Corrosion Resistance Properties Research Articles

Efficient and Eco-Friendly UV-Cured Polyurethane Coating: Harnessing Thiol-Yne Systems for Corrosion Protection

The UV-curable coatings have received significant attention from researchers due to their excellent advantages in corrosion protection. However, there has not been much effort made to investigate the UV-curable thiol-yne system. This project aims to prepare effective and environmentally-friendly polyurethane coatings capable of being cured by UV light using thiol-yne systems. Utilizing the chain extender derived from the glycolysis of PET, the bis(2-hydroxyethyl) terephthalate (BHET) as a glycolysis product was synthesized via the glycolysis reaction. Polyurethanes (PUYNE: yne-terminated polyurethanes and PUSH: thiol-terminatted polyurethanes) were synthesized by utilizing BHET, and by altering the quantity of the BHET, and PUX coatings were formed upon exposure to UV light. The impact of PUYNE molecular weight and the resulting amount of thiol-yne crosslinking on mechanical and thermal properties were evaluated, and corrosion resistance was examined with electrochemical impedance spectroscopy (EIS). PUX1, which had the lowest molecular weight and the highest number of thioether bonds, exhibited the superior corrosion resistance properties so that after 8 weeks of immersion in saline solution, the impedance modulus at 0.01Hz was 1.43×108 Ω.cm2. This study provides insight into the application of thiol-yne systems in forming UV-cured coatings and their protective role in preventing corrosion.

Enhancing the protective performance of anti-impact, corrosion resistant and flame retardant polyurea coatings using bio-based supramolecular decorated montmorillonite

Developing bio-based nano-additives for enhancing mechanical strength, corrosion resistance, and flame retardancy in polyurea (PUA) coatings at low loading levels is crucial for human well-being and environmental preservation. In this study, montmorillonite (MMT) was first exfoliated by ball milling with the aid of chitosan, and then further co-assembled with phytic acid and urea to form a nanohybrid (CPN@MMT). The resulting CPN@MMT nanohybrid exhibited good compatibility and dispersibility within matrix and endowed PUA composites with improved anti-impact, corrosion resistant and flame retardant properties. Remarkably, the addition of CPN@MMT improved the mechanical and impact protection properties of PUA coatings. Electrochemical and salt spray tests confirmed that the excellent anti-corrosion performance of PUA composite coating stemmed from the dispersed nano-sheets forming a protective nano-barrier. CPN@MMT in the PUA matrix formed a compact char layer, reducing heat release and smoke by inhibiting heat diffusion and volatile gas evaporation, as evidenced by cone calorimeter and TG-FTIR tests. The enhanced fire safety was primarily attributed to the physical barrier, catalytic charring and dilution effect of CPN@MMT. Hence, a green and feasible method was developed to create bio-based nano-additive in PUA coatings with anti-impact, corrosion resistant and flame retardant performance.

Tribological evaluation of thermoplastic polyurethane-based bearing materials under water lubrication: Effect of load, sliding speed, and temperature

AbstractPolymers are widely used in bearing applications. In the case of water-lubricated stern tube bearings, thermoplastic polyurethane (TPU)-based composites are used due to their excellent wear resistance, corrosion resistance, and tunable mechanical properties. Their tribological performance, however, depends on operating conditions. In this work, TPU was blended with carbon fiber, graphene platelet, and ultra-high molecular weight polyethylene (UHMWPE). Friction tests of TPU based-composites against copper countersurface were carried out in water to mimic the actual operating conditions of the bearing. Most of the resulting contacts were in the boundary lubrication regime, in which friction was attributed to both contact mechanics of asperities as well as water lubrication. Our results show that the viscoelasticity of TPU has a considerable impact on its tribological performance. Water lubrication at 50 °C promotes the softening of polymer surface material during sliding, resulting in higher fluctuation in the coefficient of friction and wear loss. This is attributed to the reduced thermomechanical properties. In addition, Schallamach waviness is observed on worn surface. The tribological properties of TPU are significantly improved by the inclusion of carbon fiber, graphene platelet, and UHMWPE. The formation of graphene transfer-layers and UHMWPE transfer film reduces friction and wear loss, while the inclusion of carbon fiber enhances wear resistance due to improved mechanical properties and load bearing capacity.

Preparation and properties of Mg-Nd binary alloy MAO/SiO2@α-Fe2O3 organic composite coating

In order to make magnesium alloys better used in aviation, electronic information and other fields, it is necessary to improve their corrosion resistance and wave absorption properties. In this paper, a composite coating with corrosion resistance and wave absorption properties was prepared on magnesium alloy by micro-arc oxidation-organic coating technology. An organic absorbing coating with a thickness of about 40 μm was sprayed on the MAO coating containing Yb2O3 nanoparticles. Among them, the absorbing fillers in the organic coating are mainly SiO2 and α-Fe2O3. Three different mass ratios of SiO2 and α-Fe2O3 were set to 20%, 22.5% and 25%, respectively, to prepare three different MAO/SiO2@α-Fe2O3 organic composite coatings. The morphology, roughness, microstructure and chemical composition of the organic composite coating are characterized. The results show that after coating the organic composite coating, the roughness of the coating is significantly reduced, and the compactness and interlayer adhesion of the coating are significantly improved. The electrochemical test and SKPFM test of the organic composite coating were carried out. The results showed that with the increase of the mass ratio of SiO2 and α-Fe2O3, the corrosion resistance and stability of the organic composite coating increased, and the Volta potential also gradually moved up. The microwave absorbing properties of organic composite coatings were studied by vector network analyzer. The results show that the microwave absorbing properties of the coatings are positively correlated with the mass ratio of SiO2 and α-Fe2O3.

Surface modification of biomedical titanium alloy for hard tissue repair and reconstruction

In biomedical applications, various materials are used, including metals and their alloys, polymers and ceramics. Among them, titanium (Ti) and titanium alloys are widely utilised in implant materials due to their excellent corrosion resistance and high mechanical strength. However, despite these advantages, titanium is biologically inert and does not integrate well with human cells. Therefore, surface modification of titanium implants plays a crucial role in determining the rate of osseointegration and the overall success of the implants. The primary objective of this review is to provide a detailed introduction to surface modification technologies for titanium alloy implants. The aim is to enhance the biological activity, wear resistance, corrosion resistance and antibacterial properties and reduce the release of ions from the implants. By modifying the surface of titanium implants, it is possible to create a more favourable environment for cell adhesion, proliferation and differentiation. Various techniques, such as physical methods (e.g. sandblasting, acid etching) and chemical methods (e.g. surface oxidation, plasma treatment) can be employed to modify the surface properties of titanium implants. These surface modification techniques can enhance the interaction between the implant and the surrounding biological environment, promoting osseointegration and improving the long-term stability of the implant. Additionally, surface modifications can help reduce the release of potentially harmful ions from the implant, minimise bacterial adhesion and improve the overall biocompatibility of the implant. In conclusion, surface modification of titanium alloy implants is a critical aspect of biomedical engineering. By improving the biocompatibility of titanium implants, these modifications contribute to the success and longevity of implants used in hard tissue repair and reconstruction.

Microstructure, corrosion resistance and wear properties of laser directed energy deposited CrCoNi medium-entropy alloy after cyclic deep cryogenic treatment

ABSTRACT Subjected to repeated heating and cooling, laser directed energy deposited (LDED) parts always possess considerable residual stress, which severely limits their industrial applications. In this work, cyclic deep cryogenic treatment (CDCT) was performed to finely tune the residual stress and microstructure of LDED-fabricated CrCoNi medium-entropy alloy (MEA). With increasing number of CDCT cycles, crystalline defects within the sample became denser due to the repeated visco-plastic deformation. The compressive residual stress (CRS) of the sample was estimated to be 361.9 ± 16.8 MPa after 30 cycles of CDCT, 64.2% higher than that in the as-built condition. Due to the existence of dense crystalline defects and high CRS, the corrosion and wear rates of CDCT-treated CrCoNi MEA were significantly decreased compared with the as-built condition. This work demonstrated CDCT as an effective means for regulating the residual stress, microstructure, and surface performance of LDED-fabricated MEA.

Investigation on the Osteogenic and Antibacterial Properties of Silicon Nitride-Coated Titanium Dental Implants.

The silicon nitride (Si3N4) coating exhibits promising potential in oral applications due to its excellent osteogenic and antibacterial properties. However, a comprehensive investigation of Si3N4 coatings in the context of dental implants is still lacking, especially regarding their corrosion resistance and in vivo performance. In this study, Si3N4 coatings were prepared on a titanium surface using the nonequilibrium magnetron sputtering method. A systematic comparison among the titanium group (Ti), Si3N4 coating group (Si3N4-Ti), and sandblasted and acid-etched-treated titanium group (SLA-Ti) has been conducted in vitro and in vivo. The results showed that the Si3N4-Ti group had the best corrosion resistance and antibacterial properties, which were mainly attributed to the dense structure and chemical activity of Si-O and Si-N bonds on the surface. Furthermore, the Si3N4-Ti group exhibited superior cellular responses in vitro and new bone regeneration and osseointegration in vivo, respectively. In this sense, silicon nitride coating shows promising prospects in the field of dental implantology.

Investigation of structure, morphology, and corrosion behavior of carboxylic acids/hydroxyapatite/chitosan coatings on Ti discs for implants

Titanium (Ti) and its alloys are widely used in bone defect repair owing to their advantages, including high strength, corrosion resistance, and biocompatibility. The formation of a stable oxide layer on Ti implants enhances the osseointegration process. Nevertheless, additional progress is required to improve the incorporation of these implants at the microscopic and nanoscopic levels to achieve a biocompatible interface. The main objective of this study was to enhance the morphology of hydroxyapatite and the corrosion resistance of Ti implants by applying hydroxyapatite/chitosan (HA/Cs) nanocomposite coatings embedded with carboxylic acids. The coatings were fabricated by electrodeposition, wherein various acid concentrations (acrylic and acetic acids) were employed as Cs electrolyte solvents to enhance the adhesion and bond strength with the titanium metal substrate. The microstructures of the HA/Cs coatings were analyzed using X-ray diffraction. The results demonstrated that the structure of HA was affected by the type of acid used and its concentration as the crystallinity increased with a high concentration of acrylic acid. Additionally, the morphology of HA/Cs was analyzed using a transmission electron microscope. The results showed that the morphology of HA/Cs changed from a hexagonal rod-like shape with acrylic acid samples into a needle-like shape in acetic acid samples. The corrosion behavior was investigated using electrochemical impedance spectroscopy (EIS) in a simulated body fluid (SBF) at 37±2ºC. The EIS results showed a high corrosion resistance with phase angles close to −80° and high impedance values of 80.5 kΩ cm2 with a high concentration of acrylic acid. These results indicated the formation of a highly adhesive and stable film on the implants in the test solution. In conclusion, based on this study and our previous work, the corrosion resistance, good biocompatibility, and biomineralization properties of the prepared HA/Cs-coated Ti recommend it as an alternative implant for clinical applications.

Analysis of Chemical, Microstructural and Mechanical Properties of a CuAlBe Material Regarding Its Role as a Non-Sparking Material.

We developed and analyzed a novel non-sparking material based on CuAlBe for applications in potentially explosive environments. Using a master alloy of CuBe, an established material for anti-sparking tools used in oil fields, mines, or areas with potentially explosive gas accumulations, and pure Al, we used an Ar atmosphere induction furnace to obtain an alloy with ~10 wt% Al and ~2 wt% Be percentages and good chemical and structural homogeneity. The new material was tested in an explosive gaseous mixture (10% H2 or 6.5% CH4) under extremely strong wear for 16,000 cycles, and no hot sparks capable of igniting the environment were produced. The material was used in the form of hot-rolled plates obtained from melted ingots. The experimental results reflect the use of a suitable material for non-sparking tools. This material has good deformability during hot rolling, abnormal grain growth during deformation under heat treatment and special thermo-mechanical processing, and no high chemical composition variation. Additionally, there are slightly different corrosion resistance and mechanical properties between the melt and hot-rolled state of CuAlBe material. Through hot rolling, the material's corrosion resistance increased, reducing the chances of generating sparks capable of causing explosions.

Preparation and performance research of ecological concrete using waste wood

To mitigate environmental damage from mineral aggregate extraction, bio-based materials have garnered research interest as potential replacements for natural mineral aggregates. This work utilized waste wood as filler to prepare lightweight foam concrete with thermal insulation, low-temperature and corrosion resistance properties. The feasibility of using wood aggregate-based foam concrete (WFC) was explored in terms of dry density, softening coefficient, compressive strength, thermal conductivity, chloride ion permeability, freezing resistance, and sulfate attack resistance. Results showed that simultaneous addition of waste wood aggregate (WA) and foam effectively reduced WFC bulk weight and thermal conductivity while enhancing water resistance. However, the porous morphology of WA and foam caused the reduction of mechanical properties. In terms of durability, the addition of WA can increase the energy absorption capacity when WFC is subjected to expansion stress, reduce the damage to the structure, and have an inhibiting effect on the cracking of WFC caused by sulfate attack and freeze-thaw cycles. Nevertheless, WA's high water absorption loosened the matrix in WFC's interfacial transition zone (ITZ), increasing harmful pores and negatively affecting durability. In addition, in order to predict the mechanical properties of WFC and the resistance to sulfate attack, this study established a function model for the relationship between the compressive strength (Maintenance specimens of the same age and Specimen of sulfate attack) and the WA dosage. In conclusion, The use of waste wood for the preparation of WFC is more advantageous and sustainable than conventional foam concrete for the insulation of precast walls and coastal structures.

Investigating nano-SiC reinforced WE43 magnesium matrix surface composites

Abstract Magnesium matrix surface composites have been garnering attention due to their superior mechanical and corrosion resistance properties. An idea of facile fabrication of surface composite composed of nano-SiC reinforced WE43 matrix through friction stir processing was explored in this study. Also, the effects of tool geometries, tool rotations, and tool feeds on resultant properties were comprehensively investigated. Uniform dispersion of SiC nanoparticles within stir zone was evident. Square tool demonstrated the most promising results. Processing at 1700 rev min−1 and 60 mm min−1 with a square tool produced finest grains in surface composites exhibited exceptional microhardness (180.8 HV), nanohardness (1.867 GPa), elastic modulus (41.69 GPa), and wear resistance (0.0254 mm3 min−1). Besides it, WE43 substrates also exhibited superior mechanical properties when processed with a square tool at 800 rev min−1 and 60 mm min−1. This research opens up new possibilities for the development of reliable magnesium matrix surface composites for multifunctional applications.

Rust Prevention Property of a New Organic Inhibitor under Different Conditions.

The corrosion resistance properties of a new type of environmentally-friendly organic inhibitor containing amino ketone molecules are presented in this paper. To evaluate the prevention effect of the inhibitor on corrosion of reinforcement, the electrochemical characteristics of steels in the simulated concrete pore solution (SPS) were investigated under varied conditions of the relevant parameters, including concentrations of the inhibitor and NaCl, pH value, and temperature. The inhibition efficiency of the material was characterized through electrochemical impedance spectroscopy (EIS), potentiodynamic polarization, and the weight loss of steels. The results reveal a significant improvement in the corrosion resistance of steels with the inhibitor. A maximum resistance value of 89.07% was achieved at an inhibitor concentration of 4%. Moreover, the new organic inhibitor exhibited good corrosion protection capability for steels under different NaCl concentrations. Its inhibition efficiency was determined to be 65.62, 80.06, and 66.30% at NaCl concentrations of 2, 3.5 and 5%, respectively. On the other hand, it was found that an alkaline environment was favorable for an enhanced corrosion prevention effect, and an optimal pH value of 11.3 was observed in this work. Besides, the inhibition efficiencies at different temperatures showed a trend of 25 > 35 > 40 > 20 > 30 °C, with a maximum value of 81.32% at 25 °C. The above results suggest that the new organic material has high potential to be used as an eco-friendly and long-term durable inhibitor for steel corrosion prevention under complex conditions.

3D-printed porous tantalum artificial bone scaffolds: fabrication, properties, and applications.

Porous tantalum scaffolds offer a high degree of biocompatibility and have a low friction coefficient. In addition, their biomimetic porous structure and mechanical properties, which closely resemble human bone tissue, make them a popular area of research in the field of bone defect repair. With the rapid advancement of additive manufacturing, 3D-printed porous tantalum scaffolds have increasingly emerged in recent years, offering exceptional design flexibility, as well as facilitating the fabrication of intricate geometries and complex pore structures that similar to human anatomy. This review provides a comprehensive description of the techniques, procedures, and specific parameters involved in the 3D printing of porous tantalum scaffolds. Concurrently, the review provides a summary of the mechanical properties, osteogenesis and antibacterial properties of porous tantalum scaffolds. The use of surface modification techniques and the drug carriers can enhance the characteristics of porous tantalum scaffolds. Accordingly, the review discusses the application of these porous tantalum materials in clinical settings. Multiple studies have demonstrated that 3D-printed porous tantalum scaffolds exhibit exceptional corrosion resistance, biocompatibility, and osteogenic properties. As a result, they are considered highly suitable biomaterials for repairing bone defects. Despite the rapid development of 3D-printed porous tantalum scaffolds, they still encounter challenges and issues when used as bone defect implants in clinical applications. Ultimately, a concise overview of the primary challenges faced by 3D-printed porous tantalum scaffolds is offered, and corresponding insights to promote further exploration and advancement in this domain are presented.

The improvement of wear and corrosion resistance of nickel-graphite coating with modified graphite phase size

The corrosion resistance, friction and wear properties of an abradable seal coating are highly dependent on the size and distribution of lubrication phase. In this work, nickel-graphite (Ni-G) coatings were fabricated by a supersonic atmospheric plasma spraying system (SAPS) and a standard atmospheric plasma spraying system (APS), respectively. The effect of size and distribution of graphite phase on the performance of Ni-G coatings was investigated. The results suggested that the SAPS coating had an average single graphite phase area of 35.4 ± 5.1 μm2, which is approximately 35.4 % less than that of the APS coating, while the average graphite phase width and length in SAPS coating decreased by 22.2 % and 16.7 % compared to the APS coating. The fine distributed graphite phase improved the formation of structure with a small cathode and a large anode, which effectively increased the corrosion resistance of SAPS coating. The reciprocating sliding friction facilitated the creation of a uniform and uninterrupted lubricant layer, attributed to the finely dispersed graphite phase of SAPS coating. In comparison to the as-sprayed and subsequent corroded APS coatings, the friction coefficients of the SAPS coating exhibited a reduction of approximately 9.1 % and 13.3 %, respectively. The aforementioned findings showed that the small-sized graphite phase was conductive to the improvement of corrosion resistance, friction and wear properties of Ni-G abradable coatings.

Multifunctional superhydrophobic coatings with self-cleaning and anti-fouling properties for corrosion protection of metals

Superhydrophobic coatings have self-cleaning, antifouling, and anti-corrosion properties due to their unique surface properties, but their disadvantages such as poor durability, poor mechanical properties, and complicated preparation methods severely limit their practical applications. Here, superhydrophobic coatings with high abrasion resistance and long-lasting corrosion resistance were prepared by a simple spraying method using stearic acid-modified titanium dioxide nanoparticles (TiO2), polyphenylene sulfide (PPS) as the base material, and doped polyvinylidene difluoride (PVDF). The SA-TiO2 can provide low surface energy and rough structure, and the PPS itself has high mechanical strength and corrosion resistance properties. The PVDF doping can generate cross-linking inside the coating to improve the densification and mechanical strength of the coating, while the formation of irregular micrometer-sized protrusions can play a role in protecting the nano-surface. he synergistic effect of the various components results in an excellent mechanical stability of the coating, which remains superhydrophobic after a 400 cm sanding test. In addition, the coating has excellent corrosion resistance, and the electrochemical impedance spectroscopy (EIS) results show that the impedance modulus of the coating is as high as 21.99 kΩ·cm2. The coating has a hierarchical micro-nano structure, and shows excellent mechanical and corrosion resistance, which is of great potential for practical applications.

Mapping the roles of scan strategy and build orientation in predicting the crystallographic texture and yield strength of 316L stainless steel produced by laser powder bed fusion

Laser Powder Bed Fusion (L-PBF) has emerged as a leading additive manufacturing (AM) technique for manufacturing complex metal parts, with 316L stainless steel being favored for its exceptional corrosion resistance and mechanical properties. While previous studies have explored the effects of different scan strategies and build orientations on the microstructure and room temperature tensile properties of L-PBF printed 316L stainless steel, there is still a lack of a comprehensive predictive model that accurately captures the combined effects of these process parameters on the final crystallographic texture and tensile properties. This study presents a novel approach that establishes a direct correlation between process parameters, microstructure, and mechanical behavior by modeling the influence of scan strategy rotation angles and build orientations on the crystallographic texture of L-PBF-manufactured 316L stainless steel. To validate the model, a series of samples were fabricated using various scan strategy rotation angles and build orientations, enabling detailed microstructural analysis and mechanical testing. The findings demonstrate a direct relationship between the selected process parameters and the resulting mechanical properties, underscoring the importance of scan strategy and build orientation selection on mechanical response. Furthermore, our calibrated model exhibits high predictive accuracy as validated through a comparison with experimental data.

Effect of adding K2TiF6 and K2ZrF6 to neutral electrolyte on the performance of plasma electrolytic oxidation coatings on AZ91 Mg alloy

The traditional alkaline electrolyte preparation of plasma electrolytic oxidation (PEO) coating ignites a significant spark, and the increase of micro-defects leads to a decrease in corrosion resistance. In this study, the preparation of PEO coating with neutral electrolyte was studied, and the effects of K2TiF6 and K2ZrF6 doping on the microstructure, phase composition, corrosion resistance and mechanical properties of the coating were explored. It was found that in neutral solution, the size and number of sparks decreased significantly, and the compactness of the coating increased. The phase composition was mainly MgF2. After the addition of K2TiF6 and K2ZrF6, the corrosion current density dropped from 256 to 28 and 61 nA/cm2. The long-term corrosion resistance of the coating was significantly improved. The hardness and adhesion of the coating were significantly improved.

Investigation of CMAS corrosion resistance for gradient Y2O3 stabilized ZrO2

The threat of calcium‑magnesium-alumina-silicate (CMAS) melt corrosion in thermal barrier coatings (TBCs) is significant at elevated working temperatures. In this study, a gradient Y2O3 stabilized ZrO2 coating (gradient YSZ coating) was designed and prepared by electron beam physical vapor deposition (EB-PVD) and its CMAS corrosion resistance was examined. The CMAS corrosion resistance test on the YSZ pellets highlighted the significance of dissolved Y2O3 and identified the critical Y2O3 content. Compared with the classical 8 wt% Y2O3 stabilized ZrO2 (8YSZ) coating, new crystal phases generated in the gradient YSZ coatings effectively blocked the CMAS melt infiltration for a short time; further, even after a long time, the CMAS melt was primarily distributed in the upper part of the gradient YSZ coating. In addition, the impact of coating microstructure on the CMAS resistance was investigated. The results showed the dense-gradient YSZ coating outperformed the 8YSZ coating on the resistance to CMAS infiltration. Finally, it is demonstrated that the gradient YSZ coating has potential applications against CMAS attacks, providing valuable design guidelines for TBCs with balanced corrosion resistance and promising mechanical properties.

Enhancing the corrosion resistance of high Mo S31254 super austenitic stainless steel using grain boundary engineering

Super austenitic stainless steel (SASSs) with a high Mo content exhibit excellent resistance to intergranular corrosion (IGC), Its mechanical properties mainly depend on solid solution strengthening. Meanwhile, grain boundary engineering (GBE) can simultaneously improve the corrosion resistance and mechanical properties of Mo-rich austenitic stainless steel using the resistance to IGC of Mo. However, recrystallization annealing is extremely difficult due to the sensitive precipitation of Cr-rich and Mo-rich precipitations in SASSs. Therefore, this study explores the effect of large deformation, high temperature, and short-time annealing on the corrosion resistance of SASSs. The results show that a recrystallized organization with an average grain size of 13.3 μm was prepared by 50% cold rolling deformation and 2min high-temperature short-time annealing at 1150 °C. The highest percentage of Σ3 GBs is about 34%, the percentage of other low-energy GBs is relatively low (only about 6%), and the rest are random high-angle grain boundaries (RHAGBs), which account for about 60%. It can be seen the corrosion resistance of random GBs after GBE treatment is superior to that of solution treatment. Meanwhile, medium-temperature aging improved the resistance to IGC of SASSs, especially after aging at 450 ℃, a small amount of Mo is enriched along the GBs, which promotes the formation of Cr2O3 and Mo-rich oxides in the passivation film and improves the corrosion resistance. The above results provide guidance for improving the corrosion resistance of Mo-rich austenitic stainless steels.

Selective etching-induced surface modifications of FeCrAl alloy bipolar plates: Mechanisms for enhanced corrosion resistance and hydrophobicity

The FeCrAl alloy has been considered a potential candidate material for bipolar plates (BPs) in fuel cells, emphasizing the improvement of corrosion resistance through surface modification. This study involves a selective etching process that facilitates the preferential dissolution of iron ions to establish a high-chromium surface, enhancing both corrosion resistance and hydrophobic properties. This crucial etching process alters the surface roughness and enhances the surface energy. The transformed rough surface due to surface polishing and etching changes from hydrophilic to hydrophobic, which facilitates corrosion management and moisture control based on the Cassie-Baxter model. The modified micro/nanostructure of the FeCrAl alloy surface and the reconstituted protective film exhibit excellent corrosion inhibition and long-term stability. The study elucidates how the correlation between surface free energy (SFE) and the formation of hydrophobic and rough surfaces acts as a mechanism for enhancing the corrosion resistance of FeCrAl surfaces. Utilizing the Van Oss-Chaudhury-Good (Van Oss) method based on the Lewis acid/base theory further clarifies this corrosion inhibition process, proposing a novel approach that offers significant advantages over traditional methods. Furthermore, this method offers economic and efficient benefits compared with traditional coating methods, providing a promising avenue for reliable corrosion protection in fuel cell applications.