High Temperature Corrosion Research Articles

Microstructural and mechanical investigation of dissimilar U-groove weld of IN 718/ASS 304L employing ERNiCr-3 filler

This study investigates the dissimilar welding of Inconel 718 (IN 718) and austenitic stainless steel 304L (ASS 304L) using Gas Tungsten Arc Welding (GTAW) with Ni-based filler ERNiCr-3. IN 718 is valued for its high-temperature stability, oxidation, and corrosion resistance, while ASS 304L offers excellent ductility, formability, and corrosion resistance. The objective is to evaluate the impact of ERNiCr-3 on the weld’s metallurgical and mechanical attributes. The materials, prepared with U-groove edges, were optimized for manual multi-pass welding. Microstructural analysis revealed an austenitic matrix with dispersed Ti(CN) and NbC precipitates, enhancing strength through dispersion-strengthening mechanisms, with no solidification cracking due to Nb presence. FESEM/EDS and colour mapping identified elemental migration and stable carbide formation at the weld interfaces. Mechanical testing revealed uniform hardness within the weld zone and tensile resistance of 510 MPa, underscoring the robustness of ERNiCr-3 weld metal. These results indicate that ERNiCr-3 is highly effective for producing superior quality dissimilar welds amidst IN 718/ASS 304L, making it suitable for applications in elevated-temperature and mechanically demanding environments.

Research Progress on the Relationship Between Microstructure and Properties of AISI 321 Stainless Steel

AISI 321 stainless steel is widely used in chemical pipelines and nuclear power, prompting research on its high-temperature performance and corrosion resistance. This review focuses on the effects of alloy elements, second-phase particle formation, and heat treatment processes on the microstructure and properties of AISI 321 stainless steel. Fine tuning of alloying elements can affect the mode and effect of dynamic recrystallization, altering the high-temperature flow deformation of AISI 321 stainless steel. In order to achieve phase equilibrium, the relationship between corrosion resistance and high-temperature creep behavior and high-temperature mechanical behavior in the presence of second-phase particles was also analyzed. This review outlines the basic heat treatment procedures for improving material properties, providing a new perspective for solution treatment and improving corrosion resistance. In addition, the latest research progress on other factors affecting the high-temperature performance of AISI 321, such as coatings, was briefly introduced.

Experimental Study on the Mechanical Properties of C30 Molybdenum Tailings Concrete after High-Temperature and Sulfate Corrosion

In order to study the durability of molybdenum tailings concrete after a specific period of wet-dry cycle tests and exposure to high temperatures, this paper investigates the rule of change of the mechanical properties of molybdenum tailings concrete under the coupled influence of sulfate corrosion and high-temperature environmental conditions. A total of five C30 concrete prisms with molybdenum tailings content (0%, 25%, 50%, 75%, and 100%) were considered in the tests, with sulfate solution concentrations of 0 g/L, 20 g/L, and 50 g/L, and exposure temperatures of 25° at room temperature and 400° at high temperature, respectively. The test results showed that the mass loss rate of concrete prisms with different molybdenum tailings substitution rates under sulfate corrosion and high temperature environment showed an increasing and then decreasing trend. The specimens with 25% molybdenum tailings content still maintain high mechanical properties after wet-dry cycle tests of sulfate solution and high temperature, and the reduction of peak stress in this group is only 11%, and the reduction of elastic modulus is 1%; the rest of the molybdenum tailings content has a reduction of peak stress of about 25%, and the reduction of modulus of elasticity is more than 10%. The plastic deformation capacity of molybdenum tailings concrete decreases under the single-factor effects of wet-dry cycle tests of sulfate solution and high temperature effects, but the plastic deformability capacity of the specimens is enhanced under the combined effects of multiple factors. The stress-strain curve formulas for molybdenum tailings concrete under high temperature, wet-dry cycle tests of sulfate solution, and coupled wet-dry cycle tests of sulfate solution and high temperature were fitted. The results of this study can provide experimental data and valuable references for the engineering application of molybdenum tailings concrete under wet-dry cycle tests of sulfate solution and high temperature conditions, laying a foundation for further research.

Efficient carburization of high-entropy alloys from polyethylene microplastics using a green mechanochemical process to obtain excellent wave absorbing performance

Polyethylene as a major white pollutant has a significant negative impact on the environment and the human health. Beneficial recycling of polyethylene through mechanochemical processes not only can eliminate environmental hazards, but also enable some beneficial industrial applications. In this work, polyethylene was used as the raw materials of carburization of FeCoNiMn high-entropy alloys (HEAs) by a green mechanochemical method. The phase structure, magnetic properties, high-temperature oxidation resistance, corrosion resistance and electromagnetic-wave absorbing performance of the obtained carburized HEAs were investigated in detail. The carburized-FeCoNiMn HEAs exhibited excellent corrosion resistance, suggesting great application potential for use in harsh environments. Besides, the impedance matching was optimized and the electromagnetic-wave absorption bandwidth was expanded by this carburization process. Specifically, the reflection loss of C10 (FeCoNiMnC0.1) at 8.88 GHz reached −65.07 dB at a thickness of 2.79 mm, and both the C50 (FeCoNiMnC0.5) and C90 (FeCoNiMnC0.9) exhibited a maximum absorption bandwidth of 5.45 GHz. This work provides a new concept of utilizing common microplastic pollutants to achieve efficient carburization of HEAs by a green mechanochemical process.

Effect of laser cladding layers on microstructure and mechanical properties of NiCoCrAlY bond coat

The NiCoCrAlY alloy is usually used as a bonding layer material in thermal barrier coatings (TBCs) system. Owing its excellent high-temperature oxidation resistance and corrosion resistance, it plays a crucial role in maintaining the structural integrity and functionality of TBCs. Laser cladding technology is a flexible and efficient processing technique for the manufacturing of NiCoCrAlY bond coat, with the characteristics of precisely control the layers of the laser cladding and further modulate the quality of the bond coat. Therefore, the investigation on the influence of cladding layers on the microstructure and mechanical properties of the bond coat is of great significance for improving the service performance and lifetime of aircraft engines. To this end, the scanning electron microscopy (SEM), electron backscatter diffraction (EBSD), and X-ray diffraction (XRD) were used in this study to explore the influence of cladding layers on the microstructure and mechanical properties of the NiCrAlCoY bond coat. The results indicate that the microstructure of the cladded alloy can be divided into substrate, heat-affected zone, and cladded zone. The hardness of both the heat-affected zone and the cladded zone increases as the number of cladding layers increases, while the hardness of the substrate maintains constant. In addition, as the number of laser cladding layers increases, so does the residual stress of the cladded alloy.

Combinatorial synthesis of AlNi alloys by low-pressure cold spray deposition and post-laser alloying process

Aluminum-Nickel (AlNi) alloys are of great interest due to their exceptional high-temperature wear and corrosion resistance, making them valuable in transport, energy, and materials processing applications. However, challenges in the production and shaping of these alloys, particularly as thick coatings, remain significant. This study introduces an innovative method for the high-throughput synthesis of AlNi coatings, utilizing a two-step process: low-pressure cold spray deposition followed by laser surface alloying. The combination of these two techniques not only improves the synthesis process but also opens avenues for exploring new material compositions with specific application requirements. This approach holds significant potential for accelerating the development and optimization of advanced coatings and multiphase compounds in applications such as repair and additive manufacturing.Aluminum and nickel powders were co-sprayed to create coatings with controlled compositions ranging from 50Al50Ni to 10Al90Ni (wt%). Subsequent laser treatment induced in-situ alloying and homogenization, resulting in dense, uniform AlNi coatings. The microstructure and chemical composition were characterized using Scanning Electron Microscopy (SEM) and Energy Dispersive X-ray Spectroscopy (EDS), while X-ray Diffraction (XRD) identified the formation of various phases, including Al3Ni and AlNi3 phases. The process demonstrated effective alloying and microstructural homogeneity, with residual alumina present at the surface. Despite the presence of some microstructural defects, such as cracking, this method provides a robust foundation for further refinement and opens new possibilities for tailoring alloy properties through combinatorial cold spray and laser alloying techniques.

FEATURES OF THE FORMATION OF THE PHASE COMPOSITION AND PROPERTIES OF HIGH ALLOY STEEL 03Х17Н3Г9МБДЮЧ

Purpose. Evaluation of the influence of alloying elements of corrosion-resistant steel 03Х17Н3Г9МБДЮч on the phase composition and indicators of high-temperature corrosion. Research methods. In order to check the effect of the chemical composition on the structure of steel 03Х17Н3Г9МБДЮч, laboratory steels were made. The production of these steels was carried out in an induction furnace with a main lining with a capacity of 50 kg. The resulting castings were forged into blanks 40 ´ 80 ´100 mm in size, with subsequent hot rolling into samples 25, 20, and 15 mm thick. Determination of the yield strength of steels was carried out after exposure at a temperature of 850 °С for 10,000 hours. The corrosion resistance of the test samples was determined by the gravimetric method after the samples were completely immersed in molten magnesium. Results. The choice of the main alloying elements was justified and their influence on durability in the aggressive environment of the recovery process of spongy titanium production was determined. A thermodynamic calculation of the changed Gibbs energy in the operating temperature range was performed. The required phase ratio of 03Х17Н3Г9МБДЮч steel was considered and selected based on Scheffler de Long and Potak-Sahalevich diagrams. Scientific novelty. The effect of changing the chemical composition of steel 03Х17Н3Г9МБДЮч within technical conditions on the creep limit and durability in the aggressive environment of the recovery process of the production of spongy titanium was determined. Practical value. It is shown that the alloying complex of corrosion-resistant steel is capable of significantly improving the physical, mechanical and technological properties, and expanding the functional application (purpose).

Ceramic matrix composites for corrosion-resistant next-generation nuclear reactor systems: A conceptual review of enhancements in durability against molten salt attack

Ceramic matrix composites (CMCs) are emerging as a key material class for enhancing corrosion resistance in next-generation nuclear reactor systems, particularly in high-temperature molten salt environments. These environments, critical for advanced nuclear reactors such as molten salt reactors (MSRs), present severe challenges, including aggressive chemical attacks that degrade traditional structural materials over time. This conceptual review explores the development and application of CMCs to improve the durability and corrosion resistance of nuclear reactors exposed to molten salt attacks. CMCs, which consist of ceramic fibers embedded in a ceramic matrix, offer significant advantages, such as high thermal stability, mechanical strength, and improved corrosion resistance compared to conventional materials. This review examines how CMCs can be tailored to withstand harsh operational conditions, with a focus on the selection of ceramic phases, fiber-matrix interactions, and innovative fabrication techniques that enhance their protective capabilities. Key challenges addressed include the optimization of composite design to resist molten salt corrosion, the effects of temperature on the material properties, and the long-term stability of CMCs under extreme conditions. Advances in surface treatments, coatings, and the development of hybrid CMC systems are also discussed, highlighting their potential to further enhance durability. The review outlines the use of advanced characterization techniques, such as high-temperature corrosion testing and in situ microscopy, to evaluate CMC performance in molten salt environments. Additionally, it identifies knowledge gaps in current research, emphasizing the need for long-term studies on CMC behavior under realistic reactor conditions. This review concludes by proposing future research directions and technological advancements required to integrate CMCs into next-generation nuclear reactor designs, aiming to improve system reliability and operational safety.

Development of laser felling modes of gas-thermal coating

The use of copper and its alloys to create parts for metallurgical equipment is associated with an increase in abrasive wear and high-temperature corrosion. In this regard, there is a need to apply a protective coating. In particular, to prevent wear and premature chipping of the metal of copper tuyeres, the surface is hardened with a coating of zirconium dioxide stabilized with yttria oxide by thermal spraying in an air atmosphere. Due to the difference in the coefficient of thermal expansion of copper (at T = 300 K: 16.7 µm/m оС and at T = 750 K: 19.7 µm/m оС) and its low resistance to gas corrosion, the application of zirconium oxide (produced by a preapplied intermediate layer that plays a role in matching the coefficient of thermal expansion (CTE) between the copper base and the ceramic coating. In addition, the intermediate layer protects copper from gas corrosion. In this case, The use of copper and its alloys to create parts for metallurgical equipment is associated with an increase in abrasive wear and high-temperature corrosion. In this regard, there is a need to apply a protective coating. In particular, to prevent wear and premature chipping of the metal of copper tuyeres, the surface is hardened with a coating of zirconium dioxide stabilized with yttria oxide by thermal spraying in an air atmosphere. Due to the difference in the coefficient of thermal expansion of copper (at T = 300 K: 16.7 pm/m °G and at T = 750 K: 19.7 pm/m оG) and its low resistance to gas corrosion, the application of zirconium oxide (produced by a pre-applied intermediate layer that plays a role in matching the coefficient of thermal expansion (CTE) between the copper base and the ceramic coating. In addition, the intermediate layer protects copper from gas corrosion. In this case, nickel-based alloys were used as intermediate layers. The use of nickel as the basis of intermediate layers is due to the fact that copper and nickel form a continuous series of solid solutions, such as cupronickel or monel metal-like structures. This, in turn, assumes a smooth transition of thermophysical properties from copper to nickel alloy. To ensure increased adhesion of the transition layer to copper by increasing the area of mutual contact between copper and the sublayer (dagger penetration) and significantly increasing the homogeneity of the material of the intermediate layer made of a nickel alloy, laser melting of the intermediate sublayer (Ni–B–Si system) was used on a laser complex based on laser LS-5 with a power of 5 kW with a KUKA KR-60HA robot in an argon atmosphere. To test the modes, experiments were carried out on copper samples of a flat shape and a body of rotation. The optimal parameters for the process of melting flat samples were: processing speed 33 mm/s, power from 400 to 3900 W, focal length from 200 to 230 mm, pitch between tracks: 0.25, 0.5 and 1 mm. The optimal parameters for the process of melting rotating samples were: laser radiation power 400–450 W, processing step 0.125; 0.5, focal length from 200 to 210 mm.

Microstructure, mechanical and oxygen-deficient lead-bismuth eutectic corrosion properties of FeCrAlTiMo high-entropy alloy coatings for fuel claddings

The FeCrAlTiMo high-entropy alloy (HEA) coatings were deposited on the ferritic/martensitic (F/M) steel fuel cladding tubes by magnetron sputtering technology to improve their lead-bismuth eutectic (LBE) corrosion resistance. The effects of bias voltage on the microstructure, mechanical and LBE corrosion properties of the FeCrAlTiMo coatings were systematically investigated. The LBE corrosion test shows that the coatings with a bias voltage of −150 V exhibit the best oxidation resistance after exposed to the oxygen-deficient LBE at 600 °C for 500 h, and can be used as a protective candidate coating material for lead-cooled fast reactor (LFR) application. The high-temperature LBE corrosion mechanism of the FeCrAlTiMo coatings under deficient oxygen concentration was also discussed in detail.

Electrophoretic Deposition and Physicochemical Properties of Ni- and Fe-Doped Cu–Mn Spinel Coatings Enhanced with Ce0.9Y0.1O2 Nanoparticles on Fe16Cr Ferritic Stainless Steel Interconnects for SOEC Applications

Cu- and Mn-based spinel coatings are currently among the most promising materials for solid oxide electrolyzer cell (SOEC) interconnects due to their high electrical conductivity and ability to eliminate environmentally hazardous cobalt, which is included in the most widely used coatings. However, their properties are affected by the presence of the Cr2O3 scale and high-temperature corrosion, and to mitigate this they could be doped with elements such as Ni and Fe. In addition, the electrical properties of such steel/shell layered systems can be further improved using rare-earth element nanoparticles (Ce0.9Y0.1O2). In this work, low-chromium steel was modified using nanoparticles and/or spinel coatings and oxidized in air atmosphere at 800 °C for 2000 hours. The oxidized systems were then characterized using diffraction studies, microstructural observations and electrical measurements. Electrical studies in particular showed a significant reduction in area-specific resistance for steels modified using a combination of both nanoparticles and spinel coatings.

Electrochemical Machining of Micro-Pit Arrays on a GH4169 Alloy with a Roll-Print Mask Using a C6H5Na3O7-Containing NaNO3 Mixed Electrolyte.

GH4169 alloy, a nickel-based superalloy known for its excellent high temperature resistance, corrosion resistance, mechanical properties, and high-temperature tribological properties, is widely used in industrial applications, such as in gas turbines for space shuttles and rocket engines. This study addresses the issue of electrolyte product residue in the electrochemical machining process of a GH4169 alloy by utilizing a C6H5Na3O7-containing NaNO3 new mixed electrolyte. Comparative investigations of the electrochemical behavior and electrolyte product removal mechanisms at different concentrations of C6H5Na3O7 additive in NaNO3 solutions were conducted. The effects of additives, applied voltage, and the rotating speed of the cathode tool on the processing performance of micro-pit arrays on a GH4169 alloy were analyzed. The results indicate that the mixed solution containing C6H5Na3O7 significantly improves the localization and geometric morphology of the micro-pits compared to a single NaNO3 solution. The optimal electrochemical machining parameters were identified as 0.5 wt% C6H5Na3O7 + 10 wt% NaNO3 mixed electrolyte, 12 V applied voltage, and 0.1 r/min rotating speed of the cathode tool. Under these conditions, high-quality micro-pit arrays with an average diameter of 405.85 μm, an average depth of 87.5 μm, and an etch factor (EF) of 1.67 were successfully fabricated, exhibiting excellent morphology, localization, and consistency.

Enhancing high-temperature chloride molten salts corrosion resistance of 310S steel with Si-added Ni–Al coating

Ni–Al based coating is one of the common high temperature and corrosion resistant protective coatings. In the present paper, the effect of Si content on the formation of Al2O3 layer and the corrosion resistance of Ni–Al coating to chloride molten salt was studied. The research results show that the Ni–Al coatings with varying Si content mainly form NiAl2O4 and Al2O3 oxide layers after pre-oxidation, and form a three-layer structure after molten salt corrosion. The appropriate amount of Si added to the Ni–Al coating can promote the formation of the α-Al2O3 layer during pre-oxidation and thermal corrosion, improving the corrosion resistance of the coating to high temperature chloride molten salt, and hindering the diffusion of Cr elements. Particularly, the Ni–Al coating with Si content of 1.2 at.% has the thickest and densest Al2O3 protective layer, showing the best corrosion resistance. The simulation results shows that compared with the Ni–Al coating without Si, the Cl atoms in the Si-added Ni–Al coating need to overcome greater energy barriers to diffusion during the molten salt corrosion process, which also indicates that the addition of Si can improve the corrosion resistance of the coating.

A Review of CiteSpace Visualisation and Analysis of High-Temperature Corrosion Inhibitors for Oil and Gas Fields

With the increasing global energy demand, the exploitation depth of oil and gas fields is gradually increasing. At the same time, importing many high-acid crude oil makes it increasingly heavy and inferior, and its acid value is constantly improving. This change has led to the increasingly severe corrosion problem of oil and gas field equipment, which has become an essential factor affecting the national economy and society's sustainable development. As an economical and practical anticorrosion measure, corrosion inhibitors play a crucial role in the anticorrosion of oil and gas field equipment. Through the research method of biorientation, retrieve the Web of Science database in 2008-2024 about oil and gas field high-temperature corrosion inhibitor research literature information, using CiteSpace measurement analysis software visual analysis in the literature keywords, publications, high citation frequency, cooperation and word clustering information change trend, analyze the research situation of oil and gas field in recent years, summarizes the research hotspot of oil field high-temperature corrosion inhibitor, prominent authors and institutions, reference relationship and development trend. The number of documents on high-temperature corrosion inhibitors in oil and gas fields is smaller, and the authors, institutions, and countries are not closely related. There is less research cooperation on high-temperature corrosion inhibitors in oil and gas fields, and more independent studies exist. China University of Petroleum has the first number of publications, and China is the country with the first number of publications. The study of mass spectrometry for corrosion inhibitors in oil and gas fields is prominent, while the literature on high-temperature corrosion inhibitors is rare.

Effect of grain size on high-temperature corrosion performance of laser cladding inconel 625 coating

As the calorific value of waste-to-energy incineration continues to rise, the corrosion damage to boilers becomes increasingly severe. The impact of the grain size on the high-temperature corrosion resistance of Inconel 625 coating was investigated. The results indicated that the corrosion performance of the coating in 1:1 NaCl–KCl salts at 700 °C for 120 h was highly dependent on the grain size of the coating. The coating fabricated with a laser power of 1800 W and an overlapping distance of 1.5 mm had an average grain size of 13.7 μm and highest hardness, exhibiting the best corrosion performance, with a corrosion weight loss of 1.4 mg/cm2. Coatings processed under different conditions all formed a three-layered structure, with a NiO outermost layer, a Cr2O3 intermediate layer, and an innermost Cr-depletion zone. Coatings with finer grains formed a continuous and dense protective oxide layer of NiO and Cr2O3 due to the rapid diffusion of alloy elements, effectively preventing the invasion of corrosive media and protecting the substrate from corrosion.

Recrystallization of amorphous AlNbCr coatings irradiated with chromium ions

Applying an AlNbCr layer on the surface of Zr alloys significantly enhances the alloy resistance to oxidation and high-temperature corrosion. However, the effects of irradiation on AlNbCr coating remain largely unexplored. This work investigates the microstructural evolution of Cr ion-irradiated AlNbCr coatings under varying temperatures, utilizing bright-field transmission electron microscopy (TEM) observations and electron diffraction pattern analyses. With increasing Cr ion irradiation dose, the coatings gradually transitioned from an initial amorphous to a crystalline state. The onset of crystallization occurred earlier at higher temperatures, indicating that the crystallization process was significantly influenced by temperature. Moreover, the dynamic crystallization process of the crystalline structure was also analyzed, as well as the different irradiation responses at the Near-Interface Area (NIA) and Far-Interface Area (FIA). These findings provide new insights for understanding and optimizing the performance of AlNbCr coatings in high-irradiation environments.

High Temperature Corrosion Study on NiCr Coated Low Alloy and Mild Steel

Cyclic hot corrosion behaviour of bare and D-gun sprayed NiCr coated low alloy and mild steel sample having dissimilar coating thicknesses viz. 0.2-0.25 mm and 0.25-0.30 mm have been studied in molten salt environment mixture of Na2SO4 - 25wt. % NaCl at temperature of 750 ̊C. Corrosion kinetics were analysed and parabolic rate constants (Kp) for both bare and coated sample were calculated and observed that 0.2-0.25 mm thick NiCr coated specimen showed better resistance against high temperature corrosion for both materials. SEM/EDX analysis was carried out to examine scale formed on the bare and coated sample after hot corrosion.

Improving hot corrosion behaviour of Cr3C2-25NiCr coatings by reinforcing nano yttria stabilized zirconia at 850 °C

Yttria-Stabilized Zirconia (YSZ)-enhanced Cr3C2-25NiCr coatings were applied to T22 boiler tube steel using the High Velocity Oxy Fuel (HVOF) method. Conventional Ni-20Cr, 5 wt.% YSZ- Cr3C2-25NiCr, and 10 wt.% YSZ- Cr3C2-25NiCr composite coatings were prepared. High-temperature corrosion tests were conducted on both uncoated and coated samples in a Na2SO4-60%V2O5 environment at 850°C under fluctuating thermal conditions. These experiments were carried out in a silicon tube furnace at high temperatures, with each sample subjected to 50 cycles of exposure. Each cycle consisted of 1 hour in the corrosive environment followed by 20 minutes of cooling at room temperature. Corrosion products were analyzed using energy-dispersive x-ray analysis (EDS) and scanning electron microscopy (SEM). The addition of YSZ to the Cr3C2-25NiCr coatings significantly improved corrosion resistance, with the Ni-20Cr, 5 wt.% YSZ-Ni-20Cr, and 10 wt.% Cr3C2-25NiCr coatings reducing overall weight gain by 73.08%, 84.70%, and 89.96%, respectively, compared to uncoated T22 steel.

High temperature long-lasting corrosion inhibition mechanism of sodium dodecyldiphenyl ether disulfonate on ADC12 aluminum alloy in oxalic acid solution

The high temperature corrosion inhibition mechanism of sodium dodecyl diphenyl ether disulfonate (MADS) on ADC12 aluminum alloy in oxalic acid solution at 80 °C was investigated using electrochemical measurements, surface characterization and theoretical computations. The results manifested that MADS still had excellent performance in high-temperature oxalic acid solution, and was a highly efficient and long-lasting corrosion inhibitor with an optimal corrosion inhibition efficiency (ƞ) of 90.90 %. With increasing soaking time, the ƞ increased to 98.70 %. MADS molecule adsorbed on the aluminum alloy surface in an L-shaped walking scooter configuration through physicochemical adsorption to form a dense, thin and stable hydrophobic film, inhibiting the formation of aluminum oxalate and Al2O3, and protecting it from corrosion.

Study of corrosion and failure mechanism of the galvanized steel pipes of meteorological tower serviced in the South China Sea

Corrosion issues of steel in the natural tropical marine atmospheric environment widely exist, and they can easily cause the failure of engineering equipment. However, the related studies are poor. Therefore, a deep analysis of the corrosion behavior and failure mechanism of steel materials in natural environments is urgent and important. In this work, the corrosion and failure mechanisms of galvanized steel pipes of a meteorological tower in the South China Sea were deeply studied. Results demonstrated that galvanized steel pipes at a low height happen a serious uniform and localized corrosion, while the bottom surface of each pipe facing the ground is severely corroded. The damage to the galvanized layer and the subsequent steel corrosion in high temperature and humidity conditions are mainly caused by bacteria and Cl−. Some bacteria with high corrosivity, such as Desulfovibrionales, Seminibacterium, Acinetobacter, Ralstonia, Proteobacteria Streptococcus, and Lactobacillus, are found beneath the rust layer, and they can significantly accelerate steel corrosion. The maximum localized corrosion rate is 0.20 mm/y.