Surface Corrosion Research Articles

Recent advances in emerging integrated anticorrosion and antifouling nanomaterial-based coating solutions.

The rapid progress in the marine industry has resulted in notable challenges related to biofouling and surface corrosion on underwater infrastructure. Conventional coating techniques prioritise individual protective properties, such as offering either antifouling or anticorrosion protection. Current progress and innovations in nanomaterials and technologies have presented novel prospects and possibilities in the domain of integrated multifunctional coatings. These coatings can provide simultaneous protection against fouling and corrosion. This review study focuses on the potential applications of various nanomaterials, such as carbon-based nanostructures, nano-metal oxides, polymers, metal-organic frameworks, and nanoclays, in developing integrated multifunctional nano-based coatings. These emerging integrated multifunctional coating technologies recently developed and are currently in the first phases of development. The potential opportunities and challenges of incorporating nanomaterial-based composites into multifunctional coatings and their future prospects are discussed. This review aims to improve the reader's understanding of the integrated multifunctional nano-material composite coating design and encourage valuable contributions to its development.

Effect of Ultrasonic Shot Peening on Microstructure and Corrosion Properties of GTA-Welded 304L Stainless Steel

Austenitic stainless steels used in structural applications suffer from stress corrosion cracking due to residual stresses during welding. Much research is being conducted to prevent the stress corrosion cracking of austenitic steels by inducing compressive residual stresses. One method is ultrasonic shot peening (USP), which is used to apply compressive stress by modifying the mechanical properties of the material’s surface. In this study, 304L stainless steel was butt-welded by gas tungsten arc welding (GTAW) and subsequently subjected to compressive residual stress to a depth of 1 mm from the surface by a USP treatment. The influence of USP on microstructural changes in the base metal, the HAZ and weldment, and the corrosion properties was analyzed. A microstructural analysis was conducted using SEM-EDS, XRD, and EBSD methods alongside residual stress measurements. The surface and cross-sectional corrosion behavior was evaluated and analyzed using a potentiodynamic polarization test, electrochemical impedance spectroscopy (EIS) measurements, a double-loop electrochemical potentiokinetic reactivation (DL-EPR) test, and an ASTM A262 Pr. C test. The surface was deformed and roughened by the USP. The deformed areas formed crevices, and the inside of the crevices contained some cracks. The crevices and internal cracks caused pitting, which reduced the resistance of the passivation film. The cross-section was subjected to compressive residual stress to a depth of 1 mm from the surface, and the outermost area of the cross-section had fine grain refinement, forming a solid passivation film that improved the corrosion resistance.

A quick diagnostic method for corrosion-inhibition balance and a green slurry for copper chemical mechanical polishing

In this paper, a green inhibitor, adenine, is introduced into the Cu-CMP slurry to prevent the toxic ingestion in the CMP process. Moreover, in order to effectively optimize and control the copper chemical mechanical polishing based on the corrosion-inhibition balance, an expression is proposed to diagnostic the balance quickly via the least square fitting of the experimental data. Based on the corrosion-inhibition balance optimization, a pH-neutral slurry (pH = 6.8 ∼ 7.2) incorporating adenine with a high material removal rate (MRR > 600 nm/min), a low surface roughness (Ra < 1 nm) as well as low surface defects (no micro-scratches, number of surface corrosion pits ≤ 0.02 counts·μm−2, particle residues ≤ 0.98 counts·μm−2) is achieved. This newly developed slurry and the diagnostic method for the corrosion-inhibition balance should be promising for designing the green slurry for Cu-CMP.

A comparative study of YOLOv5 and YOLOv8 for corrosion segmentation tasks in metal surfaces

This study delves into the comparative efficacy of YOLOv5 and YOLOv8 in corrosion segmentation tasks. We employed three unique datasets, comprising 4942, 5501, and 6136 images, aiming to thoroughly evaluate the models’ adaptability and robustness in diverse scenarios. The assessment metrics included precision, recall, F1-score, and mean average precision. Furthermore, graphical tests offered a visual perspective on the segmentation capabilities of each architecture. Our results highlight YOLOv8’s superior speed and segmentation accuracy across datasets, further corroborated by graphical evaluations. These visual assessments were instrumental in emphasizing YOLOv8’s proficiency in handling complex corroded surfaces. However, in the largest dataset, both models encountered challenges, particularly with overlapping bounding boxes. YOLOv5 notably lagged, struggling to achieve the performance standards set by YOLOv8, especially with irregular corroded surfaces. In conclusion, our findings underscore YOLOv8’s enhanced capabilities, establishing it as a preferable choice for real-world corrosion detection tasks. This research thus offers invaluable insights, poised to redefine corrosion management strategies and guide future explorations in corrosion identification.

Evaluating Stress Corrosion Damage of Steel Wires as Bridge Cables Based on the Corrosion Surface

Evaluating Stress Corrosion Damage of Steel Wires as Bridge Cables Based on the Corrosion Surface

Effect of Shot Peening Parameters on Surface Properties and Corrosion Resistance of 316L Stainless Steel

Effect of Shot Peening Parameters on Surface Properties and Corrosion Resistance of 316L Stainless Steel

Corrosion of Heat-Transfer Materials Induced by KCl, HCl, and O2 Under Chemical-Looping Conditions

AbstractChemical-looping combustion (CLC) of biomass has the potential to facilitate negative CO2 emission in heat and power production when combined with a carbon capture technique. However, typical biomass contains alkali metals and chlorine compounds, such as potassium chloride, which can lead to corrosion of heat-transfer surfaces in the reactors. The combined influence of potassium chloride, hydrochloric acid, and oxygen on the corrosion of five typical heat-transfer materials, which are potential candidates for use in the fuel reactor in a CLC process, was studied using one-week laboratory-scale experiments. The results suggested that potassium chloride, especially in the presence of HCl and O2, greatly affects the corrosion of lower-alloyed heat-transfer materials. The outcome of this study can provide valuable information for selecting suitable heat-transfer materials for CLC.

Comparison of Friction Properties of GI Steel Plates with Various Surface Treatments

This article presents the improved properties of GI (hot-dip galvanized) steel plates in combination with a special permanent surface treatment. The substrate used was hot-dip galvanized deep-drawn steel sheets of grade DX56D + Z. Subsequently, various surface treatments were applied to their surface. The coefficient of friction of the metal sheets without surface treatment, with a temporary surface treatment called passivation, and a thin organic coating (TOC) based on hydroxyl resins dissolved in water, Ti and Cr3+ were determined by a cup test. The surface quality and corrosion resistance of all tested samples were also determined by exposing them for up to 288 h in an atmosphere of neutral salt spray. The surface microgeometry parameters Ra, RPc and Rz(I), which have a significant influence on the pressing process itself, were also determined. The TOC deposited on the Zn substrate was the only one to exhibit excellent lubrication and anticorrosion properties, resulting in the lowest surface microgeometry values owing to the uniform and continuous layer of the thin organic coating compared to the GI substrate and passivation surface treatment, respectively.

BORIDE LAYER GROWTH KINETICS ON X90CrMoV-18 STEEL

Boronizing is a type of thermal diffusion with the primary goal of increasing the surface hardness, wear and corrosion resistance. The wear resistance of boronized parts depends on the type of borides that form on the steel surface and their thickness. This study investigated the properties of boride layers formed on X90CrMoV-18 martensitic stainless steel, using pack boronizing carried out in a temperature range of 850–1000 °C and in durations of (1, 3 and 5) h. Results indicate a difference in the boride layer thickness of 3–80 µm and volume share of boride phases depending on the temperature and time of boriding. From the boriding compound depth, values of the frequency factor and activation energy were determined using the Arrhenius equation. With these values, the parabolic equation for predicting the growth rate of a boride layer was formulated and validated for different times and temperatures of boriding.

Corrosion resistance and corrosion mechanism of Zn-Cu-Ti alloy layers for hot-dip plating of structural parts

ABSTRACT A new Zn-Cu-Ti alloy suitable for hot-dip galvanising of structural parts was prepared. The effects of Cu and Ti on the microstructure, corrosion products, and corrosion resistance of the alloy were systematically investigated. The results showed that the introduction of Cu and Ti led to grain refinement on the coating surface. The precipitation of TiZn3 on the surface of Zn-Cu-Ti alloy coatings increased the surface corrosion potential of the coatings, while TiZn15 at grain boundaries played an important role in strengthening the grain boundaries The addition of Cu and Ti helped to improve the density and stability of the corrosion products on the surface of Zn-Cu-Ti coatings, resulting in a predominantly homogeneous corrosion on the surface of the coating. In addition, Cu and Ti reduced the surface corrosion rate and corrosion current density of the plated layer by 64% and 80%, respectively. This indicated that Cu and Ti significantly enhanced the corrosion resistance of the plated layer.

Effect of Voltage and concentration of polyetherimide on surface morphology and corrosion properties of AZ91D by electro-spin coating

Magnesium alloys, particularly AZ91D, exhibit promising mechanical properties but are susceptible to corrosion, limiting their widespread industrial applications. This manuscript investigates the impact of voltage and concentration of Polyetherimide (PEI) on surface morphology and corrosion characteristics of AZ91D through electro-spin coating. PEI, known for its high strength and corrosion resistance, is applied using an eco-friendly electro-spin coating method. The study optimizes polymer concentration and applied voltage to enhance the anticorrosive properties of AZ91D. Atomic force microscopy (AFM) and scanning electron microscopy (SEM) reveal the morphological alterations, while electrochemical corrosion tests provide insights into the corrosion resistance. The results show that a moderate PEI concentration (15 %) at 14 kV voltage exhibits the most favorable corrosion resistance, emphasizing the need to optimize both parameters for enhanced protection of AZ91D against corrosion. The results contribute to developing economical and effective corrosion protection techniques for magnesium alloys, mainly for automotive applications.

Corrosion reason analysis and countermeasures of buried oil unloading pipeline in an oilfield

The material, corrosion morphology and characteristics, as well as the compositions of corrosion products of a 20# steel unloading pipeline were studied using on-site C-scan detection, laboratory corrosion morphology analysis, material metallographic analysis, chemical composition analysis and tensile testing. The uniform corrosion and pitting behavior of 20# steel were studied using a high temperature and high pressure autoclave under conditions of 50 °C and CO2 partial pressure of 0.05 MPa, 0.1 MPa, and 0.2 MPa, respectively. The microstructure and composition of the surface and cross-section corrosion product film were analyzed by SEM. The results show that the uniform corrosion rate of 20# steel increases with the increase of CO2 partial pressure. When the CO2 partial pressure reaches 0.2 MPa, there are a large number of corrosion pits on the surface of the sample, and the maximum local corrosion rate reaches 1.8719 mm/a. The corrosion product film has a multi-layer structure, with a surface layer of FeCO3 corrosion product films and an inner layer of (Ca, Mg)CO3 deposition layer. There are obvious corrosion pits at the interface between the corrosion product film and the substrate locally. The severe thinning of the on-site pipeline wall is mainly caused by CO2 corrosion. The defects of the corrosion product film and the deposition of scale layer accelerate local corrosion.

Surface Modification Induces Oriented Zn(002) Deposition for Highly Stable Zinc Anode

Aqueous zinc metal batteries (AZMBs) are considered a promising candidate for grid-scale energy storage systems owing to their high capacity, high safety and low cost. However, Zn anodes suffer from notorious dendrite growth and undesirable surface corrosion, severely hindering the commercialization of AZMBs. Herein, a strategy for engineering a dense ZnO coating layer on Zn anodes using the atomic layer deposition (ALD) technique is developed, aiming to improve its long-term cycling stability with fewer Zn dendrites. The surface-modified Zn anode (ZnO@Zn) exhibits an excellent long-cycling life (680 h) and stable coulombic efficiency when being used in a symmetric cell. Moreover, the ZnO@Zn electrode shows a high stability with almost no capacity decay after 1100 cycles at 2C in a full cell using MnO2 as the cathode. The ZnO coating is conducive to reducing corrosion and the generation of by-products, thus increasing the reversibility of Zn2+/Zn stripping/plating. Particularly, density functional theory (DFT) calculation results reveal that the ZnO coating layer could effectively lower the adsorption energy of the Zn(002) plane in ZnO@Zn, inducing the preferential deposition of Zn2+ towards the (002) crystal plane with fewer Zn dendrites. The surface ZnO coating protocol provides a promising approach to achieve a dendrite-free Zn anode for stable AZMBs.

Effect of changes in organo-silicon electrolyte concentration and composition on SiO2 ceramic coating prepared by plasma electrolytic oxidation on 6061 aluminum alloy

An amorphous SiO2 ceramic coating with a thickness of ∼72 μm is prepared within 13 min in organo-silicon electrolyte, which is stable in strong acid solutions, reducing corrosion current density of 6061 aluminum alloy by 3 orders of magnitude. With the aim to reveal influence of the electrolyte concentration, NaOH content and additive (NaPO3)6 on microstructure and corrosion resistance of the coatings, SEM/EDS, XRD, electrochemical tests were used to characterize their thickness, surface and cross-sectional morphology and structure, and corrosion performance prepared by using different electrolytes under the same electric control parameters. The results show that they significantly affect the surface morphology, structure and corrosion resistance of the coatings. Dilution of the electrolyte results in a significant decrease in coating thickness and surface porosity, reduction of NaOH content leads to coating thinning, increased porosity but reduced pore size. Coatings with lower porosity or smaller pore sizes are more effective in resisting corrosive media penetration for long term immersion. Whereas, the additive (NaPO3)6 promotes coating thickening, widening of the transition layer, which helpfully improves the corrosion resistance of the coating.

Proton-driven bilateral interfacial chemistry and electrolyte structure reconstruction enable highly reversible zinc metal anodes

Uncontrolled dendrite growth, severe parasitic reactions on the Zn metal anode (ZMA), and the dissolution of cathode active materials have significantly limited the development of aqueous zinc ion batteries. Herein, 3-(Cyclohexylamino)-1-propanesulfonic acid (CAPS) featured with zwitterion as a multifunctional additive is introduced into the 2 M ZnSO4 aqueous electrolyte to simultaneously regulate the interfacial chemistry of the Zn anode and the cathode, as well as the solvated structure of Zn2+, thereby improving the interfacial and structural stability of both electrodes. Thereinto, the preferentially adsorbed CAPS zwitterion onto the ZMA surface favors for constructing a cationic protective layer originated from the electrostatic shielding effect of the cationic group (>NH2+), inhibiting the growth of dendrites. Meanwhile, the CAPS zwitterion can self-regulate the bilateral interfacial pH by forming the conjugate acid-base pair, suppressing hydrogen evolution reaction and Zn anode surface corrosion. Additionally, the CAPS zwitterion alters the solvated structure of Zn2+, weakening H2O molecule activity and reducing the dissolution of vanadium element from cathode. Consequently, the Zn||Zn symmetric cells harvest excellent cycling stability (1 mA cm−2, 1 mAh cm−2, 2300 h), and the Zn||Cu asymmetric cells display a high average Coulombic Efficiency of 99.7 % after 1600 cycles in the ZnSO4+CAPS electrolyte.

Dendrite-free and highly stable Zn metal anode with ZIF-8 ions-transport layer

As a promising anode for rechargeable aqueous batteries for grid energy storage, zinc metal has received considerable attention. However, its practical use is severely hampered by uncontrollable dendrite growth and surface parasitic reactions. In this paper, zeolite imidazole salt framework-8 (ZIF-8) interphase with open metal sites (OMSs) was constructed on the Zn anode as a highly zinc-friendly medium and ion-screening agent to synergistically induce rapid and uniform Zn nucleation/deposition. In addition, the interfacial shielding of the interphase significantly inhibited surface corrosion and hydrogen evolution. As a result, the ultra-stable zinc plating/stripping process significantly boosts cycle life by 1350 hours compared to bare Zn at 1 mA cm−2 with 1 mAh cm−2, achieving a cumulative plating capacity of 0.75 Ah cm−2. Moreover, the modified Zn anode ensures exceptional stability and cycling performance for the MnO2-based full cell, maintaining a capacity of 166.2 mAh g−1 after 1000 cycles at 1 A g−1, with a capacity retention rate of 73.2%.

A corrosion cracking mechanism-based model with molten salt corrosion damage coupling the effect of chloride impurity and plastic deformation

The corrosion kinetic models, incorporating the effects of chloride impurity and plastic deformation were proposed. Molten salt corrosion (MSC) damage was quantitatively described using the corrosion kinetic and the distance of materials points from the corrosion surface. By employing the elastic-viscoplastic theory with a hyperbolic-sine flow rule and the proposed damage model, a corrosion cracking mechanism-based model was developed and implemented using finite element (FE) analysis method. The corrosion-assisted cracking ahead of crack tips in accordance with the corrosion cracking mechanism was simulated. Furthermore, the predicted corrosion depth, corrosion morphologies, and multi-site corrosion cracking behaviors showed good agreement with the experimental results.

Studying the formation of nodules in a Ni-Fe-Cr based superalloy used in fireside corrosion under the impact of creep stress

Creep rupture tests on a Ni-Fe-Cr based superalloy were conducted in a custom-built rig at 750 °C under simulated fireside corrosion environment. The impact of creep stress on corrosion was investigated by controlling load level (without loading, loads of 120–195 MPa). The phase composition, microstructure, and morphology of surface corrosion products and corrosion-affected area were studied. The mechanism responsible for the production of surface nodules and the observed uniform oxide scale during fireside corrosion are discussed. Results show that the presence of creep stress promotes the development of surface nodules and increases the corrosion-affected area.

Effect of impact-corrosion coupling damage on fatigue properties of 2198-T8 aluminum-lithium alloy

The peeling of aircraft surface paint due to foreign object impact can expose the aluminum–lithium alloy substrate to atmospheric corrosion, resulting in the fatigue performance being affected by the combined effect of impact damage and corrosion damage. In this work, the effects of impact damage and corrosion damage on the fatigue life of 2198-T8 aluminum–lithium alloy sheet were investigated. The strain field distribution of specimens with coupled impact and corrosion damage under cyclic loading was analyzed by Digital Image Correlation (DIC) technique, and the coupling relationship between impact and corrosion damage was analyzed based on the crack propagation path and fracture morphology. The results show that surface corrosion pits depth distribution of impact dents follows the same trend as residual stress distribution. For the coupling damage of the hemispherical punch, the coupled effect between impact damage and corrosion damage is most evident at low impact energy. At higher impact energies, the impact damage dominates the coupling damage. As the salt spray corrosion time increases, the fatigue life decrease rate gradually slows with increasing impact energy, and the impact damage has a greater effect on the fatigue life in the early corrosion stage. Compared to the salt spray corrosion environment at 35 °C, the fatigue life of the specimen at 25 °C increased by a maximum of 50.48 % as the impact energy increased from 10 J to 25 J.

A Comparative Evaluation of Surface and Elemental Changes in Stainless Steel and Titanium Orthodontic Mini-screw Implants: A Multi-arm Randomized Control Trial.

The present study aimed to compare and quantify the surface changes seen in two most commonly used orthodontic miniscrew implants (MSI) materials; titanium and stainless steel after their clinical use. 40 MSIs (20 titanium and 20 stainless steel) were retrieved from the maxillary arch of 20 subjects (13 females and 7 males) in the age group of 18 - 27 years (mean age=22.4 ± 3.83 years) after their intended use. 40 (20 titanium and 20 stainless steel) asreceived MSIs were used as control. All the MSIs were analyzed under a Scanning Electron Microscope (SEM) for the characterization of their morphological condition (blunting of tip, surface defects and corrosion). Furthermore, Energy Dispersive X-ray (EDX) microanalysis was carried out to study the changes in surface characterization. When imaged using SEM, as-received Titanium and Stainless Steel MSIs demonstrated a relatively smooth surface with no surface defects. However, the retrieved titanium and stainless-steel implants showed increased surface defects (both corrosion and cracks) with the difference being statistically significant. The retrieved Titanium MSIs (115.31±24.38μm) showed 4 times more blunting compared to the retrieved Stainless-steel MSIs (29.74±8.56 μm), with the latter showing 2-3 times more surface corrosion. Clinical usage had pronounced effects on both Titanium and Stainless steel MSI alloys in terms of changes in the surface characteristics. While stainless steel MSIs are more susceptible to surface corrosion, Titanium MSIs exhibit greater alterations in the form of tipblunting and cracks in screw threads.