Corros. Mater. Degrad., Volume 2, Issue 4 (December 2021) – 14 articles

The conventional corrosion management process consists of defining the expected process conditions, identifying potential corrosion threats, and estimating their likely rate, then using that information to develop mitigation plans and inspection schedules. The Virtual Corrosion Engineer (VCE) project aims to improve this process by utilizing online monitoring data to automate the running of the best available corrosion models and provide a continuously updated dashboard in real time. This paper provides an overview of the VCE, together with a brief discussion of the underlying models for two exemplar damage mechanisms, High-Temperature Hydrogen Attack (HTHA) and Under Deposit Corrosion (UDC) in steam generators. Full article

Corrosion of metals leads to high maintenance costs, as well as potential threats to structural health and safety. Here, we demonstrate the coating of cobalt tungstate (CoWO₄) nanoparticles (NPS)/5-mercapto-1-phenyl-1 H-tetrazole derivative (MPT) used as a nano-composite film on Cu surface for the blocking of micropores to hinder the propagation of metastable pits in an aggressive NaCl medium. The mechanism of interaction between the nanoparticles and tetrazole derivative, in addition to the mode of anchoring to the metal surface and blocking the penetration of chloride ions (${\mathrm{Cl}}^{-}$), are all investigated. In this investigation, CoWO₄ is synthesized via a wet chemical route and thereafter, is combined with MPT at an optimized ratio thus formulating a nano-composite corrosion inhibitor which in solution gets coated on Cu surface. Atomic force and scanning electron microscopic images of the bare Cu reveal dip pits, which by the coating of the nano-composite are suppressed at the nucleation stage during exposure to the aggressive 3.5% NaCl electrolyte under flow conditions. Electrochemical analysis shows high protection of Cu up to 97% efficiency in the presence of the newly formulated nano-composite inhibitor film. Full article

Three different coated steel systems were aged in natural or artificial seawater, in neutral salt spray (NSS), and using alternate immersion tests in order to evaluate the aggressiveness of the different ageing conditions. Commercial epoxy coatings were applied onto steel (S355NL), hot-galvanized steel (HDG), and Zn-Al15 thermal spraying coated steel. The defect-free systems were immersed in artificial seawater at 35 °C for 1085 days and in natural seawater for 1200 days and were characterized by electrochemical impedance spectroscopy (EIS). Panels with artificial defects were immersed for 180 days in artificial seawater and, regarding adhesion, were evaluated according to ISO 16276-2. In parallel, the three coated systems were submitted to cyclic neutral salt spray (NSS) for 1440 h: defect-free panels were regularly evaluated by EIS, while the degree or corrosion was measured onto panels with artificial defect. After NSS, defect-free panels were immersed in artificial seawater at 35 °C for further EIS investigations. Finally, alternate immersion tests were performed for 860 days for the three defect-free coated systems and for 84 days for panels with a defect. The results showed that, for defect-free panels, immersions in natural or artificial seawater and NSS did not allowed us to distinguish the three different systems that show excellent anticorrosion properties. However, during the alternate immersion test, the organic coating system applied onto HDG presented blisters, showing a greater sensitivity to this test than the two other systems. For panels with a defect, NSS allowed to age the coatings more rapidly than monotone conditions, and the coating system applied onto steel presented the highest degree of corrosion. Meanwhile, the coating systems applied onto HDG and the thermal spray metallic coating showed similar behavior. During the alternate immersion test, the three coated systems with a defect showed clearly different behaviors, therefore it was possible to rank the three systems. Finally, it appeared that the alternate immersion test was the most aggressive condition. It was then proposed that a realistic thermal cycling and an artificial defect are needed when performing ageing tests of thick marine organic coating systems in order to properly rank/evaluate the different systems. Full article

A protective CoAl-layered double hydroxide (LDH) thin film was developed directly on the aluminum substrate. Further, the low-surface-energy molecules (1H, 1H, 2H, 2H perfluorododecyl trichlorosilane) were incorporated inside the LDH network through an anion exchange mechanism to obtain a superhydrophobic CoAl-LDH surface. The developed films were characterized by scanning electron microscopy (SEM-EDS), X-ray diffraction (XRD), and Fourier transform infrared spectroscopy (FT-IR), and additional contact angle measurements were made to evaluate the superhydrophobicity of modified CoAl-LDHs against different solutions. The water contact angle (WCA) of the modified CoAl-LDH surface was observed to be about 153° and remained sufficiently stable after long-term immersion in NaCl solution. The effect of excessive ultrasonication on film structural variations and superhydrophobicity was also analyzed for outdoor applications. The high charge transfer resistance observed from the analysis of long-term electrochemical impedance spectroscopy (EIS) indicates the significant corrosion-resistance properties of the developed CoAl-LDHs. This research on protective CoAl-LDHs will bring insights into the understanding of new aspects of surface protection and implementation in many engineering applications. Full article

Radiation induced corrosion is one of the possible modes of materials degradation in the concept of long-term management of used nuclear fuel. Depending on the environmental conditions surrounding the used fuel container, a range of radiolysis products are expected to form that could impact the corrosion of the copper coating. For instance, γ-radiolysis of pure water produces molecular oxidants such as H₂O₂ and the radiolysis of humid air produces compounds such as NO_x and HNO₃. This review is confined to a discussion of the effect of γ-radiation on the corrosion of copper-coated containers. A simplified mixed-potential model is also presented to calculate the extent of copper corrosion by using the steady-state concentration of H₂O₂ generated during the first 300 years of emplacement, when the radiation field is significant. Full article

A new corrosion inhibitor called ATP-6-AHA was elaborated, and its inhibition action on S235 low carbon steel in 3.5% sodium chloride (NaCl) was investigated using gravimetry, potentiodynamic polarization (PP), and electrochemical impedance spectroscopy (EIS). The release of ecofriendly 6-aminohexanoic acid (6-AHA) from its established aluminum tri-polyphosphate intercalate (ATP-6-AHA) is investigated using electrochemical and surface characterization techniques such as X-ray diffraction (XRD) and X-ray fluorescence (XRF). The results revealed that ATP-6-AHA is a good inhibitor, with an inhibition efficiency of approximately 70%. The efficiency is related to the passivation of a steel surface by a phosphate protective layer due to the synergistic effect of 6-AHA, as confirmed by a steel surface analysis conducted using X-ray photoelectron spectroscopy (XPS) and scanning electron microscopy (SEM). This study suggests that the intercalation of 6-AHA as a sustainable organic molecule within the interlayer spaces of aluminum tri-polyphosphate can well serve as a good flaky inhibitor for protecting S235 low-carbon steel from corrosion in 3.5% NaCl. Full article

Not counting domestic dwellings, it has been estimated that in Australia alone, some tens of thousands of masonry buildings and structures have exceeded their design life, with many of these being at risk of partial (or worse) collapse from falling or dislodged masonry. This has significant implications for human life but also for the urban environment and economic health of building owners, managers, and insurers and for local and national economies. This risk can mainly be attributed to the slow deterioration of masonry under atmospheric and other environments and the corrosion of so-called wall ties. Wall ties are relatively thin pieces of steel that tie the outer leaf of masonry walls to the stabilized inner leaf. The problem is likely severe for scenarios such as cyclonic and earthquake events, as they cause area-wide damage and the potential wide-spread loss of human life—losses that could be prevented by timely intervention. This paper reports on the in situ inspection of two case study buildings and the data obtained from controlled wall tie corrosion field trials, which are used to develop predictive models of structural response. These models will inform practical tools that will be developed for building assessment, cost-effective monitoring, and rectification, assisting in the management of existing masonry buildings. Full article

In this paper, the recent research progress on the corrosion of reinforced alkali-activated materials (AAMs) concrete structures is reviewed. The corrosion mechanisms induced by carbonation and chloride ingress in AAMs concrete are discussed, from the perspectives of composition, microstructure and pore solution chemistry, in comparison to ordinary Portland cement (OPC) concrete. The steel–alkali-activated concrete interface is a key to investigating corrosion initiation and propagation, which has different physical and chemical characteristics of the steel–concrete interface in OPC concrete. Moreover, the electrochemical process testing methods including half-cell potential and linear polarization resistance are critically discussed with a focus on what could be inherited from the OPC concrete and what criteria are no longer suitable for AAMs concrete due to underestimation in most cases. New data and theories are urgently needed for using AAMs in concrete structures to replace OPC. At the end of this paper, the research gaps and future research needs are summarised for the sake of widespread application of AAMs in concrete structures for sustainable and low-carbon construction. Full article

The aim of this study was to investigate the oxidation kinetics of copper at low temperatures (60 °C to 100 °C) in air by isothermal thermogravimetric analysis (TGA) and quartz crystal microbalance (QCM). The weight change in thermogravimetric tests showed periodic weight increase and decrease. In thermogravimetric tests the mass of the copper sample increased until the oxidation gradually slowed down and finally started to decrease due to cracking and spalling of the oxide formed on the surface. In QCM tests using electrodeposited copper film, the weight change was rapid at the beginning but slowed to a linear relationship after few minutes. Temperature and exposure time appeared to have a large effect on oxide film thickness and composition. With QCM, oxidation at 60–80 °C produced less than 40 nm films in 10 days. Oxidation at 90–100 °C produced 40 nm thick films in a day and over 100 nm films in a week. Although SEM-EDS analyses in TGA tests indicated that oxygen was adsorbed on the copper surface, neither XRD patterns nor Raman spectroscopy measurements showed any trace of Cu₂O or CuO formation on the copper surface. Electrochemical reduction analysis of oxidized massive copper samples indicated that the oxide film is mostly Cu₂O, and CuO develops only after several days at 90–100 °C. Full article

In Finland, the repositories for low and intermediate-level radioactive waste (LLW and ILW) will be situated at three different geographical locations in about 60 to 100 m deep granite bedrock where the waste and waste containers can be subjected to anoxic groundwater containing microbes. The composition of groundwater varies in terms of chemistry and microbial activity in different locations. In this study, groundwater from the three repository areas was analyzed in respect to chemistry and microbial community. Corrosion tendency of three steel grades, carbon steel AISI/SAE 1005 and stainless steels AISI 304 and 316L, was studied in these groundwater environments using electrochemical methods. As a reference, measurements were also performed in simulated groundwater without microbes. The measurements show that corrosivity of the water and thus the steels’ performance differs depending on water origin. In addition, the groundwater differed remarkably in their chemical composition as well as abundance and diversity of microbial community between the sites. Consequently, the local environment has to be considered when evaluating the long-term evolution of disposal concepts. Full article

Environmental cracking- and fatigue-related failures threaten all major industries and, to combat such degradation, numerous residual stress impingement (RSI) methods have been developed with varying levels of efficacy and ease of use. Some of the most commonly used RSI methods, such as shot peening, laser shock peening, and low plasticity burnishing, as well as new methods, such as ultrasonic nanocrystal surface modification, are reviewed in the context of corrosion, corrosion fatigue, and environmental cracking mitigation. The successes and limitations of these treatments are discussed, with a focus on their efficacy against these three damage modes based on the available literature. Case studies are reviewed that demonstrate how these treatments have been adopted and advanced by industry, and application-specific research efforts are explored with a focus on future opportunities. Research is identified that illustrates how the utility of these surface treatments may vary between alloy systems, and where the benefits must be weighed against the risks to a component’s service performance. Full article

A perspective is presented on the evolution of damage due to environmentally assisted cracking (EAC), from crack precursor development through to long crack growth. The variable nature of crack precursors is highlighted with an observation that uncontrolled chemistry excursions or fabrication defects could eliminate any significant delay associated with that step in the damage evolution process. Specimen preparation by machining and grinding can be critical in determining the apparent susceptibility of the metal to EAC and corrosion, and an example for 316L stainless steel is given to show how physical defects generated by the grinding wheel can become the dominant site for pitting attack relative to MnS inclusions. Corrosion pits are the most commonly observed precursor to cracks in aqueous chloride environments. The loci of sites of crack initiation around a pit are discussed and the inherent challenges in quantifying the growth of cracks smaller than the pit depth described with implications for modelling of the pit-to-crack transition. The remarkably enhanced stress corrosion crack growth rate data for short and small cracks in a 12Cr steam turbine blade in a simulated condensate environment are discussed in the context of crack electrochemistry modelling and the implications for engineering integrity. Full article

Different structural lightweight concrete mixtures of specific density and strength classes were produced by using various lightweight aggregates (LWAs) such as pumice, perlite, and rice husk ash. Their properties were evaluated in fresh and hardened states with regards to compressive strength and durability parameters such as water absorption (open porosity and capillary absorption), chloride’s penetration resistance, and carbonation depth. According to the results, most LWA concrete mixtures performed satisfactorily in terms of the designed strength and density and they could be used as structural LWA concrete mixtures. As far as the durability of LWA concrete was concerned, open porosity and resistance to the carbonation of LWA concrete were burdened with the porous nature of LWAs, while sorptivity in some mixtures and especially chlorides’ penetration resistance in all mixtures were reported to be significantly improved. The overall strength and durability performance of the designed LWA concrete mixtures could mitigate the concerns stemming from its vulnerability to extreme exposure conditions. Full article

This paper tackles bacteria of the genus Bacillus as both biodamaging/biodegrading and biocontrolling agents. The article addresses the said bacteria’s ability to form biofilms and corrosive, antimicrobial and antibiofilm proactive compounds, primarily, siderophores. Their role depends on the species, microorganism strain, production of antimicrobial substances, biofilm formation, and the type of damaged material. The bacteria under analysis have demonstrated the ability to cause as well as inhibit biodamage. The involvement of bacteria of the genus Bacillus in microbiologically influenced corrosion processes is determined by the production of corrosive metabolites and the impact of certain bioelectrochemical mechanisms. Lipopeptides generated by Bacillus subtilis (surfactin, iturin and fengycin) are capable of modifying surfaces’ hydrophobic properties and impacting the microbes’ adhesion to surfaces. Produced by Bacillus velezensis, the siderophore bacillibactin at a high concentration is capable of inhibiting the formation of bacterial biofilms, thus slowing down the degradation of materials. Further study of siderophores as green inhibitors of microbiologically influenced corrosion may be promising as the said compounds possess antibiofilm-forming properties and high-intensity inhibitory capabilities. Full article