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Feature Paper Collection of “Current Challenges in Corrosion Research”

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A special issue of Metals (ISSN 2075-4701). This special issue belongs to the section "Corrosion and Protection".

Deadline for manuscript submissions: 31 May 2024 | Viewed by 12491

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Prof. Dr. Belén Díaz Fernández

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Department of Materials Science and Engineering, University of Vigo, 36310 Vigo, Spain
Interests: surface treatments; interfacial characterization; wear and corrosion; protective coatings and films; surface characterization techniques; advanced surface engineering; novel surface solutions
Special Issues, Collections and Topics in MDPI journals

Prof. Dr. Jianqiang Wang

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Shenyang National Laboratory for Materials Science, Institute of Metal Research, Chinese Academy of Sciences, Shenyang, China
Interests: metallic glasses; coatings; powder metallurgy; additive manufacturing; corrosion; mechanical properties
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Prof. Dr. Branimir N. Grgur

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Faculty of Technology and Metallurgy, University of Belgrade, Karnegijeva 4, 11020 Belgrade, Serbia
Interests: Intrinsically conducting polymers; electrochemical synthesis; electrochemical characterisation; corrosion; electrode materials
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Special Issue Information

Dear Colleagues,

Long-lasting materials have become a priority to reduce the carbon footprint and mitigate climate change. Raw materials are increasingly scarce, and the product manufacturing costs are reaching unprecedented levels. In addition to new technologies with, in most cases, hazardous exposure conditions, the development of new design strategies, prevention methods, and monitoring procedures is required to fight against corrosion. Thus, corrosion control is essential for the goal of a sustainable society.

This Special Issue is intended to compile the most recent advances in corrosion research. Contributions from traditional fields such as transport, chemical industry or civil engineering are welcome, but innovative improvements in the areas of additive manufacturing or biomaterials are also expected.

Methods for corrosion mitigation, including environmentally friendly solutions such as high-performance coatings, cost-effective advanced materials, inhibitors, or novel solutions, as well as innovative testing procedures, including sensors or remote monitoring, to reliably assess corrosion behavior and to predict corrosion damage are encouraged.

Prof. Dr. Belén Díaz Fernández
Dr. Jianqiang Wang
Prof. Dr. Branimir N. Grgur
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. Metals 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 prevention
monitoring
design
modeling and prediction

Published Papers (10 papers)

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Research

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17 pages, 6560 KiB

Open AccessArticle

Advanced EIS-Based Sensor for Online Corrosion and Scaling Monitoring in Pipelines of Geothermal Power Plants

by Lorena Freire, Ignacio Ezpeleta, Julio Sánchez and Rubén Castro

Metals 2024, 14(3), 279; https://doi.org/10.3390/met14030279 - 27 Feb 2024

Viewed by 754

Abstract

Corrosion and scaling in metal pipelines are the major issues in the exploitation of geothermal sources. Geothermal fluids are complex mixtures consisting of dissolved gases and high-salinity solutions. This creates very aggressive environments primarily due to the high concentrations of carbon dioxide (CO₂), hydrogen sulfide (H₂S), chlorides, and other chemical species. Besides, the high temperature of the brines also increases corrosion rates, which can lead to failures related to stress and fatigue corrosion. On the other hand, reinjection of cooled brine exiting the heat exchanger favors the onset of scaling, since the chemicals dissolved in geothermal waters may tend to precipitate promoting inorganic depositions on the casing. Corrosion and scaling phenomena are difficult to detect visually or monitor continuously. Standard techniques based on pH, temperature pressure, electrical resistance measurements, chemistry composition, and physical properties are habitually applied as indirect methods for corrosion rate control. These methods, however, lack enough robustness for accurate and reliable measuring of the corrosion behavior of materials. To address this issue, a novel system has been proposed for the continuous monitoring of corrosion degradation caused by the effect of the geothermal brines. The present work aims to design, develop, and validate a dedicated electrochemical-based test system for online and onsite monitoring of the corrosion rate and scaling growth occurring on different materials exposed to real operating conditions. This system uses non-standard methods based on electrochemical impedance spectroscopy (EIS) to obtain quantitative data related to the material quality. It can be used to track the condition of the pipeline, reducing the operation and maintenance (O&M) costs and shutdown times. By providing early corrosion rate data, this system allows the prediction of failures in critical units of the plant. Full article

(This article belongs to the Special Issue Feature Paper Collection of “Current Challenges in Corrosion Research”)

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17 pages, 3126 KiB

Open AccessArticle

Evaluation of the Applicability of Voltammetric Modes in Scanning Electrochemical Microscopy for In Situ Corrosion Characterisation of Copper-Based Materials

by Brenda Hernández-Concepción, Adrián Méndez-Guerra, Ricardo M. Souto and Javier Izquierdo

Metals 2023, 13(12), 1965; https://doi.org/10.3390/met13121965 - 01 Dec 2023

Viewed by 841

Abstract

Chemical imaging of corrosion processes involving copper species using scanning electrochemical microscopy has been hampered by the lack of soluble oxidation states for copper that can be achieved by amperometric conversion at the tip. Indeed, the only possibility is to reduce the corrosion products at the tip, thus modifying the chemical response of the electrode material and requiring subsequent redissolution of the copper deposits. Consequently, the limitations arising from the system prevented a full-scale quantification, requiring the development of new methodologies or the optimisation of those currently available, as we pursued with the present work. Therefore, the voltammetric behaviours of gold macro- and microelectrodes were evaluated with respect to the collection and redissolution of Cu²⁺ ions, with the aim of using them as sensing probes in scanning electrochemical microscopy (SECM) to investigate the activity of copper surfaces in acidic chloride-containing environments. Cyclic and square-wave voltammetric techniques were explored for copper collection and subsequent stripping on Au microelectrode tips in SECM with the objective to capture in situ image electrochemical reactivity distributions across copper surfaces undergoing corrosion. Full article

(This article belongs to the Special Issue Feature Paper Collection of “Current Challenges in Corrosion Research”)

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13 pages, 11915 KiB

Open AccessArticle

Effect of Al/Mg Ratio on the Microstructure and Phase Distribution of Zn-Al-Mg Coatings

by Ziyue Zhang, Jie Zhang, Xingyuan Zhao, Xin Liu, Xuequn Cheng, Sheming Jiang and Qifu Zhang

Metals 2023, 13(12), 1963; https://doi.org/10.3390/met13121963 - 01 Dec 2023

Cited by 3 | Viewed by 733

Abstract

In contrast with studies such as those on the effect of a single elemental variable on Zn-Al-Mg coatings, Mg/Al is considered a variable parameter for evaluating the microstructure of Zn-Al-Mg coatings in this work, and the combined effect of the two elements is also taken into account. The Mg/Al ratios in the continuous hot-dip plating of low-alumina Zn-Al-Mg coatings were 0.63, 0.75, 1.00, 1.25, and 1.63. respectively, and the microstructures of the different coatings were observed using scanning electron microscopy (SEM). The surface elemental distributions of the coatings were analyzed with energy dispersive spectrometry (EDS) and X-ray diffraction (XRD) analysis to understand the phase distributions of the coatings, which mainly consisted of a zinc monomeric phase, a binary eutectic phase (Zn/MgZn₂), and a ternary eutectic phase (Zn/Al/MgZn₂). Statistical calculations of the phase distributions in colored SEM images were performed using ImageJ-win64 software, comparative analysis of the solidification simulation results was carried out with thermodynamic simulation software (PANDAT-2023), and evaluation of the corrosion resistance of the platings was performed using macroscopic cyclic immersion corrosion experiments. The results show that with the increase in the Mg/Al ratio, the binary eutectic phase in the coatings gradually increased, the variation trend of the ternary eutectic phase was not obvious, and the corrosion resistance of the coatings gradually improved. Full article

(This article belongs to the Special Issue Feature Paper Collection of “Current Challenges in Corrosion Research”)

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16 pages, 8120 KiB

Open AccessFeature PaperArticle

Investigation of Long-Term Corrosion of CoCrMoW Alloys under Simulated Physiological Conditions

by Loredana Preda, Sorina Alexandra Leau, Cristina Donath, Elena Ionela Neacsu, Monica Elisabeta Maxim, Veronica Sătulu, Alexandru Paraschiv and Maria Marcu

Metals 2023, 13(11), 1881; https://doi.org/10.3390/met13111881 - 13 Nov 2023

Cited by 1 | Viewed by 778

Abstract

The corrosion resistance of two cast CoCr-based alloys with different amounts of chromium and with different alloying elements in the bulk composition of the alloy was assessed. In this study, we investigated the corrosion behavior of Co21Cr8Mo7W and Co29Cr7W by open-circuit potential (OCP), potentiodynamic polarization (PP) and electrochemical impedance spectroscopy (EIS) in 0.1 M phosphate buffer solution (PBS) at 37 °C with long immersion times. After 1000 h of immersion, the corrosion current density (i_cor), estimated from anodic polarization tests, was lower for the Co21Cr8Mo7W (i.e., 49 nA cm⁻²) alloy compared to the Co29Cr7W alloy (180 nA cm⁻²). As regards the corrosion potential (E_cor), a greater value was observed for Co21Cr8Mo7W (i.e., −59 mV vs. Ag/AgCl) compared to Co29Cr7W (i.e., −114 mV vs. Ag/AgCl). Microstructure analysis before and after immersion revealed the formation of a more compact passive film on the Co21Cr8Mo7W alloy, suggesting superior corrosion resistance compared to Co29Cr7W. These findings suggest better corrosion resistance for the film formed on the alloy containing lower amounts of Cr and two alloying elements, Mo and W. These results are promising in terms of medical applications because they open the door to new strategies for obtaining alloys with lower chromium content and with more protective anti-corrosion properties. Full article

(This article belongs to the Special Issue Feature Paper Collection of “Current Challenges in Corrosion Research”)

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13 pages, 3260 KiB

Open AccessArticle

The Use of Thin Films as Defect Sealants to Increase the Corrosion Resistance of Thermal Spray Coatings

by Alex Lanzutti, Francesco Sordetti, Elia Marin, Francesco Andreatta, Antonio Carabillo, Matteo Querini, Samuele Porro, Alfredo Rondinella, Michele Magnan and Lorenzo Fedrizzi

Metals 2023, 13(10), 1778; https://doi.org/10.3390/met13101778 - 20 Oct 2023

Viewed by 690

Abstract

Thermal spray-coated components are widely used as wear-resistant coatings in many applications. However, these coatings have high levels of discontinuities that affect the corrosion resistance of the coated system. To reduce this problem, these coatings are usually sealed with liquid sealants (metals, organic or inorganic). The aim of this work is to seal the surface discontinuities of thermal-sprayed coatings using PVD and/or ALD coatings. To this end, CrN (arc deposition PVD) and TiO2 (ALD) coatings were deposited on thermal-sprayed alumina coatings. The samples produced were then analysed in both cross-sectional and planar views to detect the possible permeation of the thin film coatings into the thermal spray defects. Rf-GDOES measurements were performed to detect the very thin ALD deposit on the surface. The corrosion resistance of the sealed coatings was verified with immersion tests, wherein the OCP was monitored for 24 h, and potentiodynamic tests were performed after 15 min and 24 h immersions. The results showed that the thin films were not able to block the permeation of corrosive media, but they could reduce the permeation of corrosive media with a beneficial behaviour on corrosion resistance. Full article

(This article belongs to the Special Issue Feature Paper Collection of “Current Challenges in Corrosion Research”)

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15 pages, 11673 KiB

Open AccessFeature PaperArticle

Investigation of Corrosion Properties and Composition of the Surface Formed on AISI 321 Stainless Steel by Ion Implantation

by Tamara I. Dorofeeva, Marina V. Fedorischeva, Tatiana A. Gubaidulina, Oleg V. Sergeev, Alfred R. Sungatulin and Viktor P. Sergeev

Metals 2023, 13(8), 1468; https://doi.org/10.3390/met13081468 - 15 Aug 2023

Cited by 4 | Viewed by 895

Abstract

In this work, the corrosion resistance of AISI 321 stainless steel is increased through. the two-stage implantation of oxygen ions and of both aluminum and boron ions together. During ion implantation, a modified layer with a thickness of about 200 nm is formed, which affects the properties of material. The increase in corrosion resistance is confirmed by prolonged acid corrosion tests at pH 3.5 and by accelerated electrochemical tests using a potentiostat. The corrosion rate of the implanted sample is 0.708 μA/cm², in contrast to the non-implanted sample (1.26 μA/cm²). The modified surface layer is examined using X-ray photoelectron spectroscopy (XPS), secondary-ion mass spectrometry (SIMS), and transmission electron microscopy (TEM). Aluminum and boron are implanted to a depth of more than 250 nm. It is found that the modified surface of the stainless steel substrate contains oxides of implanted ions (Al₂O₃) and oxides of substrate ions (Cr₂O₃ and NiCr₂O₄). Full article

(This article belongs to the Special Issue Feature Paper Collection of “Current Challenges in Corrosion Research”)

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12 pages, 6025 KiB

Open AccessArticle

Influence of Alkyd Composite Coatings with Polyaniline Doped with Different Organic Acids on the Corrosion of Mild Steel

by Branimir N. Grgur, Aleksandra S. Popović and Ayad Salem

Metals 2023, 13(8), 1364; https://doi.org/10.3390/met13081364 - 29 Jul 2023

Viewed by 979

Abstract

Composite coatings prepared by mixing 5 wt.% polyaniline with commercial alkyd-based paints were applied on carbon steel. The polyaniline emeraldine chloride salt was prepared by procedure recommended by IUPAC, including deprotonation by ammonia hydroxide, and reprotonation with sulfamic, succinic, citric, and acetic acids with different doping degrees or oxidation states. The steel samples with base and composite coatings were immersed in 3% NaCl and the corrosion current density was determined after 96 h in situ using the ASTM 1,10-phenanthroline method. The samples were also inspected by optical microscopy. It was shown that the composite coatings reduced the possibility of blister formations and delamination. The corrosion current density and the appearance of the corrosion products, whose area was determined by ImageJ software, closely followed the initial oxidation state of the polyaniline. It was also shown that damaged composite coatings with higher degrees of oxidized (doped) polyaniline were more prone to formation of corrosion products. The role of the initial state of the polyaniline is discussed. It is suggested that such behavior could be connected to the oxygen reduction reaction mechanism that proceeds mainly via two electron paths on the polyaniline particles, releasing a much smaller amount of hydroxyl ions, which is responsible for the delamination and blister formation of the commercial coatings. Full article

(This article belongs to the Special Issue Feature Paper Collection of “Current Challenges in Corrosion Research”)

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13 pages, 3048 KiB

Open AccessFeature PaperArticle

Biofilm-Induced Corrosion Inhibition of Q235 Carbon Steel by Tenacibaculum mesophilum D-6 and Bacillus sp. Y-6

by Xiaoxi Ruan, Linlin Yang, Yan Wang, Yizhe Dong, Dake Xu and Mingxing Zhang

Metals 2023, 13(4), 649; https://doi.org/10.3390/met13040649 - 25 Mar 2023

Cited by 2 | Viewed by 1608

Abstract

The corrosion of carbon steel causes dramatic economic losses each year. Since conventional corrosion prevention approaches may cause pollution problems to the environment, ecofriendly and effective corrosion approaches are desired. Microbiologically influenced corrosion inhibition (MICI) has been reported as a sustainable corrosion prevention method. This work aims to evaluate the corrosion inhibition effect of two bacterial strains, Tenacibaculum mesophilum D-6 and Bacillus sp. Y-6 by choosing Q235 carbon steel as a model system. Scanning electron microscopy (SEM), confocal laser scanning microscopy (CLSM) and a series of electrochemical techniques were applied to study the corrosion prevention effect. The electrochemical and pitting results indicated that T. mesophilum D-6 displayed a better corrosion protection effect. T. mesophilum D-6 formed a denser and thicker biofilm on the Q235 surface than Bacillus sp. Y-6. The maximum thickness of the T. mesophilum D-6 biofilms was 11.6 ± 0.7 μm, which is about twice as thick than that of Bacillus sp. Y-6. The corrosion prevention mechanism was ascribed to the formation of biofilms as a barrier to block corrosive agents such as O₂. This study provides a theoretical foundation for the application of biofilms as green and effective corrosion inhibitors for carbon steel. Full article

(This article belongs to the Special Issue Feature Paper Collection of “Current Challenges in Corrosion Research”)

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21 pages, 14270 KiB

Open AccessEditor’s ChoiceArticle

Effect of Laser Shock Peening on the Stress Corrosion Cracking of 304L Stainless Steel

by Young-Ran Yoo, Seung-Heon Choi and Young-Sik Kim

Metals 2023, 13(3), 516; https://doi.org/10.3390/met13030516 - 03 Mar 2023

Cited by 6 | Viewed by 1931

Abstract

Storage canisters used in nuclear power plants operating in seaside areas—where the salt content in the atmosphere is high—may be susceptible to chloride-induced stress corrosion cracking (CISCC). Chloride-induced stress corrosion cracking is one of the ways in which dry storage canisters made of stainless steel can degrade. Stress corrosion cracking depends on the microstructure and residual stress, and it is therefore very important to improve the surface properties of materials. Laser shock peening both greatly deforms the material surface and refines grains, and it generates compressive residual stress in the deep part from the surface of the material. This study focused on the effect of laser shock peening on the stress corrosion cracking of 304L stainless steel. The laser shock peening was found to induce compressive residual stress from the surface to a 1 mm depth, and the SCC properties were evaluated by a U-bend test. The results showed that the SCC resistance of laser-peened 304L stainless steel in a chloride environment was enhanced, and that it was closely related to grain size, the pitting potential of the cross section, and residual stress. Full article

(This article belongs to the Special Issue Feature Paper Collection of “Current Challenges in Corrosion Research”)

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29 pages, 15823 KiB

Open AccessEditor’s ChoiceReview

Corrosion Behavior of High Entropy Alloys and Their Application in the Nuclear Industry—An Overview

by Tianrun Li, Debin Wang, Suode Zhang and Jianqiang Wang

Metals 2023, 13(2), 363; https://doi.org/10.3390/met13020363 - 10 Feb 2023

Cited by 9 | Viewed by 2491

Abstract

With multiple principal components, high entropy alloys (HEAs) have aroused great interest due to their unique microstructures and outstanding properties. Recently, the corrosion behavior of HEAs has become a scientific hotspot in the area of material science and engineering, and HEAs can exhibit good protection against corrosive environments. A comprehensive understanding of the corrosion mechanism of HEAs is important for further design of HEAs with better performance. This paper reviews the corrosion properties and mechanisms of HEAs (mainly Cantor alloy and its variants) in various environments. More crucially, this paper is focused on the influences of composition and microstructure on the evolution of the corrosion process, especially passive film stability and localized corrosion resistance. The corrosion behavior of HEAs as structural materials in nuclear industry applications is emphasized. Finally, based on this review, the possible perspectives for scientific research and engineering applications of HEAs are proposed. Full article

(This article belongs to the Special Issue Feature Paper Collection of “Current Challenges in Corrosion Research”)

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