Carbon Steel Specimens Research Articles

Synergistic inhibition effect of Chlorella sp. and benzotriazole on the corrosion of Q235 carbon steel in alkaline artificial seawater

The interaction of microalgae on the reinforced concrete with corrosion inhibitor is not well understood. Moreover, the inhibition role of microalgae on corrosion has been reported in recent years. In this study, the corrosion inhibition behavior of Q235 carbon steel (CS) due to the presence of Chlorella sp. and benzotriazole (BTA) in alkaline artificial seawater was investigated by means of weight loss, electrochemical measurements including open circuit potential, electrochemical impedance spectroscopy, and potentiodynamic polarization curves, and surface analysis including scanning electron microscopy, energy dispersion spectrometer, and X-ray photoelectron spectroscopy. The results of reduced corrosion rates in the algae-BTA system demonstrated that Chlorella sp. could facilitate the corrosion inhibition efficiency of BTA on the CS specimens. Moreover, polarization measurement showed the algae-BTA system had a mixed-type corrosion inhibition effect. The mechanisms of inhibition were proposed to be the precipitation of iron complexes such as Fe-BTA-EPS and Fe-BTA and iron compounds on the steel surface in the presence of the microalgae and BTA–. This study highlights the application of CS corrosion control by combining biological and chemical approaches that can be used for future research and practice, rather than purely chemical approaches.

تأثير استعمال ليزر النيوديميوم ياك (Nd-YAG) على البنية الدقيقة وصلابة سطح الفولاذ AISI1012

The unique characteristics of the laser beam such as directionality, monochromaticity, and brightness make it a very important tool in the surface treatment engineering. The concentrated heat in the laser beam can be precisely directed toward the processed region on the surface. The laser beam power, beam size, and scanning velocity are easily controlled during the different processing methods. Laser surface modifications of metallic materials, such as laser surface melting, laser surface alloying, and laser cladding are some of the most important methods to improve the mechanical properties of the processed layer on the surface. A pulsed Nd-YAG laser surface melted specimens of low carbon steel with a maximum power of 90W at different processing parameters. The rapid melt and solidification of the treated layer produced a refinement in the microstructure. The original microstructure of this steel (Ferrite + Pearlite) has been transformed to new phases of martensitic and bainitic structures. The melted layer consists of the melted pool, the heat affected zone, and the substrate. The maximum hardness of the laser melted layer is more than 400 HV. The effect of different lasers such as high power CW CO2 laser on the mechanical properties and corrosion resistance of steel alloys will be carried out in future studies. Keywords: Nd-Yag Laser, Laser surface treatment, Microstructure and hardness of AISI1012 steel

Spatial-frequency parallel subsampling for distributed compressive sensing in ultrasonic imaging inspection

To address the problem of the high hardware requirements and insufficient data storage capacity in current ultrasonic imaging testing, a novel approach is developed using a programmable device, which combines spatial-frequency parallel subsampling with the distributed compressive sensing simultaneous orthogonal matching pursuit (DCS-SOMP) algorithm to achieve fast and high-quality ultrasonic imaging inspection with a small amount of subsampled data. The spatial sparse measurement method was employed to achieve spatial subsampling and minimize the count of signals. Additionally, frequency subsampling was utilized to significantly reduce the data volume of time-domain signals while ensuring signal quality by truncating the primary testing frequency components. The subsampled data was then reconstructed using distributed compressive sensing (DCS) for multi-channel data reconstruction. The experiment of ultrasonic scanning imaging was conducted on a carbon steel specimen containing six transverse through-holes with a diameter of Ф1.5 mm at different depths. The ultrasonic signals were acquired using the spatial-frequency parallel subsampling method, and subsequently reconstructed using the DCS-SOMP algorithm. The results show that the proposed method achieves comparable image quality to that obtained with complete data, using only 1/8 of the complete data, while accurately locating and quantifying defects.

Fatigue assessment of structural components through the Effective Critical Plane factor

The integrity assessment of structural components under complex loading conditions relies on the evaluation of the fatigue damage typically arising from stress concentrations, such as geometric irregularities, notches, weld beads, grooves etc.. Various methodologies, including the Notch Stress Approach (NSA), the Theory of Critical Distances (TCD), the Strain Energy Density (SED), and the Critical Plane (CP) concept, have been pivotal in assessing fatigue strength for notched and welded components. Recent works combine some of the above mentioned methodologies, while other works propose to vary the embedded parameters accounting for the loading type or the fatigue lives, trying to improve the accuracy of the fatigue assessment process. This paper introduces a novel approach, the Effective Critical Plane (ECP), which is founded on the critical plane concept. The CP factor is, however, calculated starting from an averaged, over a small volume, stress–strain field. The size of the averaging volume is assumed to be a material parameter and is determined by a best fitting procedure over different experimental data sets. The novel approach is illustrated by means of the Fatemi-Socie and the Smith-Watson-Topper CP damage factors. Its potential application to other CP formulations is straightforward, as well. Literature experimental data for low carbon steel specimens possessing different notches and loading conditions are used to validate the method’s capability in accurately determining the fatigue life and to set the radius of the averaging volume for the given material and CP parameter. A spherical volume or circular area are used in case of fully 3D or 2D numerical models, respectively. Results are compared to those of some of already existing methods, namely SED, TCD and the Modified Wöhler Curve Method.

Antimicrobial non-porous surfaces: a comparison of the standards ISO 22196:2011 and the recently published ISO 7581:2023.

The application of antimicrobial surfaces requires the proof of their effectivity by in vitro methods in laboratories. One of the most well-known test methods is ISO 22196:2011, which represents a simple and inexpensive protocol by applying the bacterial suspension with known volume and concentration covered under a polyethylene film on the surfaces. The incubation is then done under defined humidity conditions for 24 h. Another approach for testing of non-porous surfaces is the newly published ISO 7581:2023. A "dry test" is achieved through spreading and drying 1 μL of a bacterial suspension on the surface. In this study, low alloyed carbon steel, polyethylene terephthalate (PET), and glass specimens were tested uncoated (reference) and coated with zinc according to both ISOs to compare and to evaluate the advantages and disadvantages of each one of them. Although ISO 7581:2023 allows a more realistic test environment than ISO 22196:2011, the reproducibility of the results is not given due to the low application volume. In addition, not all bacterial strains are equally suitable for this testing type. Individual adaptations to the protocols, including incubation conditions (time, temperature, or relative humidity), testing strains and volume, seem necessary to generate conditions that simulate the final application. Nevertheless, both ISOs, if used correctly, provide a good basis for estimating the antimicrobial efficacy of non-porous surfaces.

Effect of anions on formation of ferrite coatings on carbon steel by hydrothermal method

The major concerns in Primary Heat Transport circuits of water cooled nuclear power plants are corrosion of structural materials and radiation field buildup on out-of-core surfaces due to accumulation of activated corrosion products. To address these concerns, hot conditioning and metal ion passivation are employed, which lead to the formation of protective magnetite coating on structural alloys like carbon steel. In this study, investigations were undertaken to modify the magnetite/ferrite films hydrothermally in the presence of zinc (Zn2+) and nickel (Ni2+) ions by using different salts of these ions containing anions such as acetate, nitrate and sulphate. Mixed ferrite coatings containing Zn2+ and Ni2+ ions were developed on carbon steel in lithiated water in presence of these anions at 250 °C by hydrothermal method and subsequently characterized by grazing incidence-X-ray diffraction for phase identification and scanning electron microscopy for surface morphology. The effects of these anions were studied by comparing the corrosion resistance properties of ferrite coated carbon steel specimens. The corrosion properties were studied in lithium hydroxide medium at ambient temperature by electrochemical techniques and the results of the investigation are discussed in this paper.

Corrosion inhibition properties of sweet crude oil for carbon steel 1018 in NaCl solution

Abstract Aged oil pipeline production systems, historically designed without corrosion protection due to predominantly oil-wetted conditions, now face significant changes as increased water content in produced oil arises from field maturation. This work investigates the corrosion inhibition properties of sweet crude oil on carbon steel 1018 in a CO2-saturated NaCl solution using electrochemical testing (open circuit potential, polarization resistance, electrochemical impedance, potentiodynamic polarization) and surface characterization (SEM, EDS) techniques at 50 °C and pH 6. Carbon steel specimens were immersed in crude oil for durations ranging from 0 to 144 h before undergoing corrosion testing. Results showed that a 144-h immersion in crude oil led to an 88 % reduction in corrosion rate, comparable to the efficiency of standard quaternary ammonium-based inhibitors. Furthermore, a semi-empirical model predicting uniform CO2 corrosion rates for varying oil immersion durations is proposed and validated by comparing its predictions with experimental data from the electrochemical tests.

Accelerated corrosion of low carbon steel by oscillatory acidic streams generated with a bio-inspired claw device.

A mechanical device inspired by the pistol shrimp snapper claw was developed. This technology features a claw characterized by a periodic opening/closing motion, at a controlled frequency, capable of producing oscillating flows at transitional Reynolds numbers. An innovative method was also proposed for determining the corrosion rate of carbon steel samples under oscillating acidic streams (aqueous solution of HCl). By employing very-thin carbon steel specimens (25 μm thickness), with one side coated with Zn and not exposed to the stream, it became possible to electrochemically sense the Zn surface once the steel sample was perforated, thus providing the average dissolution rate into the most relevant pit on the steel surface. Furthermore, a laser light positioned beneath the metallic sample, along with a camera programmed to periodically capture images of the steel surface, facilitated the accurate counting of the number of newly formed pits. The system consisting of the thin steel sample and the Zn coating can be seen as a type of corrosion sensor. Furthermore, the proposed laser illumination method allows corroborating the electrochemical detection of pits and also establishing their location. The techniques crafted in this study pave the way for developing alternative corrosion sensors that boast appealing attributes: affordability, compactness, and acceptable accuracy to detect in time and space localized damage.

Evaluation of ionic liquids based imidazolium salts as an environmentally friendly corrosion inhibitors for carbon steel in HCl solutions

The features of this work on corrosion inhibition have been investigated based on the ecological awareness and according to the strict environmental legislations. This was done by studying how different imidazolium derivatives ionic liquids containing different alkyl chains R8, R10 and R12 affected the corrosion reaction of carbon steel specimen immersed in 1 M hydrochloric acid at various temperatures. Weight loss, potentiodynamic polarization and electrochemical impedance spectroscopy were utilized to examine the corrosion inhibition behavior on carbon steel. In addition, FT-IR spectroscopy was used to analyze the coated film that has been formed on the metal surface. The prepared ionic liquids showed effective inhibition efficiency, where the corrosion rate after the using of 100 ppm of R8-IL, R10-IL and R12-IL was decreased from 5.95 (µg cm−2 min−1) to 0.66, 0.56, and 0.44 (µg cm−2 min−1), respectively at 20 °C. In the polarization curves, the corrosion current, Icorr, decreases by ILs addition and suggest that ILs act as mixed type inhibitors. From EIS findings, the increase in Rct and decrease in Cdl values proves the adherence of inhibitor molecules on carbon steel surface. The temperature effect was also studied on the film formed, where increasing the temperature from 20 to 50 °C, the corrosion rate increased and the inhibitors efficacy decreased. The increasing in the length of the attached alkyl chain, the efficacies of the prepared inhibitors increases. Various thermodynamic parameters such as the reaction activation free energy (ΔG*), the entropy of activation (ΔS*), and the enthalpy of activation (ΔH*), as well as the adsorption isotherm were investigated in order to interpret the mechanism and obtain the most accurate perception.

Analysis of Beibu Gulf tidal zone exposure on properties of carbon steel

Marine tidal zone is a corrosive environment that has a negative impact on carbon steel. This research investigates the change of mechanical properties and corrosion behaviour of carbon steel specimens subjected to field exposure test and simulation test for 12 and 6 months, respectively. The corrosion behaviour of carbon steel exposed to real marine tidal zone and simulation environment was discussed through morphological observation and corrosion kinetics analysis, in order to reveal the essential reason for the degradation of its mechanical properties. Then the tensile test was performed on the corroded specimens and true stress–strain curves were obtained. In addition, regression equations were derived for the mechanical properties as a function of the degree of corrosion degradation and a constitutive model with time factor for corroded carbon steel is proposed.

Axial/torsional fatigue tests on notched tubular specimens of carbon steel and life estimation using theory of critical distance method

The present study aims to bring out the individual effect of peak equivalent strain and strain gradient on the fatigue life in presence of notch/discontinuity. Tests have been conducted under remote pure axial and pure torsion conditions on tubes of C-Mn steel with single circular hole. Tubes having different size holes have been taken to study the effect of strain gradient. The remote strain amplitude has been so adjusted that it results nearly same peak equivalent strain amplitude (using pre-test FE analyses) for different size holes. This test methodology brings out the individual effects of fatigue damage in terms of fatigue crack initiation life as a function of strain gradient (owing to different hole size) and peak equivalent strain amplitude at hole tip.Further, the localized strains ahead of hole have been measured using digital image correlation and strain gauge techniques. The fatigue life has been predicted using point based critical distance and critical plane models. The predicted fatigue life is compared with test fatigue life for different hole sizes and remote pure axial/ pure torsion conditions.

Experimental and theoretical approach for a better understanding of the mechanisms of adsorption and inhibition of corrosion for carbon steel by thiazolidine derivatives in 1 M HCl medium.

Many sectors have employed various strategies to prolong the life of steel because of its strength and high manufacturing and installation costs. The use of organic inhibitors has been widespread in recent years. The purpose of this investigation is to evaluate the activity of recently synthesized derivatives, namely (Z)-5-benzylidenethiazolidine-2,4-dione (FT-2a), (Z)-5-(2,4-dichlorobenzylidene)thiazolidine-2,4-dione (FT-2c), and (Z)-3-allyl-5-(2,4-dichlorobenzylidene)thiazolidine-2,4-dione (FT-3c), in inhibiting corrosion through electrochemical assays on carbon steel (CS) in 1 M HCl at 303 K. The chosen products (FT-2a, FT-2c, and FT-3c) were selected as corrosion inhibitors due to their eco-friendly composition and biodegradability, aligning with the increasing demand for sustainable products. The findings revealed that the inhibitory activities of FT-2a, FT-2c, and FT-3c improved with increasing concentration, reaching maximum values of 94.10%, 95.30%, and 96.50% for FT-2a, FT-2c, and FT-3c, respectively. In contrast, the corrosion mitigation effectiveness decreased by around 22.69% (for FT-2a), 18.87% (for FT-2c), and 17.81% (for FT-3c) with the rise in temperature from 303 to 333 K. An overview of potentiodynamic polarization (PDP) plots revealed that the three products function as mixed-type inhibitors and adsorb according to the Langmuir isotherm in the corrosive 1 M HCl solution. Surface analysis [scanning electron microscopy (SEM-EDX), contact angle (CA), and X-ray diffraction (XRD)] of the CS specimens demonstrated that the chosen inhibitors were absorbed and formed protective layers that mitigated the impact of corrosion. Strong interactions between FT-2a, FT-2c, and FT-3c molecules and Fe ions at particular atomic sites were identified by analysis of UV-visible spectra. Using techniques such as Fukui functions, molecular dynamics simulations (MDS), and DFT calculations, the impact of the molecular structure of FT-2a, FT-2c, and FT-3c on their capacity to suppress corrosion was investigated. In addition, the protonation of thiazolidine derivatives in acidic media was studied. The results of these various methods were very coherent.

In Situ Fatigue Damage Monitoring by Means of Nonlinear Ultrasonic Measurements

In the present work, the results of acoustic nonlinear response of ultrasonic wave propagation when monitoring the progress of damage induced by fatigue on notched C45 carbon steel specimens have been reported. Two ultrasound probes were fixed to the specimens during the tests. The input signal was sinusoidal type, while the corresponding ultrasound response signal was acquired and recorded at each stage of the test by means of a digital oscilloscope. A nonlinear frequency study was performed on the acquired data to evaluate the change in the second- and third-order nonlinearity coefficients of β1 and β2, respectively, on the tested specimens. Ultrasonic results were correlated to plastic strain at the notch tip in the initial phases of fatigue and stiffness degradation. The results showed a significant increase in second-order nonlinearity β1 in the early stages of fatigue life. Subsequently, starting from about 30–40% of the fatigue life, the nonlinearity of β1 increases. Before final failure, from 80 to 85% of fatigue life, the second-order nonlinearity further increases in the crack propagation stages. The nonlinear parameter of the third-order β2 was less sensitive to damage than the parameter β1, showing a rapid increase only starting from approximately 80 to 85% of the fatigue life. The proposed method proved to be valid for detective damage induced by fatigue and to predict the lifetime of metal materials.

A detailed study of short fatigue crack directions for carbon steel specimens with circular holes subject to cyclic biaxial loads

The effect of notches and biaxial fatigue loading on the crack paths was studied in detail for thin-walled tube specimens with a passing-through hole, paying special attention to the short-crack period. The study was focused on the high cycle fatigue regime. The material was a carbon steel and the tests were under load control, at Rσ=−1. The crack initiation point on the notch surface and the crack direction were studied with an optical microscope on the specimen outer surface and with a scanning electron microscope and a non-contact 3D optical profilometer on the fracture surface. The crack direction was analyzed for several crack lengths, ranging from the length of one average grain to the length of twenty average grains, all lengths within the short-crack regime, in order to carefully observe the evolution of the crack direction in the Stage I and during the transition from Stage I to Stage II. A statistical analysis of the crack initiation point and the experimental crack directions was carried out. In general, the crack initiation point was close to the maximum principal stress point. The crack direction during the first grains was approximately the Mode I direction. There was no initiation in Mode II. The crack continued in the Mode I direction as it got longer, within the short-crack period. The experimental fatigue limits were compared with the predictions calculated with two models from the literature. The direction of the straight lines used by the models to make the predictions were compared with the average crack directions measured experimentally. The goodness of the models, not only from the point of view of the fatigue limit value prediction but also from the closeness of the direction of the line used for the prediction to the experimental crack direction, was discussed.

Study of corrosion properties of carbon steel, 304 and 316L stainless steels in sulfuric acid and their degradation products

In this study, corrosion properties of carbon steel and stainless steels, and degradation of sulfuric acid by the corrosion mechanism are presented. Carbon steel (CS), 304 stainless steel (SS304), and 316L stainless steel (SS316L) specimens were analyzed through their electrochemical response by using a potentiostat measurement. The specimens were submerged in concentrated 98 wt.% of H2SO4 acid for 0 day to 60 day. The degradation of H2SO4 was determined by its volume change, turbidity, and color due to the corrosion mechanism. Corrosion rate of CS, SS304 and SS316L specimens are 43.237 mm/year, 0.420 mm/year and 0.086 mm/year, respectively. After 60 days, the weight-loss of CS, SS304 and SS316L specimens are 48 wt%, 33 wt% and 0.1 wt%, respectively. Corrosion resistance of the materials are influenced by the passive oxide layer that forms on its surface and associated with electrochemical activity or semiconductive composition. The degradation of H2SO4 acid was observed due to the corrosion process of specimens and related to the turbidity and volume increase while the wt% concentration of H2SO4 acid decreases. In order to make material choices that enable continuous and safe operation of the process, it is important to understand the corrosion mechanism changes.

Corrosion mitigation of carbon steel using triazole Mannich base derivatives: Correlation of electrochemical studies with quantum chemical calculations

The study investigated the corrosion-inhibitory properties of three synthetic triazole Mannich bases on C1018 carbon steel using various electrochemical techniques. The inhibitors, namely 4-amino-2-[(4-methylpiperazin-1-yl)methyl]-5-(pyridin-4-yl)-2,4-dihydro-3H-1,2,4-triazole-3-thione (4MPT), 4-amino-2-[(piperidin-1-yl)methyl]-5-(pyridin-4-yl)-2,4-dihydro-3H-1,2,4-triazole-3-thione (PPT) and 4-amino-2-[(morpholin-4-yl)methyl]-5-(pyridin-4-yl)-2,4-dihydro-3H-1,2,4-triazole-3-thione (MPT), demonstrated the high inhibition efficiencies of 92.8%, 93.3% and 92.6%, respectively, and adhered to the Langmuir adsorption isotherm. The inhibitors also functioned as mixed-type inhibitors and improved the protective layer on the metal surface. The study also utilized scanning electron microscopy - energy dispersive x-ray (SEM-EDX) analysis to examine the surface morphology of the uninhibited and inhibited carbon steel specimens. Furthermore, density functional theory (DFT) was utilized for theoretical calculations, which corroborated with experimental measurements.

Bounding surface plasticity model modification for ratcheting of metals

The Bounding Surface (BS) plasticity model for metals is modified according to the proposition introduced in the works of Burlet and Cailletaud (1986) and Delobelle (1993) for the kinematic hardening of a classical Armstrong/Frederick (AF) model, called the BCD modification from the initials of the foregoing authors. The BCD modification was introduced in the relative kinematic hardening between Yield Surface (YS) and BS, unlike its introduction in the absolute and single kinematic hardening of YS for an AF model, hence, achieving two objectives: first, maintaining the inherent feature of BS for decoupling plastic modulus and direction of kinematic hardening, and, second, allowing a flexibility as to the relative kinematic hardening direction without altering the value of the plastic modulus, a property of BCD modification. In addition, the introduced BCD modification for the BS is significantly modified itself, by introducing a properly varying modification parameter instead of the fixed one used in the original works. This simple feature of the novel BCD modification provides a dramatically improved capability to simulate multiaxial ratcheting (MR), because it affects directly the changing flow rule direction, due to the relative kinematic hardening, during complex multiaxial loading, without sacrificing accurate simulations under uniaxial ratcheting (UR) since the plastic modulus is not affected. An additional significant contribution to successful UR simulations is provided by the free-to-choose kinematic hardening of the BS, since the BCD modification is applied only to the relative kinematic hardening between BS and YS. The new model, named SANIMETAL-BCD, is shown to yield superior or equal simulations of UR and very complex MR experimental data for three Carbon Steel specimens, in comparison with other models, within a much simpler constitutive framework. Shortcomings and future necessary improvements are discussed in details.

Investigation of carbon steel corrosion rate in different acidic environments

This study focused on evaluating the rate of carbon steel corrosion in one molarity of HNO3 H2SO4 and HCl in various acidic conditions. The twenty-day exposure of carbon steel specimens to acidic conditions was investigated and followed by the evaluation of corrosion penetration rate and mils per year. The results showed that the 1 M HNO3 solution was the most damaging to carbon steel due to its oxidizing character. Among the tested acidic media HNO3 was the most harmful followed by H2SO4 and HCl. Carbon steel metal's corrosion behaviour was affected by acid medium strength and exposure duration. Dissolving of carbon steel increased with increasing corrosive media severity and exposure time. Concept of passive behaviour in metals has been proposed as the primary reason for this effect. The corrosion penetration rate values for carbon steel used in the present investigation followed the order of HNO3 > H2SO4 > HCl when exposed to the three acidic environments. The maximum corrosion penetration rate values for carbon steel metal subjected to HCl H2SO4 and HNO3 were determined to be 0.008952 (2nd day) 0.03095 (1st day) and 0.039373 (1st day) respectively. In addition corrosion penetration rate values steadily dropped throughout the final days of immersion eventually becoming essentially constant in all acidic media. As a result of the greater impact of all the acidic media used in this investigation corrosion pitting occur on carbon steel consistently. By intensifying the acid medium these effects were exacerbated.

Influences of abrasive particles on tribological behaviours of rotary vane steering gear seals under oil

The wear particles often cause the abnormal wear processes to the rotary vane seals, which lead to seals failure and dropping hydraulic oil pressure, and eventually result in losing of the function of rotary vane steering gear. Clarifying the friction and wear mechanisms between the vane seals and the cylinders and extracting their key wear characteristics are the keys to extend the service life and realize intelligent fault diagnosis of the rotary vane steering gears. Different kinds of hydraulic oils mixed up with different sizes of iron particles were chosen to investigate the abrasive particles on the wear behaviours between the polyurethane polymer and carbon steel specimens. The wear characteristics such as coefficients of friction (COF), wear morphologies, frictional-induced vibration signals were examined and analyzed synthetically. The results showed that the coefficients of friction, wear morphologies, surface roughnesses and vibration signals increased as a function of the iron particle sizes, which indicated that the wear state was gradually worsening. The three-body friction and wear mechanisms were disclosed clearly. There was a certain mapping relationship between the wear characteristics and wear states, and sensing the tribological information between the rubbing pairs, including coefficient of friction, abrasive particle size in hydraulic oil, wear morphology, vibration signal and other characteristics, was a potential and effective way for evaluating or predicting the wear states or failure modes of rotary vane steering gear seals. This study provides a theoretical basis for revealing the friction and wear mechanisms of ship rotary vane steering gear seals, and is useful for accomplishing their intelligent monitoring and fault diagnosis.

Use of waste to wealth process derived sustainable silica-rich graphene analogues to provide enhanced corrosion resistance properties for coatings on carbon steel, exposed to marine environments

Here, we have demonstrated the effects of the application of silica-rich green-graphene analogues (SRGA) mixed epoxy coating on carbon steel in terms of corrosion resistance and other properties. The anticorrosion performance of SRGA/EP coatings with various concentrations (0.05 wt%, 0.1 wt%, and 0.5 wt% SRGA) on carbon steel in 3.5 wt% NaCl was investigated using the potentiodynamic polarization technique (PDP) and electrochemical impedance spectroscopy (EIS). The surface morphologies of pure epoxy (EP) and SRGA/EP-coated specimens were investigated by scanning electron microscopy (SEM). Incorporating the SRGA/EP coating approach on carbon steel pipes can improve the thermal stability, hydrophobicity, and surface finish of the produced composite coatings. The corrosion inhibition efficiency of 0.1 wt% SRGA/EP-coated carbon steel specimens was 99 % higher than uncoated carbon steel specimens. The thermal stability of 0.1 wt% SRGA/EP coating was improved by 5–7 % compared to pure EP coating. The synthesized SRGA/EP coating showed acceptable uniform distribution on the carbon steel. The average roughness (Ra) of SRGA/EP-coated carbon steel was 67.8 % lower compared to the uncoated ones and 37.3 % lower than the pure EP-coated carbon steel specimens. These materials, derived from green processes can be suitable replacements for traditional toxic chemicals employed for corrosion-resistant coating in carbon steel surfaces of water pipes. Apart from the benefits of use in performance, SRGA application can help environmental -social-governance (ESG) compliance for the paints and coatings industry.