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Special Issue "Corrosion Science and Surface Engineering II"

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A special issue of Coatings (ISSN 2079-6412). This special issue belongs to the section "Corrosion, Wear and Erosion".

Deadline for manuscript submissions: 30 September 2023 | Viewed by 9978

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Dr. Judit Telegdi

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Guest Editor

Research Centre for Natural Sciences, Institute of Materials and Environmental Chemistry, Hungarian Academy of Sciences, Budapest, Hungary
Interests: corrosion inhibition; microbiologicallyinfluenced corrosion, nanolayers against corrosion and biofilms/biofouling; self-healing and slow-release microsphers/microcapsules
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Dr. Nikolai Boshkov

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Bulgarian Academy of Sciences, Sofia, Bulgaria
Interests: corrosion resistance; zinc coatings
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Special Issue Information

Dear Colleagues,

The aim of this Special Issue is to summarize and highlight the latest achievements in the literature, experimental work, and analytical techniques in the field of corrosion science connected with surface engineering. Though there have been good monographs, books, and articles on similar topics in the past, this Special Issue will be dedicated to recent developments as well as to the most often applied and paramount methods, techniques, and instrumentations that not only elucidate the corrosion phenomenon, its inhibition, and its kinetics, but also inform us about proper surface engineering to decrease and control these undesired phenomena.

The corrosion phenomenon is well known all over the world; it merits extensive scientific understanding. The scope of corrosion covers a wide range of phenomena: general corrosion, pitting and stress corrosion, cracking, passivity, high temperature oxidation (to mention only some of them), as well as their inhibition, with emphasis on the mechanisms and methods used to control the corrosion. In order to achieve successful results, the cooperation of scientists and industrial specialists is necessary.

Surface engineering, which is an important tool to modify the surface properties and the appearance (with no change in the bulk composition), to provide protection from environmental damage, to enhance mechanical and physical performance by modifications (coating, chemical and physical deposition, anodizing, thermal spraying, mechanical deformation, etc.), includes technologies that convert the very upper surface layer of the substrate that results in increased anticorrosion characteristics. The achieved altered properties depend on the techniques and parameters, on the surface characteristics, on the metal composition and microstructure, and the surface roughness.

The Corrosion Science and Surface Engineering Special Issue would like to inspire engineers, scientists, and specialists working on the topics mentioned above, who will contribute to this important topic with reports on their own work done in the field of corrosion, corrosion inhibition by special surface treatments, as well as in surface characterization. Review papers are also welcome.

We have to keep in mind that the environmental impact of chemicals could be significantly decreased, and the energy consumption and CO₂ emission could also be decreased with special surface treatments.

Original papers and critical reviews are awaited in topics such as:

New appearance in general and localized corrosion, corrosion resistant alloys;
Principles and modes of corrosion inhibition by surface engineering;
Recently developed surface modification techniques (chemical, physical, electrochemical, etc.);
Newest results in surface coatings with microcapsules of self-healing and slow release activity;
Most effective characterization and testing of surfaces before and after modification.

Dr. Judit Telegdi
Dr. Nikolai Boshkov
Guest Editors

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 100 words) can be sent to the Editorial Office for announcement on this website.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Coatings is an international peer-reviewed open access monthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2600 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

corrosion inhibition
special surface engineering
coatings with molecular layers
self-healing and slow-release coatings
surface characterization techniques

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Corrosion Science and Surface Engineering in Coatings (16 articles)

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Research

Open AccessArticle

Preparation and Properties of Textured Ni–W Coatings Electrodeposited on the Steel Surface from a Pyrophosphate Bath

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Coatings 2023, 13(9), 1519; https://doi.org/10.3390/coatings13091519 - 29 Aug 2023

Viewed by 350

Abstract

Ni–W alloys with a (2 2 0) or (1 1 1) preferred orientation growth and amorphous structure were prepared from a pyrophosphate bath using the electrodeposition method. Structure transformation can be the result of the bath temperature (T_b) and the concentration of sodium tungstate (C_W) in the bath. Increasing the T_b and C_W can change the crystal growth from (2 2 0) to (1 1 1). At a higher T_b and C_W, an amorphous Ni–W alloy can be obtained. The tungsten content in the coatings should be responsible for the structure change. The three textured Ni–W alloys with a (2 2 0) texture, (1 1 1) texture and amorphous structure were annealed at different temperatures ranging from 200 to 700 °C. The microhardness, corrosion resistance and HER of the as-deposited and annealed Ni–W alloys were comparatively studied. The results show that the microhardness of the amorphous Ni–W alloy is the highest and reaches 1028 HV after annealing at 400 °C. The (2 2 0)-textured Ni–W alloy has the best corrosion resistance, which is further improved after annealing, while the HER activity of the (1 1 1) textured Ni-W alloy is superior. Full article

(This article belongs to the Special Issue Corrosion Science and Surface Engineering II)

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Open AccessArticle

Study on the Influence of Non-Metallic Inclusions on the Pitting Corrosion of API 5L X60 Steel

Julio César Velázquez

Jorge Jonathan Hernández-Huerta

Manuela Diaz-Cruz

Enrique Hernández-Sánchez

Arturo Cervantes-Tobón

Selene Irais Capula-Colindres

and

Román Cabrera-Sierra

Coatings 2023, 13(6), 1040; https://doi.org/10.3390/coatings13061040 - 03 Jun 2023

Cited by 1 | Viewed by 649

Abstract

The most economical way to move liquids and gaseous hydrocarbons is by using pipelines. According to several international organizations and oil companies, the use of fossil fuels will continue in the following decades. For this reason, it is important to continue studying different corrosion mechanisms and their origins. One of the mechanisms that provoke small leaks, affecting pipeline hermeticity, is pitting corrosion. It is well-known that non-metallic inclusion dissolution can trigger pit nucleation. As pitting corrosion is recognized to be random in nature, it is also interesting to study the random nature of the inclusions present in API 5L X60 steel. Probability distributions commonly used to describe pitting corrosion characteristics are appropriate for studying inclusion characteristics. The size of inclusions plays a key role in pit nucleation because small inclusions tend to generate more defects, especially when these inclusions are compounds of MnS, and the steel is immersed in a corrosive solution. The results of this research work show that there is a close relationship between the random nature of pitting corrosion and inclusions. Full article

(This article belongs to the Special Issue Corrosion Science and Surface Engineering II)

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Open AccessArticle

Hybrid Zinc Coatings with Chitosan/Alginate Encapsulated CuO-Nanoparticles for Anticorrosion and Antifouling Protection of Mild Steel

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Coatings 2023, 13(5), 895; https://doi.org/10.3390/coatings13050895 - 09 May 2023

Viewed by 887

Abstract

The construction of anticorrosion coatings containing antifouling agents is an effective way to ensure the long-term durability of marine steel infrastructures. In this work, an innovative hybrid coating was prepared by introducing biocide CuO nanoparticles in ordinary zinc coating to improve its protective ability for steel in aggressive salt water environments. The CuO nanoparticles were embedded inside the matrix of chitosan/alginate complexes to prevent spontaneous copper leaching during corrosive attacks. Two procedures were applied for the electrodeposition of hybrid/composite zinc-based coatings on low-carbon steel substrates (DC current): first—the co-electrodeposition of encapsulated CuO nanoparticles with zinc on a cathode (steel) electrode from a sulfate electrolyte with a relatively low pH value of about 4.5–5.0 and second—the encapsulated CuO nanoparticles were electrodeposited from aqueous solution as an intermediate layer between two zinc deposits. The particles size and stability of suspensions were evaluated using dynamic light scattering. Both hybrid coatings were compared in terms of surface morphology and hydrophilicity (SEM and AFM analysis, contact angle measurement) and corrosion resistance (potentiodynamic polarization curves, polarization resistance). The protective characteristics of the coatings were compared in a 3.5% NaCl solution and artificial sea water. The hybrid coating showed 2–4 times higher polarization resistance than the bare zinc coating during a 30 day immersion in artificial sea water, indicating that this coating has the necessary characteristics to be used in a marine environment. Full article

(This article belongs to the Special Issue Corrosion Science and Surface Engineering II)

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Open AccessArticle

The Tribological Behavior of TiN/TiC CVD Coatings under Dry Sliding Conditions against Zirconia and Steel Counterparts

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Coatings 2023, 13(5), 832; https://doi.org/10.3390/coatings13050832 - 26 Apr 2023

Viewed by 766

Abstract

During this research work, the wear and friction properties of TiN/TiC coatings produced with different manufacturing parameters were investigated against steel and zirconium counterparts. The coatings, which were deposited on WC–Co substrate, were characterized based on their microstructure, phase composition, and microhardness. The tribological behavior of the coatings was examined in accordance with ASTM G99 and ASTM G133 standards using pin-on-disc tests with steel and zirconium counterfaces, while the adhesion of the coatings was investigated with a modified scratch test. According to the results obtained from the experiments, the use of zirconium counterpart is advantageous even for coatings produced with different microhardness and layer thickness using the CVD method. The results show that the change in the friction coefficient can be well traced with properly chosen parameters, thereby determining the wear resistance of the coating. Full article

(This article belongs to the Special Issue Corrosion Science and Surface Engineering II)

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Open AccessFeature PaperArticle

Protective Characteristics of TiO₂ Sol-Gel Layer Deposited on Zn-Ni or Zn-Co Substrates

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Coatings 2023, 13(2), 295; https://doi.org/10.3390/coatings13020295 - 28 Jan 2023

Cited by 3 | Viewed by 1008

Abstract

This study aimed to present the differences in the corrosion properties and protective ability of two bi-layer systems obtained on low-carbon steel in a model corrosive medium of 5% NaCl solution. These newly developed systems consist of Zn-Co (3 wt.%) or Zn-Ni (10 wt.%) alloy coatings as under-layers and a very thin TiO₂ sol-gel film as a top-layer. Scanning electron microscopy (SEM) is used for characterization of the surface morphology of the samples indicating that some quantitative differences appear as a result of the different composition of both zinc alloys. Surface topography is investigated by means of atomic force microscopy (AFM), and the hydrophobic properties are studied by contact angle (CA) measurements. These investigations demonstrate that both sample types possess grain nanometric surface morphology and that the contact angle decreases very slightly. X-ray diffraction (XRD) and X-ray photoelectron spectroscopy (XPS) are used for characterization of the chemical composition and electronic structure of the samples. The roughness R_q of the Zn-Ni/TiO₂ is 49.5 nm, while for Zn-Co/TiO₂, the R_q value is 53.4 nm. The water contact angels are 93.2 and 95.5 for the Zn-Ni/TiO₂ and Zn-Co/TiO₂ systems, respectively. These investigations also show that the co-deposition of Zn and Ni forms a coating consisting entirely of Ni₂Zn₁₁, while the other alloy contains Zn, Co and the intermetallic compound CoZn₁₃. The corrosion resistance and protective ability are estimated by potentiodynamic polarization (PDP) curves, as well as polarization resistance (R_p) measurements for a prolonged test period (35 days). The results obtained are compared with the corrosion characteristics of ordinary zinc coating with an equal thickness. The experimental data presents the positive influence of the newly developed systems on the enhanced protective properties of low-carbon steel in a test environment causing a localized corrosion—lower corrosion current density of about one magnitude of order (~10⁻⁶ A.cm⁻² for both systems and ~10⁻⁵ A.cm⁻² for Zn) and an enhanced protective ability after 35 days (~10,000–17,000 ohms for the systems and ~900 ohms for Zn). Full article

(This article belongs to the Special Issue Corrosion Science and Surface Engineering II)

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Open AccessArticle

Comparative Corrosion Characterization of Hybrid Zinc Coatings in Cl⁻-Containing Medium and Artificial Sea Water

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Coatings 2022, 12(12), 1798; https://doi.org/10.3390/coatings12121798 - 22 Nov 2022

Cited by 1 | Viewed by 835

Abstract

The presented investigations demonstrate the corrosion behavior and protective ability of hybrid zinc coatings specially designed for combined protection of low-carbon steel from localized corrosion and biofouling. Polymer-modified copper oxide (CuO) nanoparticles as widely used classic biocide are applied for this purpose, being simultaneously electrodeposited with zinc from electrolytic bath. The corrosion behavior of the hybrid coatings is evaluated in a model corrosive medium of 5% NaCl solution and in artificial sea water (ASW). Scanning electron microscopy (SEM) and atomic force microscopy (AFM) are used to characterize the surface morphology of pure and hybrid zinc coatings. Contact angle measurements are realized with an aim to determine the hydrophobicity of the surface. X-ray photoelectron spectroscopy (XPS) is applied for evaluation of the chemical composition of the surface products appearing as a result of the corrosion treatment. Potentiodynamic polarization (PDP) curves and polarization resistance (Rp) measurements are used to estimate the protective characteristics in both model corrosive media. The results obtained for the hybrid coatings are compared with the corrosion characteristics of ordinary zinc coating with the same thickness. It was found that the hybrid coating improves the anticorrosion behavior of low-carbon steel during the time interval of 35 days and at conditions of external polarization. The tests demonstrate much larger corrosion resistance of the hybrid coating in ASW compared to 5% NaCl solution. The obtained results indicated that the proposed hybrid zinc coating has a potential for antifouling application in marine environment. Full article

(This article belongs to the Special Issue Corrosion Science and Surface Engineering II)

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Open AccessArticle

The Effects of Reaction Parameters on the Corrosion Resistance of an Mg-Al Hydroxide Coating via in Situ Growth on a Biomedical Magnesium Alloy

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Coatings 2022, 12(10), 1388; https://doi.org/10.3390/coatings12101388 - 22 Sep 2022

Viewed by 824

Abstract

An in situ Mg-Al hydrotalcite (LDH) film was prepared using a one-step hydrothermal method on the surface of a medical magnesium alloy. The importance and influence of the reaction parameters on the corrosion resistance of the LDH coatings were optimized and investigated through an orthogonal array and range analysis. The reaction parameters included the temperature, reaction time, pH, and concentration of the aluminum source. The relationship between the parameters and corrosion resistance performance of each coating was compared with the chemical composition, electrochemical corrosion current, and hydrogen evolution rate. Suitable reaction parameters were obtained. The morphology, element distribution, adhesion strength, and electrochemical properties of the preferred coatings were further analyzed and evaluated to optimize the treatment process. The results showed that temperature had the most significant impact on the quality of the LDH coating; a suitably high temperature, a longer reaction time, a higher aluminum source concentration, and a high pH were conducive to forming high-quality LDH coatings. There was an inverse relationship between the corrosion resistance and the LDH-to-Mg(OH)₂ content ratio of the coatings. The optimal reaction parameters for this Mg-Al LDH coating on the substrate were 130 °C for 8 h at a pH of 13 using a 10 mM Al³⁺ solution. Full article

(This article belongs to the Special Issue Corrosion Science and Surface Engineering II)

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Open AccessArticle

Hybrid Zinc Coating with CuO Nanocontainers Containing Corrosion Inhibitor for Combined Protection of Mild Steel from Corrosion and Biofouling

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Coatings 2022, 12(9), 1254; https://doi.org/10.3390/coatings12091254 - 27 Aug 2022

Cited by 2 | Viewed by 1143

Abstract

In this study, a multifunctional hybrid coating is designed for the combined protection of mild steel from corrosion and biofouling in aggressive salt water. This involves preparation of a pH-responsive-release system based on copper oxide (CuO) as a biocide, and the corrosion inhibitor Safranin loaded in polymeric nanocontainers by alternate adsorption of poly(acrylic acid) and poly(ethylenimine) on CuO nanoparticles in water solutions. By optimizing the conditions, i.e., pH and concentration, good stability of the suspensions and the loading amount of Safranin is achieved. The nanocontainers are electrodeposited as an intermediate layer in an ordinary zinc coating on steel (“sandwich-like” structure) from the water solution in order to minimize the effect of CuO dissolution. To highlight the role of Safranin in reducing steel corrosion, a second zinc coating containing CuO nanoparticles without a corrosion inhibitor is also examined. The surface morphology and corrosion behavior of the hybrid coatings are evaluated in a model corrosion medium (5% NaCl solution). Both coatings are found to improve the anticorrosion behavior of steel for a time interval of 55 days and at conditions of external polarization. It can be expected that the newly developed hybrid coatings would also demonstrate potential for marine applications due to the main characteristics of their components. Full article

(This article belongs to the Special Issue Corrosion Science and Surface Engineering II)

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Open AccessArticle

Hybrid Zinc-Based Multilayer Systems with Improved Protective Ability against Localized Corrosion Incorporating Polymer-Modified ZnO or CuO Particles

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Coatings 2021, 11(10), 1223; https://doi.org/10.3390/coatings11101223 - 08 Oct 2021

Cited by 2 | Viewed by 1184

Abstract

Localized corrosion and biofouling cause very serious problems in the marine industries, often related to financial losses and environmental accidents. Aiming to minimize the abovementioned, two types of hybrid Zn-based protective coatings have been composed. They consist of a very thin underlayer of polymer-modified ZnO or CuO nanoparticles and toplayer of galvanic zinc with a thickness of ~14 µm. In order to stabilize the suspensions of CuO or ZnO, respectively, a cationic polyelectrolyte polyethylenimine (PEI) is used. The polymer-modified nanoparticles are electrodeposited on the steel (cathode) surface at very low cathodic current density and following pH values: 1/CuO at pH 9.0, aiming to minimize the effect of aggregation in the suspension and dissolution of the CuO nanoparticles; 2/ZnO at pH 7.5 due to the dissolution of ZnO. Thereafter, ordinary zinc coating is electrodeposited on the CuO or ZnO coated low-carbon steel substrate from a zinc electrolyte at pH 4.5–5.0. The two-step approach described herein can be used for the preparation of hybrid coatings where preservation of particles functionality is required. The distribution of the nanoparticles on the steel surface and morphology of the hybrid coatings are studied by scanning electron microscopy. The thickness of the coatings is evaluated by a straight optical microscope and cross-sections. The protective properties of both systems are investigated in a model corrosive medium of 5% NaCl solution by application of potentiodynamic polarization (PDP) curves, open circuit potential (OCP), cyclic voltammetry (CVA), and polarization resistance (Rp) measurements. The results obtained allow us to conclude that both hybrid coatings with embedded polymer-modified CuO or ZnO nanoparticles ensure enhanced corrosion resistance and protective ability compared to the ordinary zinc. Full article

(This article belongs to the Special Issue Corrosion Science and Surface Engineering II)

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Open AccessArticle

Protective Efficiency of ZrO₂/Chitosan “Sandwich” Coatings on Galvanized Low-Carbon Steel

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Coatings 2021, 11(9), 1103; https://doi.org/10.3390/coatings11091103 - 13 Sep 2021

Cited by 2 | Viewed by 1486

Abstract

Enhanced corrosion efficiency of low-carbon steel was achieved by newly developed hybrid multilayers, composed of low-carbon steel coated with an electrodeposited zinc sublayer (1 µm), a chitosan (CS) middle layer and ZrO₂ coating by the sol–gel method (top-layer). The middle chitosan layer was obtained by dipping galvanized steel substrate in 3% tartatic acid water solution of medium molecular-weight chitosan, composed of β-(1–4)-linked D-glucosamine and N-acetyl-D-glucosamine with a deacetylation degree of about 75–85% (CS). The substrates were dipped into CS solution and withdrawn at a rate of 30 mm/min. One part of the samples with the CS layer was dried at room temperature for 2 weeks, and another part at 100 °C for 1 h, respectively. After CS deposition treatment, the substrates were dipped into an isopropanol sol of zirconium butoxide with small quantity of polyethylene glycol (PEG400). The dipping-drying cycles of the ZrO₂ coatings were repeated three times. After the third cycle, the final structures were treated at 180 °C. The samples were denoted as T25, which consists of the CS middle layer, and dried at RT and T100 with the CS middle layer treated at 100 °C, respectively. The samples were characterized by means of differential thermal analysis (DTA-TG), XRD analyses, X-ray photoelectron spectroscopy (XPS) and atomic force microscopy (AFM). Hydrophobicity properties were evaluated by measuring the contact angle with a ramé-hart automated goniometer. Two electrochemical tests—potentiodynamic polarization technique (PD) and electrochemical impedance spectroscopy (EIS)—have been used to determine the corrosion resistance and protective ability of the coatings in a 5% NaCl solution. The results obtained by both methods revealed that the applied “sandwich” multilayer systems demonstrate sacrificial character and will hopefully protect the steel substrate in corrosion medium containing chloride ions as corrosion activators. The newly obtained hybrid multilayer coating systems have dense structure and a hydrophobic nature. They demonstrated positive effects on the corrosion behavior at conditions of external polarization independent of their various characteristics: morphology, grain sizes, surface roughness and contact angle. They extend the service life of galvanized steel in a chloride-containing corrosion medium due to their amorphous structure, hydrophobic surface and the combination of the positive features of both the chitosan middle layer and the zirconia top layer. Full article

(This article belongs to the Special Issue Corrosion Science and Surface Engineering II)

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