Corrosion Resistance Research Articles

Regulation of Osteogenic and Angiogenic Markers in Alkali Treated Titanium for Hard Tissue Engineering Applications.

Titanium (Ti) and Ti alloys are of great interest in bone and dental tissue engineering applications due to their biocompatibility, corrosion resistance, and close mechanical properties to natural bone. However, the formation of fibrous tissue prevents osteointegration and results in implant loosening. Thus, physical and chemical methods are used to improve the surface properties of Ti. This study aimed to understand the role of alkali treatment conditions, including alkali medium concentration, temperature, rotation speed, and post-heat treatment. Our results showed that alkali treatment using 5 and 10 molar sodium hydroxide solution allows the formation of web-like microstructure. However, a higher concentration of 15 molar resulted in cracks along the surface. Interaction between the human fetal osteoblast cells (hfOBs) and Ti samples showed that heat treatment is necessary for increased cellular proliferation, which was not significantly different at later time points compared to the polished Ti. Alkali heat treatment did not induce inflammatory reactions at later time points. It showed an increase in vascular endothelial growth factor, osteoprotegerin/nuclear factor kappa-В ligand ratio, and osteocalcin expression, which is evidence for accelerated osteoblast cell maturation and bone remodeling in surface-modified samples. Together, these data show that alkali treatment using 5 or 10 molar of NaOH followed by heat treatment may have therapeutic effect and assist with bone tissue integration with Ti implant.

A Study on Microstructural Evolution and Corrosion Behavior of Ti36-Al16-V16-Fe16-Cr16 High-Entropy Alloy Fabricated via Spark Plasma Sintering Technology

AbstractThis study focused on the synthesis of Ti36-Al16-V16-Fe16-Cr16 high-entropy alloys (HEAs) through spark plasma sintering to ascertain their corrosion resistance performance. Varied sintering temperatures, ranging from 700 to 1100 °C were employed to discern their impact on the alloy's characteristics. The fabricated HEAs underwent characterization using scanning electron microscopy and X-ray diffraction. A potentiodynamic polarization measurement was employed to compare the electrochemical properties of HEAs sintered at different temperatures in sulfuric and chloride aggressive media. The study outcomes indicate that the HEA sintered at 1000 °C exhibited superior corrosion resistance compared to other HEAs at other temperatures. This study contributes valuable insights into the nuanced relationship between sintering temperature, microstructure, and corrosion resistance of Ti36-Al16-V16-Fe16-Cr16 HEAs.

Sustainable Fire Protection: Reducing Carbon Footprint with Advanced Coating Technologies

Metallum Fire-Resistant paint, denoted as MFR henceforth, represents a cutting-edge insulating material with dual functionality as a fireproof solution, presenting substantial advantages in the realm of construction applications. This exposition derives its primary insights from the scholarly contributions documented in publications. The focal point of these investigations includes the assessment of fire hazards associated with polyethylene materials in building structures and the enhancement of mortars in high-temperature environments in tunnels. The purpose of this study is to evaluate the effectiveness of a modified cork-based coating (MFR) compared to traditional coatings in terms of corrosion protection, fire resistance, and thermal insulation properties in construction applications. This evaluation focuses on quantifying the efficacy of MFR by examining key properties, such as adhesion, the reduced thickness required for fire protection, thermal conductivity reduction, and corrosion resistance under extreme environmental conditions. MFR is highly effective in fire prevention for buildings and tunnels, withstanding temperatures over 1000 °C while maintaining structural integrity. A unique aspect of MFR is its use of cork shavings, a typically underutilized byproduct from wine-bottle-stopper production. This innovative not only amplifies MFR’s fire-resistant attributes, but also introduces sustainability and judicious resource utilization into its manufacturing processes.

Corrosion behavior and strengthening mechanism of Ni-Cu alloy coating on NdFeB magnets

In this paper, the pulse-reverse current electroplating technique was utilized to deposit nickel–copper (Ni-Cu) alloy coatings on the surface of neodymium magnets (NdFeB). Compared with the nickel (Ni) coating, the corrosion resistance of the nickel–copper alloy coating has been significantly improved. Additionally, the results show that alloying can effectively prolong the incubation period of pitting nucleation and improve the self-healing ability of coating. The structure and microstructure of the coating show that the surface of the nickel–copper coating is flat and the grains preferentially grow along the (111) close-packed surface, which also makes the coating to have higher densification and significantly reduces the number of self-corrosion sites and corrosion tendency of the coating. The lower binding energy copper(I) oxide (Cu2O) produced by nickel–copper coatings at the initial corrosion stage can reduce the formation of metal cation holes and prolong the incubation period of pitting corrosion. After pitting formation, the corrosion products copper(I) oxide and dicopper chloride trihydroxide (Cu2(OH)3Cl) of copper (Cu) in the pitting hole have a certain hindrance to corrosion and are conducive to promoting passive reconstruction, which is an important reason for higher self-healing ability and higher corrosion resistance of the nickel–copper alloy coating.

Durable and Hydrophobic Self-Healing Coating with Rapid Thermal Activation and Prolonged Corrosion Resistance

Durable and Hydrophobic Self-Healing Coating with Rapid Thermal Activation and Prolonged Corrosion Resistance

Fatigue Analysis of Composite Leaf Springs - A Review

The purpose of this paper is to provide a review of work that has been carried out in analyzing composite leaf springs. Leaf springs made of fibre reinforced composites exhibit much more advantages when compared with steel leaf springs. Most importantly, polymer composites increase the performances of vehicles by decreasing the weight of the leaf spring and also by providing corrosion resistance. This paper summarizes the fatigue analysis of composite leaf springs by considering the results obtained by some of the research works.

INFLUENCE OF GAS ENVIRONMENT OF SPRAYING ON THE PROPERTIES OF GAS-THERMAL METALLIZED COATINGS

This article is devoted to the study of the influence of the technological parameters of spraying, in particular the gaseous medium, on the physical and mechanical properties and corrosion resistance of gas-thermal metallization coatings. To protect the housings of submersible electric motors (PAD) in oil and gas wells, the method of electric arc metallization (EDM) has become widespread, due to the high level of physical and mechanical properties of the resulting gas-thermal metallization coating, high productivity and cost-effectiveness of the process, as well as the mobility of equipment. Despite the effectiveness of this method of protection, it does not exclude the occurrence of corrosion processes in the metal of the PAD body. In this regard, research aimed at increasing the operational life of the metallization coating is relevant and promising.The article considers the theoretical aspects of the influence of the technological parameters of the spraying process on the properties of the metallization coating. The effect of the sputtering gas medium on the physical and mechanical properties and corrosion resistance of metallization coatings has been experimentally investigated. Comparative tests and studies of gas-thermal metallization chromium-nickel coatings applied by the EDM method in an air environment and in an argon environment have been carried out. The main trends and features of the formation of metallization chromium-nickel coatings applied by the EDM method and the effect of the application mode, in particular the technological gas spraying medium on the microstructure studied on metallographic grinds using a scanning electron microscope with an attachment for energy dispersion analysis; microhardness determined by the Vickers method are determined; The wear resistance is determined by abrasive wear during friction against non-rigidly fixed abrasive particles and the corrosion resistance of the resulting coatings, determined by autoclave tests during exposure in a simulated environment containing corrosive components.The study of the influence of certain technological parameters of spraying of gas-thermal metallization coatings, including the gas medium, on the properties of the coatings obtained is a fairly promising task aimed at increasing the operational life of the metallization coating, which in the future will reduce the cases of premature failure of oilfield equipment.

Enhanced electrochemical corrosion resistance of 316L stainless steel manufactured by ultrasonic rolling assisted laser directed energy deposition

Enhanced electrochemical corrosion resistance of 316L stainless steel manufactured by ultrasonic rolling assisted laser directed energy deposition

Engineering Corrosion Resistance in Magnesium Alloys for Biomedical Applications: A Synergy of Zn/Ca Atomic Ratio and Texture-Based Approach

Magnesium (Mg) and Magnesium-Zinc-Calcium alloys present a compelling option for biodegradable implant materials. Utilizing Vacuum Induction Casting, Mg–2.5Zn-xCa (with x = 0.3, 0.5, 0.9, 1.15 wt%) alloys were fabricated and subjected to hot-rolling for thermo-mechanical processing. The hot-rolled Mg–2.5Zn-0.3Ca alloy exhibits the lowest corrosion rate along with the highest basal texture. Increasing the Zn/Ca atomic ratio intensifies the basal texture and enhances corrosion resistance. Elevated Zn concentration improves corrosion resistance via Ca2Mg6Zn3 phase formation, while increased Ca content diminishes corrosion resistance due to the Mg2Ca phase. Advancement of this alloy is poised to extend Mg alloy use in innovative biomedical bone implants.

Enhanced Corrosion Protection of Printed Circuit Board Electronics using Cold Atmospheric Plasma-Assisted SiOx Coatings.

The miniaturization and widespread deployment of electronic devices across diverse environments have heightened their vulnerability to corrosion, particularly affecting copper traces within printed circuit boards (PCBs). Conventional protective methods, such as conformal coatings, face challenges including the necessity for a critical thickness to ensure effective barrier properties and the requirement for multiple steps of drying and curing to eliminate solvent entrapment within polymer coatings. This study investigates cold atmospheric plasma (CAP) as an innovative technique for directly depositing ultrathin silicon oxide (SiOx) coatings onto copper surfaces to enhance corrosion protection in PCBs. A systematic investigation was undertaken to examine how the scanning speed of the CAP deposition head impacts the film quality and corrosion resistance. The research aims to determine the optimal scanning speed of the CAP deposition head that achieves complete surface coverage while promoting effective cross-linking and minimizing unreacted precursor entrapment, resulting in superior electrical barrier and mechanical properties. The CAP coating process demonstrated the capability of depositing SiOx onto copper surfaces at various thicknesses ranging from 70 to 1110 nm through a single deposition process by simply adjusting the scanning speed of the plasma head (5-75 mm/s). Evaluation of material corrosion barrier characteristics revealed that scanning speeds of 45 mm/s of the plasma deposition head provided an effective coating thickness of 140 nm, exhibiting superior corrosion resistance (30-fold) compared to that of uncoated copper. As a proof of concept, the efficacy of CAP-deposited SiOx coatings was demonstrated by protecting an LED circuit in saltwater and by coating printed circuits for potential agricultural sensor applications. These CAP-deposited coatings offer performance comparable to or superior to traditional conformal polymeric coatings. This research presents CAP-deposited SiOx coatings as a promising approach for effective and scalable corrosion protection in miniaturized electronics.

Influence of the Dispersion of Carbon Nanotubes on the Electrical Conductivity, Adhesion Strength, and Corrosion Resistance of Waterborne Polyurethane Composites

Due to the presence of many flammable substances in the working environments of the petrochemical industry, anticorrosive conductive coatings need to be used on metal equipment to avoid safety accidents like fires. However, existing conductive solvent-based coatings are volatile when exposed to flammable and toxic organic solvents. Thus, in this work, a series of eco-friendly anticorrosive waterborne polyurethane (WPU) composites with multi-walled carbon nanotubes (MWCNTs) were prepared via a low-cost and practical process; the dispersion of MWCNTs was revealed when present in different amounts, and the mechanism behind the conduction of WPU composites was determined. We concluded that low amounts of MWCNTs were well dispersed, generating a conductive network, and the WPU composite was not entirely covered by the MWCNT particles, so the electrical conductivity in certain parts of the coating was good. When the content of MWCNTs was excessive, some stretched MWCNTs dispersed to the top of the composite and many MWCNTs agglomerated at the bottom. Additionally, when the content of MWCNTs was increased, the electrical conductivity, corrosion resistance, and adhesion strength of the WPU composite decreased. Our results could provide a theoretical foundation for the preparation of anticorrosive conductive waterborne composites for protecting equipment in the petrochemical industry.

The Influence of Surface Nanocrystallization of TA2 Titanium Alloy on Its Corrosion Resistance

In this study, the surface nano treatment of TA2 titanium alloy was realized by means of surface mechanical wear treatment. The microstructure and electrochemical properties of the nanocrystalline layer were investigated by SEM, TEM, Electrochemical Impedance Spectroscopy, and Potentiodynamic Polarization, while the nucleation mechanism of the passivation film was discussed. The results indicate that the original coarse grains on the sample’s surface are transformed into randomly oriented nanocrystals by surface mechanical attrition treatment (SMAT). The corrosion current density of the surface nanocrystallized TA2 titanium alloy (9.2 nA·cm−2) experienced a reduction of two orders of magnitude compared to untreated TA2 titanium alloy (134.5 nA·cm−2) in 3.5 wt.% NaCl solution. The SMAT methods accelerates nucleation mechanism transitioning to continuous nucleation.

Strengthening of RC Beam with GFRP Composites in Shear N. B. Bhopale

The rehabilitation, repair and strengthening of existing reinforced concrete (RC) structures is essential due to factors such as aging, steel reinforcement corrosion, construction/design defects, increased service loads demand, seismic events, and advancements in design guidelines. Fiber-reinforced polymers (FRP) are now being recognized as a promising material for the rehabilitation of such structures, through strengthening or repairing. In buildings and bridges, RC sections are commonly found in the form of beams and girders. Shear failure of RC beams is particularly due to its sudden occurrence without warning. Therefore, the utilization of externally bonded (EB) FRP composites for shear strengthening of RC beams has gathered popularity as a structural enhancement technique, primarily due to advantages of FRP composites, such as high strength-to- weight ratio and exceptional corrosion resistance. In addition, FRP repair systems give a cost-saving choice to traditional repair methods and materials. A study was performed to analyse the shear characteristics of RC beams enhanced with continuous glass fiber-reinforced polymer (GFRP) sheets. Reinforced concrete beams externally bonded GFRP sheets subjected to failure using a symmetrical two-point concentrated static loading system. The experimental data obtained included load, deflection, and failure modes of each beam, along with the effect of the number of GFRP layers on the beams The failures observed in strengthened beams typically commence with the debonding of the FRP sheets, followed by brittle shear failure. The shear capacities of these beams were higher than that of the control beam.

Predicting shear strength of fiber-reinforced concrete beams reinforced with longitudinal FRP bars with machine learning techniques

ABSTRACT This study investigates the shear strength prediction of Fibre-Reinforced Concrete (FRC) beams reinforced with Fibre-Reinforced Polymer (FRP) bars and without stirrups through the application of Machine Learning (ML) techniques. The utilisation of FRP bars, particularly Glass Fibre-Reinforced Polymer (GFRP) and Basalt Fibre-Reinforced Polymer (BFRP) bars, has emerged as a promising alternative to traditional steel reinforcement due to their superior mechanical properties and corrosion resistance. Moreover, the incorporation of macro- and micro-discrete fibres into concrete compositions enhances both shear and flexural behaviour while reducing crack propagation induced by tensile stresses. The primary objective of this research is to develop accurate predictive models for the shear capacity of FRP-reinforced concrete beams, considering various influential parameters. Six different ML techniques, namely Multiple Linear Regression (MLR), Gaussian Process Regression (GPR), k-Nearest Neighbors (KNN), Support Vector Machines (SVMs), Artificial Neural Networks (ANNs) and Random Forest Regression (RFR), are employed to analyse the complex interactions between input variables, such as fibre type, bar diameter, concrete compressive strength, beam dimensions and the resulting shear strength. By leveraging these computational approaches, we aim to overcome the limitations of conventional analytical methods and provide robust predictions for structural design and optimisation.

Controlled Compositions in Zn–Ni Coatings by Anode Material Selection for Replacing Cadmium

Cadmium-based coatings have long been used to protect high-strength steel in aerospace, but due to cadmium’s toxic and carcinogenic nature, its use is increasingly restricted. Zinc–nickel coatings, containing 10–14 wt% Ni, offer superior corrosion resistance compared to pure zinc, making them a promising alternative. However, Zn–Ni coatings are prone to cracking, which can compromise their protection. This study investigates how different anode materials influence crack formation and coating properties during electrodeposition. Zinc and nickel anodes produced coatings with consistent thicknesses of 13–15 µm, while 1020 steel and stainless steel resulted in thicker coatings of up to 33 µm. Notably, coatings deposited with nickel anodes demonstrated strong adhesion and consistent interface quality. Zinc anodes achieved a high Ni content of about 13.5 wt%, whereas 1020 steel and stainless steel produced lower Ni content, around 7 wt%. Additionally, zinc and nickel anodes led to fewer defects and minimal porosity, in contrast to the higher porosity observed with 1020 steel and stainless steel anodes. Furthermore, zinc anodes maintained stable voltages (~0.5 V), contributing to more uniform coatings. In terms of corrosion resistance, zinc anodes exhibited a lower corrosion rate of 0.44 mm/year compared to 1.54 mm/year for nickel anodes. This study highlights the importance of anode selection in reducing cracking and optimizing Zn–Ni coatings, presenting them as a safer and more effective alternative to cadmium-based coatings.

Fabrication and Properties of Superhydrophobic Colored Stainless Steel Surface for Decoration and Anti-Corrosion

A colored superhydrophobic surface on a stainless steel substrate was achieved by means of high temperature oxidation combined with subsequent spraying modification by superhydrophobic nano-silica film. Comprehensive characterizations of the surface were performed in terms of color, morphology, composition, wettability, and corrosion resistance by optical microscopy, X-ray diffraction (XRD), scanning electron microscopy (SEM), energy-dispersive spectroscopy (EDS), contact angle, potentiodynamic polarization, and electrochemical impedance spectroscopy measurement. At 400 °C, the surface was pale yellow, gradually turning yellow and then red as the temperature increased. At 700 °C and 800 °C, the surface colors were blue and dark brown, respectively. The samples with oxide films demonstrated lower contact angles, specifically 80.5° ± 2.5 at 400 °C, 79.1° ± 2.8 at 500 °C, and 75.6° ± 3.4 at 600 °C. The polarization resistance measured on the oxidized film formed at 600 °C exceeded 7.93 × 104 Ω·cm2. After spraying the treatment, these colorful surfaces exhibited superhydrophobicity, they were self-cleaning, and they satisfied anti-corrosion properties. The treatment performs as an excellent barrier and exhibits a high corrosion resistance of 4.68 × 106 Ω·cm2. The successful preparation of superhydrophobic colored surfaces offers the possibility of providing stainless steel with both decoration value and self-cleaning function simultaneously by our proposed chromium-free fabrication process.

Recent Progress on Atmospheric Corrosion of Field-Exposed Magnesium Alloys

It is well known that the poor corrosion resistance of magnesium alloys is a key factor limiting their application. Field exposure is the most reliable means to evaluate the atmospheric corrosion performance of magnesium alloys. This article reviews the field exposure corrosion behavior of magnesium alloys in typical atmospheric environments (including the marine atmosphere, industrial atmosphere, etc.) in recent years. According to the literature review, it was found that there are significant regional differences in the atmospheric corrosion behavior of magnesium alloys, which is the result of the coupling of multiple factors in the atmospheric environment. By investigating the corrosion rate and corrosion products of different types of magnesium alloys in different environments, the corrosion mechanism of magnesium alloys in different environments was summarized. Specifically, environmental parameters such as atmospheric temperature, relative humidity, CO2, and chloride ion deposition rates in the marine atmospheric environment can affect the corrosion behavior of magnesium alloys. The corrosion of magnesium alloys in different industrial atmospheric environments is mainly affected by atmospheric temperature and relative humidity, as well as atmospheric pollutants (such as SO2, CO2, NO2) and dust. This review provides assistance to the development of new corrosion-resistant magnesium alloys.

Impact of CC and PCTIG Welding on SMO 254 Joints Using Alloy 625 Filler

Objectives: This investigation analyzes the microstructure, mechanical and corrosion characteristics of SMO 254 joints welded using constant current TIG (CCTIG) and pulse current TIG (PCTIG) with alloy 625 (ERNiCrMo-3) filler metal. Method: Optical microscopy and SEM with EDAX were employed for microstructural characterization and phase analysis. Mechanical properties were assessed through Vickers microhardness, tensile, and Charpy impact tests, followed by fracture analysis. Findings: EDAX point analysis indicates reduced Mo segregation and the absence of Nb segregation in PCTIG weldments. The overall corrosion resistance remains acceptable despite a slightly higher corrosion rate in PCTIG weldments. The study highlights the superior mechanical properties and microstructural control achieved with PCTIG welding, making it a preferable technique for SMO 254 joints. Novelty: Notably, the research establishes PCTIG as a superior method for welding SMO 254, demonstrating that it not only refines the grain structure but also significantly enhances mechanical properties, particularly toughness, by 50% compared to CCTIG. Keywords: SMO 254, SASS, Microstructural characterization, Mechanical properties, CCTIG, PCTIG

A review on AI-driven environmental-assisted stress corrosion cracking properties of conventional and advanced manufactured alloys

Stress corrosion cracking (SCC) poses a significant challenge to the integrity and longevity of both conventional and advanced manufactured alloys, impacting critical industries such as aerospace, marine, and nuclear energy. This review explores the use of artificial intelligence (AI) to analyse and predict SCC properties. Traditional alloys such as steel, aluminium, and titanium, as well as advanced materials such as additive-manufactured and high-entropy alloys, exhibit unique SCC behaviours influenced by corrosive environments, mechanical stress, and temperature variations. AI techniques, including machine learning models, offer transformative approaches to understanding and mitigating SCC. Leveraging extensive datasets from experiments and field studies, AI can identify patterns and correlations that traditional methods might miss. Predictive modelling through supervised learning forecasts SCC initiation and propagation, aiding in material design and maintenance. Unsupervised and reinforcement learning enhances alloy composition and processing parameter optimisation for better SCC resistance. In conventional alloys, AI identifies specific SCC conditions, leading to improved protective measures. For advanced alloys, AI-driven insights tailor additive manufacturing processes and design high-entropy alloys with superior corrosion resistance. This review includes case studies demonstrating AI's effectiveness in predicting SCC across various alloy–environment combinations, highlighting successes and challenges. Despite hurdles such as data quality and integration, AI holds immense potential to revolutionise SCC research, enhancing understanding of SCC mechanisms and fostering innovations in alloy design and preventative maintenance.

Corrosion Assessment of Arc Thermal Sprayed Al and its Alloy Coatings in Aggressive Environments: An Overview

Arc thermal sprayed coatings have a wide range of applications, including corrosion resistance, wear resistance, thermal barriers, and electromagnetic pulse protection. However, these coatings often suffer from significant defects and pore formation, which can reduce their overall effectiveness. This overview focuses on the corrosion resistance properties of Al and its alloys. Al coatings demonstrate good corrosion resistance in marine environments due to the formation of sparingly soluble corrosion products on the surface. When Zn is alloyed with Al, the initial corrosion resistance decreases due to an increased number of pores. However, over extended exposure, these coatings exhibit excellent corrosion resistance as corrosion products fill the pores, providing barrier protection. Additionally, incorporating 5 wt.% Mg in Al coatings enhances bond adhesion and improves corrosion resistance in aggressive environments. To further reduce porosity and enhance corrosion resistance, the use of phosphate-based eco-friendly pore sealing agents is discussed. Optimizing the amount of phosphate during treatment is crucial, as it significantly reduces porosity and enhances corrosion resistance. Both insufficient and excessive amounts of phosphate can deteriorate the coating, while the optimal amount improves corrosion resistance over prolonged exposure to aggressive conditions.