Corrosion Resistance Research Articles

Study on Bonding Characteristics of Aluminum Alloy Treated by Plasma Electrolytic Oxidation Process and Polymer Resin Bonded by Direct Injection Molding

Aluminum alloy and polymer resin hybrid bonding technology is essential for lightweight mobile phone frames and automotive components. Recently, there has been extensive research on a method of bonding metals and polymer resins by treating the metal surface and then direct injection molding. However, this method requires separate surface treatment of the aluminum alloy after bonding to enhance its corrosion resistance. This paper studies the use of Plasma Electrolytic Oxidation, one of the surface treatment methods for aluminum, to achieve the bonding of aluminum and polymer resin in a single surface treatment step while ensuring high corrosion resistance. We conducted research to investigate optimal conditions by adjusting the process variables of Plasma Electrolytic Oxidation, in order to achieve integration with the polymer resin and measure the bonding strength and corrosion resistance. The surface characteristics of each Plasma Electrolytic Oxidation condition were analyzed using scanning electron microscopy and atomic force microscope equipment, while the bonding strength was measured using universal testing machine equipment. The corrosion characteristics were evaluated by measuring the corrosion resistance in a saltwater solution.

Focusing on the corrosion resistance enhancement of HRB400 rebar by Cr addition in the marine envrionment

The corrosion resistance of Cr reinforced HRB400 rebar in the marine environment was investigated. The addition of Cr increases the amount of Cr(OH)3 and α-FeOOH in the passivate film, resulting in a denser passivate film structure. This enhanced passivation film inhibits localized corrosion. The pitting potential and critical chloride concentration (CTL) of the steel increased with the increase in chromium content, indicating improved corrosion resistance of the steel. On the other hand, an increase in the concentration of Cl- in solution leads to a decrease in the pitting potential and resistance of the steel, which reduces the corrosion resistance. At higher Cl- concentrations, the Cl- ions form an electrochemical interface with the steel surface, resulting in a sharp decrease in the Rf value. In addition, the gradual decrease in solution pH leads to a decrease in the pitting potential and CTL of HRB400 and 1.5Cr steel. The corrosion resistance was also found to be reduced, pH reduction accelerated the intrusion of chloride ions, which led to a severe breakdown of the passivation film.

Corrosion Resistance and Bond Strength of Silica Particle Modified Enamel Coated Smooth and Deformed Steel Bars

Corrosion Resistance and Bond Strength of Silica Particle Modified Enamel Coated Smooth and Deformed Steel Bars

Corrosion Resistance of Cr10Mo1 Alloy Corrosion-Resistant Steel in Seawater–Sea Sand Concrete Pore Solution

Corrosion Resistance of Cr10Mo1 Alloy Corrosion-Resistant Steel in Seawater–Sea Sand Concrete Pore Solution

Enhanced mechanical properties and corrosion resistance of electro-deposited NiCoP composite coatings with ZrB2 particle addition

This work was initiated with the purpose of expanding the utilization of nickel-based composite coatings, especially in wear and corrosion-related industrial applications. NiCoP coatings have long attracted scientific and engineering interest due to their enhanced mechanical properties reinforced by incorporation with a reinforcement phase. In the present study, NiCoP composite coatings reinforced with ZrB2 ceramic particles were synthesized by direct current deposition using a modified Watt’s type bath. The microstructures of composite coatings were studied by x-ray diffraction analysis, energy dispersive x-ray spectroscopy, and scanning electron microscopy, respectively. The hardness and tribological properties of the composite coatings were evaluated and compared. The corrosion behaviors of the deposits were investigated using electrochemical spectroscopy and potentiodynamic polarization techniques in simulated seawater. The effect of ZrB2 content on the microstructures and mechanical properties of the composite coatings was explored and discussed. The present study indicates that there is a progressive enhancement in the hardness, corrosion resistance, and wear resistance of the composite coatings with the increase in ZrB2 loading. The NiCoP-12 g/l-ZrB2 coating possesses the highest microhardness and superior wear performance, while the NiCoP-6 g/l-ZrB2 coating exhibits the best anti-corrosion properties. The present study shows a cost-effective and feasible solution for the preparation of NiCoP protective coatings with enhanced properties, which holds great potential for industrial applications requiring wear and anti-corrosion protection.

CEMENTITIOUS SYSTEMS FOR HIGH-PERFORMANCE CONCRETES WITH IMPROVED CORROSION RESISTANCE

The article presents the results of research on cementitious systems "Portland cement CEM I 42,5 R - active mineral additives - microfillers - superplasticizer - hardening accelerators" for high-performance concrete with improved corrosion resistance. The resistance of concrete to corrosion caused by the influence of chemical substances was investigated - sulfate corrosion (class XA), which combines the processes of formation and accumulation of sparingly soluble salts in concrete, which are accompanied by internal stresses and destructive phenomena in concrete. The increase in corrosion resistance of high-performance concretes based on modified cementitious systems is explained mainly by the creation of a fine-crystalline microstructure with the formation of C-S-H phases, which contribute to the pores colmatation with age of hardening.

Atomistic study of intermetallics of Fe–Al–Zn system and their interfacial properties

Galvanizing is an important industrial process to improve the corrosion resistance of advanced high strength steels (AHSSs) that are vital for automotive industries. During galvanizing, nanoscale intermetallic phases with complex crystal structures are formed at the interface between the steel substrate and the zinc overlay. To better understand the nanoscale structures and the interfacial properties between the intermetallics, in this work, we develop a second nearest neighbor (2NN) Fe–Al–Zn ternary Modified Embedded Atom Method (MEAM) potential to describe the crystal structures of the intermetallics, i.e. Fe3Al8, Fe4Zn9 and FeZn13 and to calculate the interfacial structure and energy between them. The developed MEAM potential describes well the complex crystal structures and can be used to investigate the interfacial properties that are difficult to obtain from experiments. The Fe4Zn9, FeZn13 surface energies; the Fe–Fe4Zn9, Fe–FeZn13, Fe3Al8–FeZn13 interfacial energies; and the work of adhesion are calculated with the developed MEAM potential. The results show that FeZn13 crystal orientation has an insignificant effect on the FeZn13 surface energy and the Fe–FeZn13 interfacial energy. A negative interfacial energy is obtained for the Fe–Fe4Zn9 and the Fe–FeZn13 interface. The lowest interfacial energy is obtained in the {100}Fe case. The interfacial energy of Fe3Al8–FeZn13 depends on the surface termination of Fe3Al8 and FeZn13. A low interfacial energy is obtained when the surface termination of Fe3Al8 and FeZn13 are both Fe rich. In contrast, when the surface termination of Fe3Al8 is Al rich or the surface termination of FeZn13 is Zn rich, no low energy, stable interface can be formed between the two phases.

Effect of Impact Force on the Impact-Sliding Wear of Titanium Alloy Drill Pipes against Steel Casings

Titanium alloys have been widely used for drill pipes in complex structural wells and ultra-deep wells because they can provide great benefits in cost and operation in drilling systems due to their excellent properties such as high strength, low density, exceptional corrosion resistance and inherent flexibility. However, their wear behaviors during drilling have not been well understood by the communities. In this work, the effect of the impact force on the wear performance of titanium alloy drill pipes against steel casings was investigated through using a modified wet impact-sliding pin-on-disk test system, in which ZSA-3 titanium alloy was used for the pins and J55 steel was for the disks. The tests were conducted under simulated drilling mud conditions. As the impact force increases, the coefficient of friction tends to become stable and fluctuates slightly, and thus the wear rate of the tribo-pairs decreases gradually. The wear mechanism of J55 steel disks presents a transition from plastic deformation to plastic deformation accompanied by adhesive wear, while that of the titanium alloy pins changes from the plowing effect with adhesive wear to plastic deformation and adhesive wear. In addition, complex oxides will be formed on the surfaces of the tribo-pairs due to the oxidation of Ti and Fe during the wear process. The present results could provide as a fundamental guide for the drilling engineers in related industries for reducing casing wear in the drilling environment.

Chronic kidney disease: a contraindication for using biodegradable magnesium or its alloys as potential orthopedic implants?

Magnesium (Mg) has gained widespread recognition as a potential revolutionary orthopedic biomaterial. However, whether the biodegradation of the Mg-based orthopedic implants would pose a risk to patients with chronic kidney disease (CKD) remains undetermined as the kidney is a key organ regulating mineral homeostasis. A rat CKD model was established by a 5/6 subtotal nephrectomy approach, followed by intramedullary implantation of three types of pins: stainless steel, high pure Mg with high corrosion resistance, and the Mg–Sr–Zn alloy with a fast degradation rate. The long-term biosafety of the biodegradable Mg or its alloys as orthopedic implants were systematically evaluated. During an experimental period of 12 weeks, the implantation did not result in a substantial rise of Mg ion concentration in serum or major organs such as hearts, livers, spleens, lungs, or kidneys. No pathological changes were observed in organs using various histological techniques. No significantly increased iNOS-positive cells or apoptotic cells in these organs were identified. The biodegradable Mg or its alloys as orthopedic implants did not pose an extra health risk to CKD rats at long-term follow-up, suggesting that these biodegradable orthopedic devices might be suitable for most target populations, including patients with CKD.

In Situ Electronic Structure Analysis of Water-Corroded UNx in High Vacuum

Nitriding technologies are promising surface modification techniques of uranium based on pulsed laser irradiating and glow plasma treatment. Nitrided layers with different nitrogen contents (UN0.35, UN0.75, UN1.08 and UN1.5) were prepared on the surface of uranium. The present study aims to investigate the microstructure and corrosion properties of the reaction of the UNx layers with ultra-low water vapor at room temperature. The electronic structures were analyzed in situ by X-ray photoelectron spectroscopy in high vacuum. The results showed that the UN0.35, UN0.75, and UN1.08 samples were mainly composed of uranium nitride (UN) and metallic uranium, while the surface microstructure of the UN1.5 sample was U2N3. The dense and uniform nitride layer with a grain size of 20 to 50 nm was obtained on the uranium surface, which acted as a barrier and prevented the further diffusion of anions into the matrix. The corrosion products of the UN0.35, UN0.75, and UN1.08 samples were mainly UO2-xNy and UO2 after reaction with the water vapor. The contents of UO2-xNy increased with increasing nitrogen contents, and the corrosion rate decreased significantly. The intermediate compounds UO2-xNy reacted slowly with the water vapor, and eventually converted to UO2. Meanwhile, the corrosion products of the UN1.5 sample were mainly U2N3+xOy and UO2-xNy after reaction with the water vapor. The percentage of U2N3+xOy and UO2-xNy remained almost stable over a long period of time, which indicated that the high contents of U2N3+xOy and UO2-xNy prolonged the time for complete conversion to UO2. It can be concluded that the U-N-O ternary compounds retarded the corrosion process and the UNx layers with high nitrogen contents showed excellent corrosion resistance.

Effect of heat treatment on the anisotropic mechanical properties and corrosion resistance of laser powder bed fusion fabricated Inconel 625

The microstructure evolution of laser powder bed fusion processed Inconel 625 after heat treatment at 650 ℃ (aging), 850 ℃ (sensitization) and 1050 ℃ (homogenization) was studied. Relationship of microstructure evolution and the anisotropic mechanical properties and corrosion resistance was analyzed. Decreased corrosion resistance after aging and sensitization was observed, which is related to the different precipitation behavior. After aging, γ″ and MC carbides precipitated along cellular structures further accelerate the corrosion along melting pool boundaries. While after sensitization, δ precipitated along cellular structures aggravated the corrosion along the melting pool boundaries. At the meantime, precipitation of M23C6 carbides and δ along grain boundaries made it vulnerable to be corroded, which further accelerate the corrosion rate. After homogenization, segregation and precipitates are barely observed in the microstructure which contribute to an enhancement of corrosion resistance. Moreover, with the increasing of heat treatment temperature, recovery of anisotropic microstructure contributes to the decrease of the anisotropy of mechanical properties. This study may contribute to the profound comprehension of heat treatment procedure on microstructure evolution as well as mechanical properties and corrosion resistance of laser powder bed fusion processed Inconel 625.

Bacterial and corrosion resistance of polytetrafluoroethylene-silver composite coatings by magnetron sputtering

Titanium alloy and stainless steel implants have been widely applied in orthopedics. However, harmful ions released from implant corrosion caused by human body fluids and bacterial infections may inhibit patients’ recovery. In this work, a polytetrafluoroethylene-silver composite coating was prepared by RF unbalanced magnetron sputtering to improve the bacterial and corrosion resistance of the SS316L. The removal rates of the composite coatings for Escherichia coli and Staphylococcus aureus reached 97.27% and 99.99%, respectively. The contact angle of 131.5° and fluorescence staining experiments show that the composite coating has an antiadhesive effect on bacteria and less cytotoxicity against osteoblasts. The corrosion voltage of the composite coating was much higher than that of the control SS316L substrate, and the corrosion current density was reduced to 1/3, implying the enhancement of the corrosion resistance of the SS316L substrate.

Influence of Zirconium on the Microstructure, Selected Mechanical Properties, and Corrosion Resistance of Ti20Ta20Nb20(HfMo)20-xZrx High-Entropy Alloys.

The presented work considers the influence of the hafnium and molybdenum to zirconium ratio of Ti20Ta20Nb20(HfMo)20-xZrx (where x = 0, 5, 10, 15, 20 at.%) high-entropy alloys in an as-cast state for potential biomedical applications. The current research continues with our previous results of hafnium's and molybdenum's influence on a similar chemical composition. In the presented study, the microstructure, selected mechanical properties, and corrosion resistance were investigated. The phase formation thermodynamical calculations were also applied to predict solid solution formation after solidification. The calculations predicted the presence of multi-phase, body-centred cubic phases, confirmed using X-ray diffraction and scanning electron microscopy. The chemical composition analysis showed the segregation of alloying elements. Microhardness measurements revealed a decrease in microhardness with increased zirconium content in the studied alloys. The corrosion resistance was determined in Ringer's solution to be higher than that of commercially applied biomaterials. The comparison of the obtained results with previously reported data is also presented and discussed in the presented study.

Corrosion behavior of YSZ and YSZ/NiCo coatings on inconel 625 exposed alkali chlorides

Alkali chloride attack on boiler pipe walls is considered the main problem of corrosion in the waste-to-energy (WTE) industry, even though uses superalloy. Electrophoretic deposited (EPD) yttria-stabilized zirconia (YSZ) coating is carried out to protect the Inconel 625 substrate. YSZ is deposited directly both on the Inconel 625 substrate and NiCo-Inconel 625. Corrosion resistance was conducted using the 3.5% NaCl electrochemical test and the hot salt corrosion test at 600°C in alkaline salt media such as NaCl, KCl, and CaCl2. The potentiodynamic polarization curve shows that the YSZ coating deposited on the substrate (single-layer) has a corrosion rate of 0.065 mm∙y‒1, lower than that deposited on NiCo coating (double-layer). The double-layer, NiO2 is formed in the NiCo layer due to the NaCl solution being trapped. Meanwhile, in hot salt corrosion at 600°C, CaCrO4 is formed as a protective oxide layer. Furthermore, in the double-layer, an imperfect oxide layer is formed causing spallation and coating failure. The corrosion rate for single-layer hot salt corrosion for 40 h is 0.310 mm∙y‒1. As a result, the corrosion resistance of the single-layer is increased by the presence of the Cr2O3 oxide layer formed during sintering.

Impact of Cu and Ce on the electrochemical, antibacterial, and wear properties of 316 L stainless steel: Insights for biomedical applications

This study provides a comprehensive investigation of the tribological, electrochemical, and antibacterial characteristics of austenitic stainless steel, type 316 L, doped with Ce and Cu. The samples were doped with varying concentrations of Ce (0.5, 1.5, and 3 wt%) and Cu (1.5, 2.5, and 3.5 wt%). The initial measurements focused on determining the final density values of each sample. Subsequently, friction wear tests were conducted under both dry and wet conditions, shedding light on the wear resistance of the materials. In addition, electrochemical polarization tests were employed to assess the influence of Ce and Cu on the corrosion resistance of AISI 316 L. Furthermore, antibacterial assessments were conducted against bacterial cultures of Staphylococcus aureus (ATCC 29213) and Escherichia coli (ATCC 25922). The findings of this study illuminate several noteworthy outcomes. Namely, the results showed that all Ce and Cu-doped samples exhibited an increase in final density values when compared with the as-received AISI 316 L. The wear test results revealed that samples doped with 0.5 wt% Ce and 2.5 wt% Cu exhibited the highest wear resistance, in both dry and wet environments. Polarization curve analysis indicated that Ce was more effective in enhancing the corrosion resistance of AISI 316 L than Cu. Notably, Ce and Cu modifications endowed the material with antibacterial properties, effectively inhibiting bacterial growth in both S. aureus and E. coli cultures. In summary, this study demonstrates that the addition of even trace amounts of Ce and Cu to AISI 316 L leads to noticeable improvements in the material's tribological, electrochemical, and antibacterial performance, underscoring its potential for diverse biomedical applications. The enhanced mechanical strength, corrosion resistance, and antibacterial activity make the doped material promising for use in various medical devices, implants, and other biomedical applications.

Unveiling the diffusion pathways under high-temperature oxidation of Cr2AlC MAX phase via nanoscale analysis

The MAX phase chromium aluminium carbide (Cr2AlC) is a potential candidate for high-temperature structural and energy applications due to the unique combination of properties, including excellent oxidation and corrosion resistance in harsh environmental conditions. In this work, the oxidation behaviour of bulk Cr2AlC was studied at temperatures of 1000 °C and 1200 °C in humid synthetic air, mimicking a realistic application environment. An α-Al2O3 scale forms at both temperatures, consisting of both inward and outward-growing layers, with a continuous Cr7C3 layer beneath the oxide. A special focus was put on employing atom probe tomography (APT) to analyse the oxide and carbide layers at the nanoscale. Decomposition of Cr2AlC to Cr7C3 is the main source (>70%) of aluminium needed for the oxide scale formation, while Al depletion in the underlying MAX phase remains marginal (<1 at%), exhibiting a pattern different from the common high-temperature oxidation of alloys. Al diffusion to the oxide scale proceeds predominantly through grain boundaries (GBs) in Cr2AlC and through the bulk in Cr7C3. Ionic diffusion through GBs of the large-grained inner alumina layer seems to be the rate-limiting step for the oxide scale growth, resulting in the apparent parabolic oxidation kinetics. No segregation of Cr, C or any impurities, which could affect ionic transport, was found at these alumina GBs by APT, rendering the results of this study as characteristic of a pure Cr2AlC oxidation.

Modeling hydrogen diffusion in precipitation hardened nickel-based alloy 718 by microstructural modeling

Abstract Environmentally assisted cracking can significantly affect the performance of high strength alloys and limit material selection to minimize the risk of subcritical crack growth in service. UNS N07718 is widely used in marine service applications and under a variety of conditions, such as: alternate immersion, different levels of cathodic protection, and freely corroding galvanic couples, because of its demonstrated corrosion and fracture resistance in these environments. In this work we developed a representative model of the material microstructure including the metal grains, the material texture, and the precipitates along the grain boundaries and within the grains. The microstructural model was subjected to the boundary conditions identified at the notch root of a fracture mechanics sample and the results are used as input for a simulation of hydrogen diffusion from the surface of the notch, assuming the material has been introduced to a hydrogen producing environment. The diffusion of hydrogen was modeled by Fick’s law and included both hydrostatic stress and mobile dislocation velocity as driving forces. The influence of immobile dislocations was also modeled to account for the irreversible trapping. The results show that hydrostatic stress and immobile dislocation trapping can significantly alter the highest concentration of hydrogen and its location within the microstructure towards the fracture process zone. Mobile dislocation velocity has a small influence in determining the hydrogen distribution near the fracture process zone.

Facile design of PTFE-kaolin-based ternary nanocomposite as a hydrophobic and high corrosion-barrier coating

Abstract Superhydrophobic nanostructured coatings are a promising technology in construction engineering. This study developed a hydrophobic film through a simple mixing method, utilizing kaolin and polytetrafluoroethylene as additive particles, 1H,1H,2H,2H-perfluoro-decyl triethoxysilane as a modifier, and epoxide resin and polyamide curing agent as adhesives. By controlling variables, it was determined that the C1P0.2EP coating immersed in a 3.5 wt% NaCl solution for 1, 3, and 7 days exhibited the maximum impedance radii of 47,373, 20,334, and 1,982 Ω·cm2, respectively. It also demonstrated the highest Bode modulus values, the largest E corr, and the smallest I corr. Furthermore, after 300 h in a salt spray chamber with a 3.5 wt% NaCl solution, the C1P0.2EP coating showed no rust spots or bubbles, demonstrating its excellent corrosion resistance. Moreover, wear resistance tests and self-cleaning experiments were conducted on the C1P0.2EP coating. The results showed that after 100 friction cycles, the surface exhibited no visible scratches, and the contact angle of the coating decreased by only 4°. Additionally, neither soil particles nor dirty water adhered to the coating, indicating that the C1P0.2EP hydrophobic coating possesses not only excellent corrosion resistance but also superior wear resistance and self-cleaning capabilities.

In-vitro biocompatibility, antibacterial activity, and corrosion resistance of HA-TiO2/ZnO coating fabricated by plasma electrolytic oxidation on Ti6Al4V

The hydroxyapatite/Zinc Oxide (HA-TiO2/ZnO) coatings were grown on the Ti6Al4V substrate by plasma electrolyte oxidation from the CaP-based electrolyte containing 1, 3, and 6 g/L ZnO nanoparticles. XRD results confirmed the presence of ZnO, HA, and rutile phases in all coatings. According to SEM observations, coatings presented the porous morphology as a result of micro-arc discharges during the PEO process, whereas some of the pores in the composite coatings were filled by ZnO proportional to its content. After 7 days of immersion in SBF solution, accumulations of bone-like clusters were visible on the surface, demonstrating a promising bio-mineralization ability for all coatings, although the higher amount of 6 g/L ZnO had partially an inhibitory effect on the apatite nucleation. In-vitro studies demonstrated a time and concentration-dependent impact of ZnO on the viability of MG-63 osteoblast-like cells so that the concentration of 3 and 6 g/L caused the death of some cells after 7 days. The antibacterial tests also showcased that the presence of ZnO decreased the activity of gram-negative bacteria (E. coli) and gram-positive bacteria (S. aureus), while the higher concentration of ZnO particles led to more antibacterial activity of the coating. Finally, evaluating the corrosion behavior of PEO coatings through a potentiodynamic polarization test in Ringer's solution manifested a better protection against corrosion by increasing the ZnO content in the coating, mainly owing to the blocking of the pores by the ZnO particles, and as a result, the greater difficulty of electrolyte to reach the titanium substrate.

Comparative analysis of static and vibration characteristics of glass fiber reinforced epoxy mono composite leaf spring and conventional steel leaf spring

Leaf springs play a vital role in heavy-duty vehicles by offering substantial load support, durability, and convenient maintenance. Lightweight leaf springs enhance vehicle performance, offering benefits like improved fuel efficiency and a smoother ride. Glass fiber reinforced composites enhance fuel efficiency and durability, providing corrosion resistance. Their design flexibility improves ride comfort, and damping properties enhance vehicle stability. The examination conducted through finite element analysis, utilizing ANSYS software, demonstrated a substantial 75.32% decrease in weight for the E-Glass-Epoxy composite leaf spring (GECLS), affirming its efficacy in enhancing strength, reducing weight, and enhancing stiffness. This underscores its superiority as a viable alternative to traditional steel leaf springs (SLS) in vehicular applications. The mono-GECLS exhibited a natural frequency that was found to be 1.9 times higher than that observed in the traditional SLS. It indicates the potential to mitigate resonance issues. After analysing the SLS and GECLS using ANSYS, it was observed that the GECLS exhibits greater values in deflection, natural frequency, and strain energy, measuring 4.659 mm, 29.98 Hz, and 440.68 mJ, respectively, compared to its steel counterpart. Conversely, the SLS demonstrates elevated values in stress, mass, and density, with readings of 283.84 MPa, 3.7695 kg, and 5920 kg/m³, respectively.