Corrosion Resistance Of Stainless Steel Research Articles

Experimental Investigation of Producer Gas Effects on Coated Pipelines in Biomass Downdraft Gasifier System

Abstract This research examines the performance of epoxy, ceramic, and graphene coatings on stainless steel 316 in a producer gas environment, focusing on corrosion and erosion resistance. This research aimed to identify the most effective coating for applications in harsh gasification environments. In this research, various analyses, including microstructural examination, hardness and weight measurements, FESEM analysis, and EDAX analysis, were conducted to evaluate the performance of the coatings. The producer gas was passed on to all the coated samples for a period of 100 hours. The significant findings include the superior corrosion and erosion resistance of ceramic-coated stainless steel, as evidenced by low weight fluctuations, maintained hardness levels, and elemental stability. Graphene coatings exhibit high hardness but increased porosity, raising concerns about durability, while epoxy coatings are vulnerable to gas-induced structural alterations. The inclusion rating analysis underscored the ceramic coatings' ability to preserve consistent material properties. Overall, ceramic coatings have emerged as the preferred option for gasification environments due to their structural resilience, inclusion integrity, and elemental stability. Considering the inclusion integrity, mechanical strength, weight stability, and elemental stability, ceramic-coated stainless steel 316 samples exhibit better resistance toward producer gas influence. This research contributes valuable insights for material selection in applications exposed to harsh gasification environments, emphasizing the importance of coating selection for long-term durability and performance.

Enhanced Long-Term Corrosion Resistance of 316L Stainless Steel by Multilayer Amorphous Carbon Coatings.

Diamond-like carbon (DLC) coatings are effective in protecting the key components of marine equipment and can greatly improve their short-term performance (1.5~4.5 h). However, the lack of investigation into their long-term (more than 200 h) performance cannot meet the service life requirements of marine equipment. Here, three multilayered DLC coatings, namely Ti/DLC, TiCx/DLC, and Ti-TiCx/DLC, were prepared, and their long-term corrosion resistance was investigated. Results showed that the corrosion current density of all DLC coatings was reduced by 1-2 orders of magnitude compared with bare 316L stainless steel (316Lss). Moreover, under long-term (63 days) immersion in a 3.5 wt.% NaCl solution, all DLC coatings could provide excellent long-term corrosion protection for 316Lss, and Ti-TiCx/DLC depicted the best corrosion resistance; the polarization resistances remained at ~3.0 × 107 Ω·cm2 after immersion for 63 days, with more interfaces to hinder the penetration of the corrosive media. Meanwhile, during neutral salt spray (3000 h), the corrosion resistance of Ti/DLC and TiCx/DLC coatings showed a certain degree of improvement because the insoluble corrosion products at the defects blocked the subsequent corrosion. This study can provide a route to designing amorphous carbon protective coatings for long-term marine applications in different environments.

Fabrication of High Corrosion Resistant Stainless Steel Containing Mo-rich Grain

Fabrication of High Corrosion Resistant Stainless Steel Containing Mo-rich Grain

Study on the Effect of Microstructure and Inclusions on Corrosion Resistance of Low-N 25Cr-Type Duplex Stainless Steel via Additive Manufacturing.

Duplex stainless steels are widely used in many fields due to their excellent corrosion resistance and mechanical properties. However, it is a challenge to achieve duplex microstructure and excellent properties through additive manufacturing. In this work, a 0.09% N 25Cr-type duplex stainless steel was prepared by additive manufacturing (AM) and heat treatment, and its corrosion resistance was investigated. The results show that, compared with S32750 duplex stainless steel prepared by a conventional process, the combination value of film resistance and charge transfer resistance of AM duplex stainless steel was increased by 3.2-5.5 times and the pitting potential was increased by more than 100 mV. The disappearance of residual thermal stress and the reasonable distribution of Cr and N elements in the two phases are the reasons for the improvement of the corrosion resistance of AM duplex stainless steel after heat treatment. In addition, the extremely high purity of AM duplex stainless steel with no visible inclusions resulted in a higher corrosion resistance exhibited at lower pitting-resistance-equivalent number values.

High-throughput first-principles study on the effect of Ni segregation on the formation of Cr-depleted zone and corrosion resistance of S32205 duplex stainless steels

High-throughput first-principles study on the effect of Ni segregation on the formation of Cr-depleted zone and corrosion resistance of S32205 duplex stainless steels

Inhibition of the second phase precipitation and improvement of intergranular corrosion resistance by boron segregation at the grain boundary of S31254 superaustenitic stainless steel

The inhibition of Mo segregation and phase precipitation is vital for improving the hot workability and corrosion resistance of superaustentic stainless steels (SASS). The boron non-equilibrium segregation of S31254 SASS was implemented through solid solution, air cooling, and diffusion at low-temperature treatment (SADT). The precipitation process and intergranular corrosion (IGC) of S31254 SASS with various boron distributions were researched at a sensitive temperature. The second phases were observed and identified by SEM and TEM. IGC susceptibility was evaluated by double-loop potentiodynamic reactivation (DL-EPR) measurements. The SADT treatment promoted more segregation of B at the grain boundary, leading to lower amounts of grain boundary precipitation before aging for 6 h. The decrease of σ phases in B-regulated samples enhances the IGC resistance, compared with the samples without B addition specimens.

Enhanced the SRB corrosion resistance of 316L stainless steel via adjusting the addition of Cu and Ce elements

316L stainless steel (SS) is the key raw material for the preparation of high-performance oil and gas pipelines, but even 316L with excellent properties will be attacked by sulfate-reducing bacteria (SRB) corrosion. Excellent antibacterial effects have been obtained in other SS systems by doping antibacterial elements. However, the current research on the preparation of antibacterial 316L SS is not comprehensive, and the quantitative analysis of the antibacterial mechanism and doping elements is still unclear. In this paper, the SS with Cu and Ce added were prepared by vacuum induction melting. Then the homogenization treatment combined with hot rolling was used to improve the structure segregation and mechanical properties. Further, the weight loss tests and electrochemical tests were conducted to evaluate the corrosion resistance of SS, the corrosion products and morphology were analysed, and the deformation structure was characterized to clarify the corrosion mechanism of the modified SS and quantify the doping elements. The results indicate that the microstructure after homogenization is mainly austenite, and with the increase of Ce content, the Ce-rich phase segregates. The inhibitory effect of Cu on SRB can be explained by the destructive effect of Cu ions on cell membranes. On this basis, adding a low content of Ce element can increase the permeability of the SRB cell wall and further enhance the attack effect of Cu ions on the cell membrane. The corrosion behavior of alloys shows the deformation structure dependence, with crystal defects and segregation increasing the corrosion rate. The optimal addition amount of Ce is 0.18 wt%, and the strength and elongation of SS are 511.18 MPa and 108.2%, respectively.

Effect of Nitrogen on the Corrosion Resistance of 6Mo Super Austenitic Stainless Steel

6Mo super austenitic stainless steel (SASS) with nitrogen contents of 0.2 and 0.4 (wt.%) was melted, and solution treatments at 1100, 1180, and 1250 °C for 30 min were performed. The effects of nitrogen on the microstructure and pitting resistance of the two steels that signed as 0.2N and 0.4N samples were investigated. At a heat-treatment temperature of 1180 °C, the alloy demonstrates the highest corrosion resistance, attributed to the combined effects of grain size and precipitates. The structure of the passivation film changes with increasing nitrogen content, with the Cr/Fe ratio is significantly higher in the 0.4N sample compared to the 0.2N sample. Moreover, the increase in nitrogen content results in thicker Cr and Mo oxide layers and higher levels of NH3 and NH4+, thereby improving the corrosion resistance of the stainless steel.

Electrochemical properties of MnSe inclusions and improving the pitting corrosion resistance of stainless steel via Se microalloying

Controlling the electrochemical properties of non-metallic inclusions is of substantial interest in the design of corrosion-resistant alloys. To the best of our knowledge, the dissolution and pitting corrosion behavior of selenide inclusions in stainless steels and the improvement of the pitting corrosion resistance of type 304 stainless steels via Se microalloying have not been investigated. In this study, stainless steel specimens containing artificial MnS and MnSe inclusions were fabricated via spark plasma sintering to systematically investigate their electrochemical properties. The superior pitting corrosion resistance and dissolution resistance of MnSe to those of MnS were demonstrated. The results obtained from the sintered specimens were applied to improve the pitting corrosion resistance of type 304 stainless steels via Se microalloying. Adding a trace amount of Se (0.005 mass%) altered the readily soluble sulfide inclusions to dissolution-resistant selenide-type inclusions, resulting in improved pitting corrosion resistance of type 304 stainless steel.

CORROSION EVALUATION OF LPBF-MANUFACTURED DUPLEX STAINLESS STEEL

In this study, the effect of as built and heat-treated additively manufactured 2507 super duplex stainless steel (SDSS) on electrochemical corrosion performance was examined. The corrosion was studied by Tafel polarization and electrochemical impedance spectroscopy (EIS) methods in a 3.5% NaCl solution. For this purpose, the as-built and heat-treated printed samples (solution annealed and stress-relieved) were examined by LOM/SEM and X-ray diffraction to evaluate the phase changes of steel at different processing stages. The correlation between corrosion resistance, structure, and heat treatment was assessed. As a result of the very fast cooling rate of the LPBF process, SDSS reveals ferrite as the major phase in the printed samples. To enhance the corrosion resistance of LPBF-produced duplex stainless steel, it's crucial to balance its two-phase structure and minimize residual stresses. The ferrite grains are elongated in the build direction, with some austenite precipitation along the grain boundaries or as Widmanstatten laths.  The stress-relieved and as-printed SDSS exhibits reduced corrosion characteristics by around 20% compared to the solution-annealed SDSS, according to anodic polarization curves. Based on EIS results, the solution-annealed SDSS revealed an almost double increase in corrosion resistance (based on charge transfer resistance values) compared to the as-printed and stress-relieved conditions.

In situ chemical analysis of duplex stainless steel weld by laser induced breakdown spectroscopy

The high corrosion resistance and good mechanical properties of duplex stainless steel (DSS) are due to its special chemical composition, which is a balanced phase ratio of ferrite (α) and austenite (γ). Many industrial applications require the integration of DSS components. For this, Gas tungsten arc welding (GTAW) is an excellent choice, as it allows an automated operation with high reproducibility. However, when the weld pool solidifies, critical ratios of α- and γ- phases can occur, which lead to solidification cracking, increased susceptibility to corrosion, and a decrease in ductility and critical strength. Previous studies have shown that these defects can be caused by the accumulation of manganese and chromium in the heat affected zone (HAZ), requiring ongoing monitoring of this accumulation. A suitable method for such monitoring is laser-induced breakdown spectroscopy (LIBS), which can be used in two operating modes: calibration using standard reference samples and calibration-free. Unlike conventional quantitative LIBS measurements, which require reference samples to generate a calibration curve, calibration-free LIBS (CF-LIBS) allows chemical compositions to be determined solely from the emission spectrum of the plasma. Numerous publications show that CF-LIBS is a fast and efficient analytical method for the quantitative analysis of metal samples. In this work, CF-LIBS is applied to spectra obtained during GTAW DSS welding and the result is compared with those obtained by PLS analysis. A good correlation was found between both types of analysis, demonstrating the suitability of the CF-LIBS method for this application. The CF-LIBS method has a significant advantage over conventional LIBS due to the rapid in situ measurement of concentrations of major alloying elements without calibration procedure. This, combined with fast feedback and appropriate adjustment of welding parameters, helps prevent welding defects.

Machine Learning-Based Prediction of Intergranular Corrosion Resistance in Austenitic Stainless Steels Exposed to Various Heat Treatments

Machine Learning-Based Prediction of Intergranular Corrosion Resistance in Austenitic Stainless Steels Exposed to Various Heat Treatments

The effects of heat treatment and surface state on the corrosion resistance of laser powder bed fusion 304L stainless steel in 3.5 wt% NaCl solution

The corrosion resistance of laser powder bed fusion (LPBF) 304L stainless steel (SS) in 3.5 wt% NaCl solution was evaluated at room temperature through potentiodynamic polarization and electrochemical impedance spectroscopy tests. For electropolished samples, annealing at 1200 °C slightly enhanced the corrosion resistance due to changes in crystal orientation and inclusion composition, and reduced residual strain. In contrast, annealing at 1050 °C significantly reduced the corrosion resistance mainly due to the disappearance of dislocation cells and the remained residual dislocations. Residual stress/strain and martensitic transformation induced by sandpaper grinding can also deteriorate the corrosion resistance. Only the as-received sample shows stable passivation regardless of the surface conditions.

Effect of nitrogen content on grain boundary engineering and corrosion resistance of 316LN stainless steel

Nitrogen solid solution can effectively enhance the strength of steels, but its effect on grain boundary engineering and the corrosion mechanism of steels is still unclear and systematic investigation is needed. In this study, 316LN steel specimens with five nitrogen concentrations were melted and subjected to compression and annealing. The grain boundary character distribution was investigated by electron backscatter diffraction. The corrosion behavior was investigated by the electrochemical polarization curves, electrical impedance spectroscopy, and X-ray photoelectron spectroscopy. The results showed that nitrogen promotes the formation of low-Σ boundaries when the pre-strain is not above 10%. The polarization resistance increases with increasing nitrogen content. The quantitative relationship between the nitrogen content and the pitting potential was obtained. Nitrogen favors the formation of oxides, hydroxides, and NH3/NH4+ on the passivated surface. The effect of planar slip on grain boundary engineering and the influence of NH4+ on the corrosion resistance are discussed.

Heat Treatment, Microstructure, Hardness and Corrosion Resistance of Martensitic Stainless Steel X65Cr13 (1.4037)

Abstract The corrosion resistance of martensitic stainless steels is influenced by the alloy composition and the heat treatment. It is known that the proportion of chromium carbides in the microstructure and the resulting hardness are influenced by the heat treatment (austenitization temperature and duration, cooling rate, deep freezing, tempering temperature). The connection between carbon content, the exact heat treatment parameters and corrosion resistance of martensitic stainless steels with 13 wt.% chromium is only known for lower carbon contents (X20Cr13, X46Cr13). This paper is therefore dedicated to the steel X65Cr13, which is used in particular for razor blades. Materials research results are presented that show the influence of hardening on microstructure, hardness and corrosion resistance. It is shown that the steel X65Cr13 has only limited corrosion resistance due to its high carbon content, which can be attributed to the presence of chromium carbides and local chromium depletion in the microstructure. It is also clear that higher austenitizing temperatures and durations as well as high cooling rates lead to an improvement in corrosion resistance. However, this approach also causes retained austenite, which still has to be converted into martensite by deep freezing after quenching.

Ion Implantation Combined with Heat Treatment Enables Excellent Conductivity and Corrosion Resistance of Stainless Steel Bipolar Plates for Hydrogen Fuel Cells.

316 L stainless steel is an ideal bipolar plate material for a proton exchange membrane fuel cell (PEMFC). However, the thickening of the passivation film on the stainless steel surface and the dissolution of corrosive ions during operation will affect the durability of the PEMFC. Herein, a heterogeneous layer is prepared on the surface of 316 L stainless steel through dual ion implantation of molybdenum ion and carbon ion combined with heat treatment to promote the corrosion resistance and conductivity of the bipolar plate. The ion implantation technique resulted in a uniform distribution of Mo and C elements on the surface of 316 L stainless steel, with a modified layer depth of about 70-80 nm. The electrical conductivity of the ion implanted samples was significantly improved, and the interfacial contact resistance was reduced from 464.25 mΩ × cm2 to 42.49 mΩ × cm2. Heat treatment enhances the surface homogenization, repairs the defects of irradiation damage, and improves the corrosion resistance of stainless steel. The corrosion current density of (Mo+C)-600 samples decreased from 1.21 × 10-8 A/cm2 to 2.95 × 10-9 A/cm2 under the long-term corrosion condition of 4 h. These results can provide guidance for the modification of stainless steel bipolar plates.

A short review of medical-grade stainless steel: Corrosion resistance and novel techniques

Due to its exceptional quality as a biomedical metal, stainless steel is often utilized to produce a broad range of medical tools. The resistance of stainless steel to corrosion is a key indicator of how long and how effective it will serve its intended purpose, and it is an important factor in determining the biocompatibility of the material. However, due to the complex physiological environment within the human body, the corrosion management of medical-grade stainless steel is facing several challenges. In this article, an overview of the factors that influence the corrosion performance of medical-grade stainless steel is provided, and new technologies and methods that have been developed in recent years to improve the corrosion resistance are discussed. These cutting-edge methods are expected to improve the corrosion resistance and longevity of medical-grade stainless steel, providing strong support for the increased applicability of the material in the medical industry.

The effect of long-term exposure in mixed sulfuric acid and copper sulfate solution on corrosion behavior of austenitic stainless steels

Corrosion resistance of austenitic stainless steels in sulfuric acid solutions depends mainly on concentration and temperature of the sulfuric acid, the presence of contaminants and velocity flow. Current studies aim mostly at evaluation of electrochemical parameters in sulfuric acid solutions. Research focused on long-term exposure is lacking. This article deals with the corrosion behavior of AISI 304 and AISI 316L stainless steels in mixed 10 wt. % sulfuric acid and 10 wt. % copper sulfate solution. Sensitized (650 °C/40 hours) and solution annealed (1050 °C/15 min) specimens together with the untreated (as received) ones are evaluated by long-term (22-month) exposure immersion test at the temperature of 22 ± 3 °C on the bases of optical microscopy, SEM and mass losses. Both tested stainless steels in as received and solution annealed state proved high corrosion resistance in the given corrosive environment. The cross-sections edges of sensitized specimens revealed a close relationship between local corrosion sites and weakened grain boundaries, which indicates incipient intergranular corrosion.

Effect of Coating Damage on the Micro Area Corrosion Performance of HDR Duplex Stainless Steel

In order to determine the effect of damaged insulating enamel on the corrosion of high-chromium (H), duplex (D), and corrosion-resistant (R) duplex stainless steel, the corrosion characteristics of HDR duplex stainless steel in 3.5% NaCl solution were studied by means of local electrochemical impedance spectroscopy (LEIS) and micro-morphology analysis. It was shown that the LEIS impedance was stable at about 7.0 × 103 Ω within 10 days when the HDR duplex stainless steel was not coated. The minimum LEIS impedance of exposed HDR at the damaged area fluctuated around 6.5 × 103 Ω within 15 days when the coating of the self-control insulating enamel damaged area was 1 mm × 10 mm. The coating-damaged area from 1 mm × 10 mm reduced to a circular hole with a diameter of φ1 mm, and the LEIS impedance of the exposed HDR increased at the damaged coating. When extending along the damaged coating to the intact coating area, the impedance rapidly increased, and the further the distance from the damage, the greater the increase in impedance. The impedance of coated HDR increased with the prolongation of immersion time and ultimately stabilized. The thicker the coating, the longer the impedance took to reach a stable state. The stabilized coating had a better effect on improving the corrosion resistance of HDR duplex stainless steel. Within 15 days, the HDR ferrite structure at different areas of coating damage prioritized corrosion. Cl− mainly comes from the solution, and Si and S elements mainly come from elements of the collective itself, with Cl− adsorption, S, and Si element inclusion being the main factors influencing the corrosion of the ferrite structure.

A stochastic study of the effect of the phase ratio on the corrosion resistance of duplex stainless steel

The effect of the phase ratio of austenite and ferrite on the pitting potential (Epit) and passive current density of ASTM A890 grade 3A duplex stainless steel (DSS) was investigated using a stochastic method. The cumulative probability of the Epit value of DSS at different potential sweep velocities was linear, indicating that the pitting potential obeyed a normal distribution. In addition, the relationship between the pitting potential and the potential sweep velocity at various phase ratios was fitted by Epit ∝ log(v). The increase in ferrite promoted the sensitivity of the DSS to the potential sweep velocity. When the phase ratio of austenite and ferrite was 1:1, it showed better corrosion resistance. The phase ratio affected the passive current density more significantly than pitting potential.