Corros. Mater. Degrad., Volume 3, Issue 1 (March 2022) – 9 articles

A realistic forecast of the impact of CaCl₂-blended acrylic polymer (CP) emulsions on steel reinforcement corrosion is difficult without a detailed study. This is traceable to the conflicting effects of cement additives on the chloride threshold value, pore solution chemistry, and matrix resistivity. Hence, in the study reported herein, the actual influence of 0.5–1.5 wt% CP on rebar corrosion was assessed via an accelerated corrosion test. The macrocell current, half-cell potential measurements (HCP), reinforcement cover crack propagation, and rebar deterioration were monitored. The resistance of mortar specimens to acid-induced degradation was also evaluated over time. The corrosion test results indicate that steel rebar corrosion initiation in the mortar expedited as the CP dosage in mixtures increased. Consequently, the time required for the CP-modified specimens to crack shortened. Moreover, non-uniform rebar section loss and surface crack width widening were also observed in CP-modified mortar specimens. However, X-ray diffraction (XRD) analyses of the plain Ref and 1.5% CP corrosion byproduct residues indicated that key phases such as akaganeite, goethite, lepidocrocite, hematite, and magnetite were quantitatively similar. Interestingly, the addition of 1.0–1.5% CP to mixtures enhanced the acid attack resistance of mortars. For now, these results indicate that CP should only be used as a chemical admixture in unreinforced cement composites. Full article

The corrosion resistance of the AW7075 alloy after RRA treatment was evaluated. The corrosion rate in the NSS test was assessed and the electrochemical parameters were determined. The results were compared with the results obtained for the alloy subjected to conventional aging (T6) and dual-stage aging (DA). In order to determine the state of alloy hardening, the tests were carried out simultaneously with the material hardness measurements and microscopic examinations. The hardness of the AW7075 alloy increased in the following order: DA < T6 < RRA. The tests revealed that the achieved increase in strengthening was correlated with the preservation of high resistance to general corrosion of the alloy after RRA treatment. After the corrosion tests, SEM microscopic observations were also carried out to determine the corrosion features. The corrosion rate can be arranged in the following order: RRA < T6 ≈ DA. At the same time, the alloy after RRA was characterized by the lowest value of the corrosion potential and the open circuit. The corrosion potential value can be presented in increasing order: RRA < T6 ≈ DA. The corrosion behavior of the aluminum alloy after dual-stage aging was similar to that of T6. However, it was accompanied by a decline in hardening. Full article

Offshore installations, e.g., offshore wind turbines and pipelines, are exposed to various mechanical loads due to wind or waves and corrosive loads such as seawater or mist. ZnAl-based thermal sprayed coatings, often in conjunction with organic coatings, provide sufficient corrosion protection and are well established for applications in marine environments. In this study, machine hammer peening (MHP) is applied after twin wire arc spraying to improve corrosion fatigue behavior through increased hardness, reduced porosity, and roughness compared to as-sprayed coatings. Mn-alloyed structural steel S355 J2 + C with and without ZnAl4 coating as well as with MHP post-treated ZnAl4 coating were cyclically loaded in 3.5% NaCl solution. MHP leads to a uniform coating thickness with lower porosity and roughness. ZnAl4 coating and MHP post-treatment improved corrosion fatigue behavior in the high cycle fatigue regime with an increase of the stress amplitude, applied to reach a number of cycles 1.2 × 10⁶, up to 115% compared to sandblasted specimens. Corrosive attack of the substrate steel was successfully avoided by using the coating systems. Stress- and microstructure-dependent corrosion fatigue damage mechanisms were evaluated by mechanical and electrochemical measurement techniques. Full article

The main objective of this study was to assess the influence of salt concentration on the corrosion behaviour, including the role of hydrodynamic conditions, of two broad classes of ferrous engineering materials. These are comprised of alloys, typified by a low-alloy steel (UNS G43400) that corrodes actively in aqueous conditions and a range of passive-film-forming stainless steels (UNS S31600, UNS S15500 and UNS S32760). Corrosion monitoring employed electrochemical (potentiodynamic polarisation) techniques. Three concentrations of aerated sodium chloride were utilised: 0.05 wt% NaCl, 3.5 wt% NaCl and 10 wt% NaCl. In quiescent, liquid impingement and solid/liquid impingement conditions, the corrosion rate of the low-alloy steel was observed to peak at 3.5 wt% NaCl, followed by a reduction in 10 wt% NaCl solution. These findings expand the range of previously reported trends, focused on static conditions. Such corrosion rate/salinity trends were observed to be dictated by the progress of the anodic reaction rather than influence on the cathodic reaction. Detailed studies were undertaken using segmented specimens to facilitate comparisons of the influence of hydrodynamic variations on corrosion behavior; these revealed that such variations influence the corrosion rates of low-alloy steel to a much lesser extent than the effect of changes in salinity. For the stainless steels, in quiescent and flowing conditions, when surface passive films are stable, there was a constant increase in corrosion rate with salinity. In solid-liquid conditions, however, the periodic film-destruction/repassivation events resulted in a similar corrosion rate/salinity trend to that displayed by the low-alloy steel, but with a much larger effect of hydrodynamic conditions. Additonally, the study revealed an underlying influence of stainless steel composition that mirrored, to an extent, the corrosion behaviour in pitting/re-passivation situations Full article

The present work studies the effect of fly ash content (0–25 wt.%), pH (8, 12.5), and steel type (316L, 304L) on the cyclic polarization of stainless steel rebars in electrolytes, simulating fresh concrete exposed to acid rain and corroded concrete cover that has exposed the reinforcement to direct acid rain attack. At the same time, it tries to elucidate the corrosion inhibition activities of a Greek lignite fly ash that is a high-Ca fly ash with a questionable effect on the corrosion resistance of concrete. A higher pH results in lower corrosion rates for both steels and all fly ash content. However, different passivity trends are noted for the two steels as a function of pH. The partial replacement of Ca(OH)₂ with fly ash up to 20 wt.% has a beneficial effect on the electrochemical behavior of the stainless steel rebars, in terms of both uniform and localized corrosion resistance. However, this trend is reversed at 25 wt.% FA. The reasons for such trends are explored via microstructural examinations of the steels after polarization and XRD analysis of fly ash, as well as reinforced concrete containing fly ash. Full article

Corrosion of mooring chains is regarded as one of main threats to the offshore mooring systems. Localized corrosion is even more dangerous than uniform corrosion because it may not show significant mass loss but it can cause stress concentration and initiate cracks under force, leading to accelerated degradation of mooring chains. Localized corrosion of steel in seawater is influenced by many factors such as the local heterogeneities of the steel, and the local electrochemical and microbiological environments. It is difficult to predict and the mechanism is not fully understood. The aim of this work was to study the mechanism of localized corrosion on mooring chain steel in seawater which is helpful in the search for corresponding monitoring tools and mitigation methods. The corrosion behavior of chain steel grade R4 was studied in artificial seawater and artificial seawater containing microorganisms collected from a practice field. The corrosion behavior of the steel was studied using different techniques such as potentiodynamic polarization, linear polarization resistance measurements and electrochemical impedance spectroscopy. The microstructures such as inclusions and compositions of the chain steel were studied using SEM: Scanning Electron Microscope and EDS: Energy Dispersive Spectroscopy. The microbial cells were observed using epi-fluorescence microscopy. The corrosion morphology and pit geometry were investigated using photo-microscopy. The localized corrosion rate has been found to be much higher than the uniform corrosion rate of the steel in the seawater in the presence of bacteria. In the case of localized corrosion, applying uniform corrosion measurement techniques and formulas is not considered representative. The representative areas have to be introduced to match physical results with the measurements. Inclusions, such as MnS and TiVCr found in the steel have a critical influence on localized corrosion. The corrosion mechanism of the steel in seawater is discussed. Full article

The cement industry gains increasing public attention because of the high CO₂ emissions for which it is accountable. One approach to improve the carbon footprint of cement production is the development of alternative binders, which can be produced with less energy consumption. These alternative binders have a reduced clinker to cement ratio or contain no Portland cement at all. For the corrosion protection of the reinforcement, the same requirements apply as for standardized types of cement. To perform this evaluation, a basic understanding is necessary of the products formed during hydration, the composition of the pore solutions and pore structure, and their influence on the resistance to carbonation. In this study, various alternative binders, such as novel types of composite cement with calcined clays or modified steel mill slag, alkali-activated materials, C$\overline{\mathrm{S}}$A cement, and a C-S-H binder, are presented. The conducted investigations at mortars and cement pastes show the differences in hydration, microstructure development, and pH. The changes in microstructure and phase assemblage due to carbonation and the suitability of carbonation testing at an elevated CO₂ content of 1 vol.-% for the different binders are also presented. Full article

The corrosion processes of carbon steel immersed in natural seawater are influenced by microorganisms due to important biological activity. An analysis of the corrosion product layers formed on carbon steel coupons in natural or artificial seawater revealed that sulfate green rust GR(SO₄²⁻) was favored in natural environments. In this paper, the role of organic matter/bacteria on the formation and transformation of this compound are addressed. GR(SO₄²⁻) was precipitated from Fe(II) and Fe(III) salts in the presence of various marine bacterial species not involved in the redox cycle of Fe or S. Abiotic experiments were performed for comparison, first without any organic species and then with sodium acetate added as a small organic ion. The obtained aqueous suspensions were aged at room temperature for 1 week. The number of bacteria (CFU/mL) was followed over time and the solid phases were characterized by XRD. Whatever the fate of the bacteria (no activity, or activity and growth), the formation of GR(SO₄²⁻) was favored and its transformation to magnetite completely inhibited. This effect is attributed to the adsorption of organic molecules on the lateral sides of the GR(SO₄²⁻) crystals. A similar effect, though less important, was observed with acetate. Full article