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Special Issue: Environmental Corrosion of Metals and Its Prevention: An Overview and Introduction to the Special Issue

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Boxin Wei

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Jin Xu

Coatings 2022, 12(7), 1013; https://doi.org/10.3390/coatings12071013 - 18 Jul 2022

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Abstract

Corrosion is a natural process of deterioration and an extremely costly problem [...] Full article

(This article belongs to the Special Issue Environmental Corrosion of Metals and Its Prevention)

Research

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Open AccessArticle

Degradation Behavior of Arc-Sprayed Zinc Aluminum Alloy Coatings for the Vessel Yongle in the South China Sea

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Coatings 2023, 13(7), 1139; https://doi.org/10.3390/coatings13071139 - 23 Jun 2023

Viewed by 561

Abstract

Since thermally sprayed zinc and aluminum coatings were invented 100 years ago, they have realized extensive industrial applications for steel structure protection in a variety of fields for nearly 100 years and have been proven to be effective and reliable. However, it has [...] Read more.

Since thermally sprayed zinc and aluminum coatings were invented 100 years ago, they have realized extensive industrial applications for steel structure protection in a variety of fields for nearly 100 years and have been proven to be effective and reliable. However, it has seldom been reported in the ship industry in China since many workers worry about the risk of rapid corrosion, especially in harsh environments such as the South China Sea. In this paper, three kinds of arc-sprayed zinc aluminum coatings were tested to choose the best coating system for application on the research vessel Yongle by electrochemical behavior and a long-term atmospheric exposure experiment. The variation of the corrosion rate and the bonding strength was used to clarify the long-term protection performance. The results show that Zn15Al has the lowest corrosion (R_p larger than 2200 Ω·cm²) among the three kinds of coatings and has a bonding strength larger than 6.38 MPa after a 5 year test. The performance of the coatings in the South China Sea indicates that they can provide excellent protection for the hull above the waterline of the Yongle vessel in the 3 year test. It could be predicted that thermally sprayed zinc aluminum coating has vast application potential in the South China Sea due to its excellent anticorrosion performance. Full article

(This article belongs to the Special Issue Environmental Corrosion of Metals and Its Prevention)

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Open AccessArticle

Effect of One Sulfate-Reducing Bacterium SRB-Z Isolated from Pearl River on the Corrosion Behavior of Q235 Carbon Steel

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Coatings 2023, 13(2), 478; https://doi.org/10.3390/coatings13020478 - 20 Feb 2023

Viewed by 995

Abstract

Sulfate-reducing bacteria (SRB) have long been reported to participate in metal corrosion processes in anoxic environments. However, existing theories still need enrichment by identifying more corrosive microorganisms and exploring more plausible microbiologically-influenced corrosion pathways. In this study, a strain SRB-Z was isolated from [...] Read more.

Sulfate-reducing bacteria (SRB) have long been reported to participate in metal corrosion processes in anoxic environments. However, existing theories still need enrichment by identifying more corrosive microorganisms and exploring more plausible microbiologically-influenced corrosion pathways. In this study, a strain SRB-Z was isolated from the Pearl River in Guangzhou, and its effect and mechanisms on corrosion of Q235 carbon steel were examined. The biofilms, corrosion products, pits, and corrosion electrochemistry were characterized by SEM, XPS, CLSM, EDS, white light interferometer 3D profilometry, and electrochemical analysis, respectively. The results of this study indicate that SRB-Z could cause serious pitting of Q235 carbon steel. The maximum pit depth reached 54 μm after immersion corrosion for 7 days. Strain SRB-Z promoted the cathodic reaction rate of Q235. The relative analyses revealed that pitting corrosion occurred because of galvanic corrosion caused by the formation of an FeS-SRB/Fe galvanic couple under the synergistic effect of the SRB-Z biofilm and its metabolite (H₂S) on the Q235 coupon surfaces. Full article

(This article belongs to the Special Issue Environmental Corrosion of Metals and Its Prevention)

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Open AccessArticle

Insight on Corrosion Prevention of C1018 in 1.0 M Hydrochloric Acid Using Liquid Smoke of Rice Husk Ash: Electrochemical, Surface Analysis, and Deep Learning Studies

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Agus Paul Setiawan Kaban

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Johny Wahyuadi Soedarsono

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Wahyu Mayangsari

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Mochammad Syaiful Anwar

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Ahmad Maksum

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Aga Ridhova

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Rini Riastuti

Coatings 2023, 13(1), 136; https://doi.org/10.3390/coatings13010136 - 10 Jan 2023

Cited by 2 | Viewed by 993

Abstract

This work reports the anti-corrosion behavior of liquid smoke from rice husk ash to unveil the contribution of its active compounds in 1 M HCl solution. In this study, the developed methodology to test, analyze, and model the novel type of green corrosion [...] Read more.

This work reports the anti-corrosion behavior of liquid smoke from rice husk ash to unveil the contribution of its active compounds in 1 M HCl solution. In this study, the developed methodology to test, analyze, and model the novel type of green corrosion inhibitor for C1018 was characterized using Electrochemical impedance spectroscopy (EIS), Potentiodynamic polarization, and deep learning methods. The inhibitor structure was characterized by Fourier transform infrared analysis (FTIR) and Ultraviolet–visible spectroscopy (UV-Vis). The surface characterization of mild steel immersed in blank and 80 ppm solution inhibitor was performed using Atomic force microscopy (AFM) analysis. The corrosion test results show that the inhibitor is considered a mixed-type inhibitor to achieve the optimum inhibition of 80 ppm at 323 K, reaching up to 99% inhibition efficiency. The AFM results show a smoother surface given a lower skewness parameter at −0.5190 nm on the treated mild steel. The artificial neural network demonstrates the lower overfitting on the inhibited steel, a higher accuracy prediction of 81.08%, and a lower loss rate of 0.6001 to model the relationship between the EIS and Potentiodynamic polarization and the evolution of the passive layer on the treated mild steel. The experiment agrees well with the prediction result to model the adsorbed inhibitor. The work can be used as a guideline to pave the way for subsequent applicability in developing green corrosion inhibitors based on experimental and artificial intelligence approaches. Full article

(This article belongs to the Special Issue Environmental Corrosion of Metals and Its Prevention)

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Open AccessArticle

Effects of the IR Drop on the Electrochemical Corrosion of X80 Pipeline Steel in Different Solutions

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Coatings 2022, 12(9), 1314; https://doi.org/10.3390/coatings12091314 - 09 Sep 2022

Viewed by 1099

Abstract

Polarization curves are popularly used in many investigations; however, some wrong results are obtained when inexperienced researchers do not deeply understand electrochemical processes. In this study, the effects of the IR drop (Deviation due to I (current) and R (resistance)) and scanning direction [...] Read more.

Polarization curves are popularly used in many investigations; however, some wrong results are obtained when inexperienced researchers do not deeply understand electrochemical processes. In this study, the effects of the IR drop (Deviation due to I (current) and R (resistance)) and scanning direction on polarization curves were investigated. Three different test methods were used to test the polarization curve of X80 pipeline steel in five kinds of solutions. The different scanning directions led to differences in the cathodic polarization curves. In addition, the effect of IR drop on the Tafel curve in acidic solutions is significantly greater than in neutral and alkaline solutions. There is a large effect of the IR drop on shapes and fitting results of polarization curves in acidic solutions, and the IR drop must be considered for the fitting of curves. Scanning direction has an influence on the shape of polarization curves when a layer of corrosion products is formed on the steel surface, and a novel two-electrode coupon was introduced to solve this problem. Full article

(This article belongs to the Special Issue Environmental Corrosion of Metals and Its Prevention)

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Open AccessArticle

Behaviour and Mechanisms of Alkali Metal Sulphate-Induced Cyclic Hot Corrosion in Relation to Gradients and Preoxidised MCrAlY-Type Coatings

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Coatings 2022, 12(7), 912; https://doi.org/10.3390/coatings12070912 - 28 Jun 2022

Viewed by 1082

Abstract

In this study, two modified MCrAlY-type coatings were prepared by the same arc ion plating process. ‘Gradient annealing’ and ‘gradient annealing plus preoxidation’ were adopted as post-treatments for the two coatings. A two-layer scale of a mixed oxide layer and a pure alumina [...] Read more.

In this study, two modified MCrAlY-type coatings were prepared by the same arc ion plating process. ‘Gradient annealing’ and ‘gradient annealing plus preoxidation’ were adopted as post-treatments for the two coatings. A two-layer scale of a mixed oxide layer and a pure alumina layer with the alumina next to the substrate was formed on the latter coating. A cyclic hot corrosion test was carried out on them with a conventional MCrAlY-type coating as a reference. The kinetics and evolution of the microstructure showed them to have greater hot corrosion resistance at 900 °C. The preformed inner alumina scale by preoxidation retarded the occurrence of internal oxidation–sulphidation to some extent. Additionally, the internal sulphidation–oxidation model is elucidated and extended. Full article

(This article belongs to the Special Issue Environmental Corrosion of Metals and Its Prevention)

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Open AccessArticle

Tribo-Behavior and Corrosion Properties of Welded 304L and 316L Stainless Steel

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Coatings 2021, 11(12), 1567; https://doi.org/10.3390/coatings11121567 - 20 Dec 2021

Cited by 2 | Viewed by 2135

Abstract

The present study investigates the electrochemical corrosion response and tribo-behavior of 304L and 316L stainless steel welded by gas metal arc welding (GMAW), which offered a high deposition rate. During this research, the metallurgically prepared welded samples were subjected to a tribological test [...] Read more.

The present study investigates the electrochemical corrosion response and tribo-behavior of 304L and 316L stainless steel welded by gas metal arc welding (GMAW), which offered a high deposition rate. During this research, the metallurgically prepared welded samples were subjected to a tribological test and a corrosion test. The wear results were favorable for 316L steel, and it showed a lower coefficient of friction than the 304L specimen. These samples also underwent characterization studies, such as X-ray diffractometry (XRD) and scanning electron microscopy (SEM), to identify the different phases obtained on the cooling of the weld pool. Finally, both specimens were compared against their mechanical properties. Owing to the above properties, the 316L sample showed lasting durability, as compared to the 304L steel. The primary compositional difference is the higher presence of molybdenum and chromium in the 316L steel, compared to the 304L stainless steel. Full article

(This article belongs to the Special Issue Environmental Corrosion of Metals and Its Prevention)

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Open AccessArticle

A Study on the Laser Removal of Epoxy Coatings on SS400 Surface by Beam Scanning Patterns

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Coatings 2021, 11(12), 1510; https://doi.org/10.3390/coatings11121510 - 08 Dec 2021

Cited by 2 | Viewed by 2211

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Shipyards are very interested in improving their working environment and resolving environmental pollution issues by replacing mechanical cleaning technologies used before and after painting processes with laser cleaning technology. Because epoxy paint is thickly coated, with a thickness of 200 μm or greater, [...] Read more.

Shipyards are very interested in improving their working environment and resolving environmental pollution issues by replacing mechanical cleaning technologies used before and after painting processes with laser cleaning technology. Because epoxy paint is thickly coated, with a thickness of 200 μm or greater, it is difficult to remove using both laser cleaning and mechanical cleaning technologies. Therefore, this study tried to obtain effective cleaning results by controlling the process parameters when removing the thick epoxy coating using a Q-switching fiber laser cleaning system with an average power of 100 W developed by our research team. The pulse duration time of the laser is 150 ns. Additionally, in order to determine whether the cleaning was sufficient, the difference in laser-induced plume/plasma was compared. By controlling the beam scanning patterns, line overlap rate, and pulse overlap rate, it was possible to obtain effective cleaning results without introducing removal deviation. In addition, the NOP increased when the laser beam overlap rate increased. This increased the amount of heat input to the material and reduced the number of scans required to remove the epoxy paint. As a result of the plume/plasma analysis, less plume/plasma was generated as the paint was removed if the epoxy paint remained on the surface. On the other hand, when all of the paint was removed, a higher brightness of plume/plasma generated by evaporation of the bare metal was observed. Full article

(This article belongs to the Special Issue Environmental Corrosion of Metals and Its Prevention)

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Open AccessArticle

Study on Wear Resistance and Corrosion Resistance of HVOF Surface Coating Refabricate for Hydraulic Support Column

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Coatings 2021, 11(12), 1457; https://doi.org/10.3390/coatings11121457 - 27 Nov 2021

Cited by 7 | Viewed by 1986

Abstract

The hydraulic support column bears loading and makes reciprocating motion ceaselessly for extended periods, so its service life is far shorter than that of the overall hydraulic support. This paper offers a comparative study on the surface coating of hydraulic support columns with [...] Read more.

The hydraulic support column bears loading and makes reciprocating motion ceaselessly for extended periods, so its service life is far shorter than that of the overall hydraulic support. This paper offers a comparative study on the surface coating of hydraulic support columns with hard chrome plating and high-velocity oxygen fuel (HVOF) thermal spraying refabricating to analyze the impact of different refabricating processes on the microstructure, hardness, corrosion resistance, and wear resistance of the coating (plating). The result shows that the structure of the HVOF coating is uniformly compact, and the HVOF WC10Co4Cr coating has better wear resistance, more than four times that of hard chrome plating. In the neutral salt spray test, the HVOF Ni60 coating shows rustiness at 720 h of the test, which suggests its corrosion resistance is nearly five times that of hard chrome plating. Hence, under the harsh corrosive wear environment, the refabricating HVOF Ni60 is a more suitable replacement for the hydraulic support column coating than the hard chrome plating. Thus, the HVOF Ni60 coating could be an effective replacement for hard chrome plating. Full article

(This article belongs to the Special Issue Environmental Corrosion of Metals and Its Prevention)

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Open AccessArticle

Effect of Glutaraldehyde on Corrosion of X80 Pipeline Steel

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Feng Tian

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Lin Pan

Coatings 2021, 11(10), 1176; https://doi.org/10.3390/coatings11101176 - 28 Sep 2021

Cited by 2 | Viewed by 1616

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Glutaraldehyde (GA) is widely employed as a biocide to control microbiologically influenced corrosion in oil fields and industrial water treatment. It might be corrosive to metal. In this study, the effect of glutaraldehyde on the corrosion behavior of X80 pipeline steel was investigated [...] Read more.

Glutaraldehyde (GA) is widely employed as a biocide to control microbiologically influenced corrosion in oil fields and industrial water treatment. It might be corrosive to metal. In this study, the effect of glutaraldehyde on the corrosion behavior of X80 pipeline steel was investigated using electrochemical measurement, weight-loss tests and scanning electron microscope (SEM). The weight-loss and electrochemical data show that GA accelerates the corrosion of samples under aerobic conditions, but just slightly influences the corrosion of steel under anaerobic conditions. The results showed that the glutaraldehyde has a minor effect on the corrosion of steel under anaerobic conditions. Full article

(This article belongs to the Special Issue Environmental Corrosion of Metals and Its Prevention)

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Open AccessArticle

Effect of Curing Agents on Electrical Properties of Low-Temperature Curing Conductive Coatings and Thermodynamic Analysis

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Coatings 2021, 11(6), 656; https://doi.org/10.3390/coatings11060656 - 30 May 2021

Cited by 1 | Viewed by 1617

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Silver-based high-conductivity coatings are used in many advanced manufacturing equipment and components, and existing coatings require high-temperature curing. This paper studies the effects of different curing agents on the electrical properties of low-temperature curing (<100 °C) conductive coatings, and analyzes the effects of [...] Read more.

Silver-based high-conductivity coatings are used in many advanced manufacturing equipment and components, and existing coatings require high-temperature curing. This paper studies the effects of different curing agents on the electrical properties of low-temperature curing (<100 °C) conductive coatings, and analyzes the effects of different curing temperatures and curing time on the surface resistance, square resistance and resistivity of conductive coatings. The response surface method in Design Expert was used to construct the model, and the curing thermodynamics of different curing agents were analyzed by DSC. It was found that curing agents with lower Tm and activation energy, higher pre-exponential factor and more flexible segments are beneficial to the preparation of highly conductive coatings. Full article

(This article belongs to the Special Issue Environmental Corrosion of Metals and Its Prevention)

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Open AccessArticle

Effect of Sulfate-Reducing Bacteria (SRB) on the Corrosion of Buried Pipe Steel in Acidic Soil Solution

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Lijuan Chen

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Bo Wei

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Xianghong Xu

Coatings 2021, 11(6), 625; https://doi.org/10.3390/coatings11060625 - 24 May 2021

Cited by 11 | Viewed by 2990

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The influence of sulfate-reducing bacteria (SRB) on the corrosion behaviors of X80 pipeline steel was investigated in a soil environment by electrochemical techniques and surface analysis. It was found that SRB grew well in the acidic soil environment and further attached to the [...] Read more.

The influence of sulfate-reducing bacteria (SRB) on the corrosion behaviors of X80 pipeline steel was investigated in a soil environment by electrochemical techniques and surface analysis. It was found that SRB grew well in the acidic soil environment and further attached to the coupon surface, resulting in microbiologically influenced corrosion (MIC) of the steel. The corrosion process of X80 steel was significantly affected by the SRB biofilm on the steel surface. Steel corrosion was inhibited by the highly bioactive SRB biofilm at the early stage of the experiment, while SRB can accelerate the corrosion of steel at the later stage of the experiment. The steel surface suffered severe pitting corrosion in the SRB-containing soil solution. Full article

(This article belongs to the Special Issue Environmental Corrosion of Metals and Its Prevention)

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Study on the Corrosion Characteristics of Grounding Materials in Acid Red Soil

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Coatings 2022, 12(2), 111; https://doi.org/10.3390/coatings12020111 - 19 Jan 2022

Viewed by 1131

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The corrosion of grounding materials seriously threatens the safe operation of the power system. The corrosion resistance of four typical grounding materials as carbon steel, galvanized steel, Zn–Al-coated steel, copper was studied in acid red soil. The results show that carbon steel, galvanized [...] Read more.

The corrosion of grounding materials seriously threatens the safe operation of the power system. The corrosion resistance of four typical grounding materials as carbon steel, galvanized steel, Zn–Al-coated steel, copper was studied in acid red soil. The results show that carbon steel, galvanized steel, Zn–Al-coated steel, copper exhibit different corrosion resistance behaviors, respectively. The corrosion rate of these grounding materials usually increases first and then slowly decreases. Pitting corrosion is the main corrosion feature of carbon steel. The corrosion rate of carbon steel is the largest compared to the other three grounding materials. The corrosion rate of galvanized steel is higher than that of copper. Copper has a low corrosion rate and exhibits good corrosion resistance, but the cost of copper is high and it causes heavy metal pollution. The corrosion rate of Zn–Al-coated steel is the lowest compared to the other three grounding materials, and it has the best corrosion resistance. Full article

(This article belongs to the Special Issue Environmental Corrosion of Metals and Its Prevention)

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