corrosion sites and improves the corrosion resistance of steel.

Field corrosion study of 690 MPa grade Sb-containing high strength bridge steel in tropical oceanic environment

Bridge steel is developing towards high strength, lightweight and high corrosion resistance. Sb element is reported to be able to improve the corrosion resistance of steel in marine environments. However, current research focuses on the corrosion behavior of low-strength or Cu/Ni/Cr-added bridge steel and pays little attention to Sb-containing high strength bridge steel. Thus, this paper examined the corrosion behavior of a new 690 MPa grade Sb-containing high strength bridge steel through field exposure in a tropical marine atmosphere. The corrosion rate of the steel was calculated by the weight loss method, and the corrosion characteristic and product properties were investigated by SEM, LSCM, EDS and XRD. Results showed that the corrosion rate decreased from 68.69 to 54.88 µm/y as the exposure time increased from 6 to 24 months. The decrease was due to the improvement of corrosion products and the weakening of acidification process. Specifically, the corrosion products became compact and electrochemically stable, and the γ-FeOOH was transformed into Fe3O4 and α-FeOOH with the extension of exposure time. This paper reported for the first time the corrosion evolution process of the 690 MPa grade Sb-added high strength bridge steel in a real marine atmosphere, which is of great significance for the material selection and anti-corrosion design of bridges in the future.