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Corrosion Mechanism and Protection Technology of Metallic Materials

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A special issue of Materials (ISSN 1996-1944). This special issue belongs to the section "Corrosion".

Deadline for manuscript submissions: 20 May 2025 | Viewed by 8557

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Special Issue Editors

Dr. Shanshan Hu

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Guest Editor

Department of Mechanical and Aerospace Engineering, Benjamin M. Statler College of Engineering and Mineral Resources, West Virginia University, Morgantown, WV 26506, USA
Interests: high-temperature oxidation, hot corrosion, high-entropy alloys; electrochemistry

Dr. Xiang Zhang

E-Mail Website
Guest Editor

Department of Mechanical & Materials Engineering, University of Nebraska–Lincoln, Lincoln, NE, USA
Interests: field-assisted sintering; laser processing; high-entropy ceramics and alloys; lunar soil simulants; UHTCs

Special Issue Information

Dear Colleagues,

According to several studies in the last 30 years, the annual direct cost of corrosion to an industrial company is up to 3.1% of the country’s gross national product. Moreover, the corrosion of metallic materials also significantly impairs human safety and the environment. To mitigate the negative effects associated with corrosion, it is of significant importance to conduct research on corrosion to discover its underlying mechanism and to develop effective and efficient methods to mitigate the corrosion process. The intent of this Special Issue is to provide an overview of the new advances in the relevant study of corrosion, ranging from fundamental studies to applications.

This Special Issue covers a whole spectrum of investigations and studies on metallic corrosion, including stress corrosion cracking, soil corrosion, atmospheric corrosion, and high-temperature corrosion, which is meaningful and helpful to understand the corrosion mechanism in different media. In addition, research on novel methods to mitigate the degradation of base metals, including the development of new coatings, new corrosion inhibitors, and cathodic protection, is also welcome.

Dr. Shanshan Hu
Dr. Xiang Zhang
Guest Editors

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Keywords

metal corrosion
coating development
oxidation
cathodic protection
corrosion inhibitor

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Published Papers (7 papers)

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Research

20 pages, 10591 KiB

Open AccessArticle

Study and Characterisation of Bimetallic Structure (316LSI and S275JR) Made by Hybrid CMT WAAM Process

by Alejandro Pereira, Antonio Alonso, Primo Hernández, Javier Martínez, David Alvarez and Michal Wieczorowski

Materials 2024, 17(22), 5422; https://doi.org/10.3390/ma17225422 - 6 Nov 2024

Viewed by 699

Abstract

The main objective of this research is to conduct an experimental investigation of the bimetallic material formed by 316LSI stainless steel and S275JR structural steel, produced via hybrid wire arc additive manufacturing technology with cool metal transfer welding and machining, and with the objective of being able to reduce the industrial cost of certain requirements for one of the materials. A methodological investigation has been carried out starting with welding beads of 316LSI on S275JR plates, followed by overlapping five beads and conducting final experiments with several vertical layers, with or without intermediate face milling. The results achieved optimal bead conditions for wire speeds of 4 m/min and 5 m/min at a travel speed of 400 mm/min. Overlap experiments show that the best deposition results are obtained with an overlap equal to or greater than 28%. Cooling time does not significantly influence the final geometry of the coatings. Regarding metallographic analysis, the filler material presents an austenitic columnar structure. In the base material, a bainitic structure with inferred grain refinement was detected in the heat-affected zone. An increase in hardness is observed in the heat-affected zone. In the results obtained from the tensile tests of the bimetallic material, an increase in mechanical strength and yield strength is observed in the tested specimens. Full article

(This article belongs to the Special Issue Corrosion Mechanism and Protection Technology of Metallic Materials)

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17 pages, 7054 KiB

Open AccessArticle

Corrosion Behavior of Nacre-Inspired (TiBw-TiB₂)/Al Composites Fabricated by Freeze Casting

by Jidong Zhang, Mingfang Qian, Ruiqing Yang, Feng Yu, Xuexi Zhang, Zhenggang Jia, Aibin Li, Guisong Wang and Lin Geng

Materials 2024, 17(11), 2534; https://doi.org/10.3390/ma17112534 - 24 May 2024

Viewed by 698

Abstract

Nacre-inspired metal matrix composites have received much attention due to their excellent deformation coordination ability, which can achieve the synergy of strength and ductility. The preparation of nacre-like Al matrix composites by freeze casting has been a promising application, but the continuous ceramic-rich layer affects the corrosion resistance of the composites, facing complex corrosion problems during service. In this work, the microstructure and corrosion behavior of the nacre-inspired (TiBw-TiB₂)/Al composites fabricated by freeze casting and squeeze casting were systematically studied. The results indicated that the Al layers and ceramic-rich layers had little change, about 35 μm and 31 μm, respectively, with an increasing ratio of the Ti/TiB₂. Meanwhile, a high Ti/TiB₂ ratio resulted in an increase in the Fe-Ti intermetallic phases, which was detrimental to the corrosion performance of the composites and was prone to pitting. The electrochemical test results showed that the 3Ti7TiB₂ composite had the lowest corrosion current density (15.9 μA) and intergranular corrosion depth (231 μm), indicating that it had the best corrosion resistance, which can be attributable to its stable and dense passivation film. Two different corrosion phenomena during the intergranular corrosion test existed in the present nacre-inspired (TiBw-TiB₂)/Al composites: intergranular corrosion in the Al matrix layer and pitting corrosion in the ceramic-rich layer. Among all the composites, the corrosion depth of the 3Ti7TiB₂ composite was the smallest and significantly less than that of the 2024Al alloy. In addition, the continuous ceramic-rich layer acted as a corrosion channel during corrosion, significantly degrading the corrosion resistance of the nacre-like Al composites. Full article

(This article belongs to the Special Issue Corrosion Mechanism and Protection Technology of Metallic Materials)

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22 pages, 14618 KiB

Open AccessArticle

Corrosion Behavior of Ni-Cr Alloys with Different Cr Contents in NaCl-KCl-MgCl₂

by Peng Lei, Lizhen Zhou, Yu Zhang, Fuli Wang, Qinzhe Li, Jiangyan Liu, Xueyun Xiang, Hang Wu, Wen Wang and Fuhui Wang

Materials 2024, 17(10), 2335; https://doi.org/10.3390/ma17102335 - 14 May 2024

Viewed by 983

Abstract

This study investigates the corrosion behavior of Ni-Cr binary alloys, including Ni-10Cr, Ni-15Cr, Ni-20Cr, Ni-25Cr, and Ni-30Cr, in a NaCl-KCl-MgCl₂ molten salt mixture through gravimetric analysis. Corrosion tests were conducted at 700 °C, with the maximum immersion time reaching up to 100 h. The corrosion rate was determined by measuring the mass loss of the specimens at various time intervals. Verifying corrosion rates by combining mass loss results with the determination of element dissolution in molten salts using Inductively Coupled Plasma Optical Emission Spectroscopy (ICP-OES). Detailed examinations of the corrosion products and morphology were conducted using X-ray diffraction (XRD) and scanning electron microscopy (SEM). Micro-area elemental analysis on the corroded surfaces was performed using an energy dispersive spectrometer (EDS), and the elemental distribution across the corrosion cross-sections was mapped. The results indicate that alloys with lower Cr content exhibit superior corrosion resistance in the NaCl-KCl-MgCl₂ molten salt under an argon atmosphere compared to those with higher Cr content; no corrosion products were retained on the surfaces of the lower Cr alloys (Ni-10Cr, Ni-15Cr). For the higher Cr alloys (Ni-20Cr, Ni-25Cr, Ni-30Cr), after 20 h of corrosion, a protective layer was observed in certain areas. The formation of a stable Cr₂O₃ layer in the initial stages of corrosion for high-Cr content alloys, which reacts with MgO in the molten salt to form a stable MgCr₂O₄ spinel structure, provides additional protection for the alloys. However, over time, even under argon protection, the MgCr₂O₄ protective layer gradually degrades due to chloride ion infiltration and chemical reactions at high temperatures. Further analysis revealed that chloride ions play a pivotal role in the corrosion process, not only facilitating the destruction of the Cr₂O₃ layer on the alloy surfaces but also possibly accelerating the corrosion of the metallic matrix through electrochemical reactions. In conclusion, the corrosion behavior of Ni-Cr alloys in the NaCl-KCl-MgCl₂ molten salt environment is influenced by a combination of factors, including Cr content, chloride ion activity, and the formation and degradation of protective layers. This study not only provides new insights into the corrosion resistance of Ni-Cr alloys in high-temperature molten salt environments but also offers significant theoretical support for the design and optimization of corrosion-resistant alloy materials. Full article

(This article belongs to the Special Issue Corrosion Mechanism and Protection Technology of Metallic Materials)

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16 pages, 5880 KiB

Open AccessArticle

Rust Prevention Property of a New Organic Inhibitor under Different Conditions

by Xingxing Guo, Chengsheng Wang, Hua Fu, Li Tian and Hua Song

Materials 2024, 17(9), 2168; https://doi.org/10.3390/ma17092168 - 6 May 2024

Cited by 1 | Viewed by 898

Abstract

The corrosion resistance properties of a new type of environmentally-friendly organic inhibitor containing amino ketone molecules are presented in this paper. To evaluate the prevention effect of the inhibitor on corrosion of reinforcement, the electrochemical characteristics of steels in the simulated concrete pore solution (SPS) were investigated under varied conditions of the relevant parameters, including concentrations of the inhibitor and NaCl, pH value, and temperature. The inhibition efficiency of the material was characterized through electrochemical impedance spectroscopy (EIS), potentiodynamic polarization, and the weight loss of steels. The results reveal a significant improvement in the corrosion resistance of steels with the inhibitor. A maximum resistance value of 89.07% was achieved at an inhibitor concentration of 4%. Moreover, the new organic inhibitor exhibited good corrosion protection capability for steels under different NaCl concentrations. Its inhibition efficiency was determined to be 65.62, 80.06, and 66.30% at NaCl concentrations of 2, 3.5 and 5%, respectively. On the other hand, it was found that an alkaline environment was favorable for an enhanced corrosion prevention effect, and an optimal pH value of 11.3 was observed in this work. Besides, the inhibition efficiencies at different temperatures showed a trend of 25 > 35 > 40 > 20 > 30 °C, with a maximum value of 81.32% at 25 °C. The above results suggest that the new organic material has high potential to be used as an eco-friendly and long-term durable inhibitor for steel corrosion prevention under complex conditions. Full article

(This article belongs to the Special Issue Corrosion Mechanism and Protection Technology of Metallic Materials)

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10 pages, 3972 KiB

Open AccessCommunication

Pioneering Enhanced Corrosion Resistance along the Normal Plane of an Ultra-Light Mg-Li Extruded Sheet

by Jiexi Liang, Binbin Deng, Chuanqiang Li, Yong Dong, Naiguang Wang, Zhengrong Zhang and Shidong Wang

Materials 2023, 16(19), 6435; https://doi.org/10.3390/ma16196435 - 27 Sep 2023

Cited by 1 | Viewed by 990

Abstract

The microstructure and corrosion anisotropy of the Mg-5Li extruded sheet were investigated in this work. Three distinct samples cut from the normal plane (A), longitudinal plane (B), and cross-sectional plane (C) of the as-extruded sheet were prepared. The microstructure was analyzed using optical microscopy (OM), scanning electron microscopy (SEM), and X-ray diffraction (XRD). The corrosion resistance and behaviors of the three samples in a 0.1 mol/L NaCl solution were evaluated by employing hydrogen evolution, mass loss testing, electrochemical assessments, and corrosion morphology analyses. The results revealed that sample A displayed a distinctive bimodal (0002) basal texture, along with clearly distinguishably larger grain sizes than the other samples. The effect of grain size and crystallographic orientation on the corrosion resistance was highlighted, indicating the pioneering corrosion resistance of sample A and the lowest corrosion resistance of sample C. Furthermore, all three samples exhibited the characteristic filiform corrosion during the initial stages of corrosion, progressing into the formation of corrosion pits, with sample C displaying pronounced susceptibility. Full article

(This article belongs to the Special Issue Corrosion Mechanism and Protection Technology of Metallic Materials)

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20 pages, 17038 KiB

Open AccessEditor’s ChoiceArticle

Microstructural Understanding of Flow Accelerated Corrosion of SA106B Carbon Steel in High-Temperature Water with Different Flow Velocities

by Ying Hu, Long Xin, Chang Hong, Yongming Han and Yonghao Lu

Materials 2023, 16(11), 3981; https://doi.org/10.3390/ma16113981 - 26 May 2023

Cited by 8 | Viewed by 1911

Abstract

All light or heavy water reactors fabricated with carbon steels suffer from flow-accelerated corrosion (FAC). The FAC degradation of SA106B with different flow velocities was investigated in terms of microstructure. As flow velocity increased, the major corrosion type changed from general corrosion to localized corrosion. Severe localized corrosion occurred in the pearlite zone, which can be the prior location for generating pits. After normalizing, the improvement in microstructure homogeneity reduced the oxidation kinetics and lowered cracking sensitivity, causing a decrease in FAC rates of 33.28%, 22.47%, 22.15%, and 17.53% at flow velocity of 0 m/s, 1.63 m/s, 2.99 m/s, and 4.34 m/s, respectively. Additionally, localized corrosion tendency was decreased by reducing the micro-galvanic effect and tensile stresses in oxide film. The maximum localized corrosion rate decreased by 21.7%, 13.5%, 13.8%, and 25.4% at flow velocity of 0 m/s, 1.63 m/s, 2.99 m/s, and 4.34 m/s, respectively. Full article

(This article belongs to the Special Issue Corrosion Mechanism and Protection Technology of Metallic Materials)

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15 pages, 6003 KiB

Open AccessArticle

Effect of I-Phase on Microstructure and Corrosion Resistance of Mg-8.5Li-6.5Zn-1.2Y Alloy

by Ziming Fang, Liangxu He, Jiaxiu Wang, Xiaochun Ma, Guixiang Wang, Ruizhi Wu, Siyuan Jin, Jiahao Wang, Zihui Lu, Zhenzhao Yang, Boris Krit, Sergey Betsofen and Iya I. Tashlykova-Bushkevich

Materials 2023, 16(8), 3007; https://doi.org/10.3390/ma16083007 - 10 Apr 2023

Cited by 3 | Viewed by 1471

Abstract

The effects of solid solution treatment duration on the corrosion behavior and microstructure behavior of the cast Mg-8.5Li-6.5Zn-1.2Y (wt.%) alloy were investigated. This study revealed that with the treatment time for solid solutions increasing from 2 h to 6 h, the amount of α-Mg phase gradually decreases, and the alloy presents a needle-like shape after solid solution treatment for 6 h. Meanwhile, when the solid solution treatment time increases, the I-phase content drops. Exceptionally, under 4 h of solid solution treatment, the I-phase content has increased, and it is dispersed uniformly over the matrix. What we found in our hydrogen evolution experiments is that the hydrogen evolution rate of the as-cast Mg-8.5Li-6.5Zn-1.2Y alloy following solid solution processing for 4 h is 14.31 mL·cm⁻²·h⁻¹, which is the highest rate. In the electrochemical measurement, the corrosion current density (i_corr) value of as-cast Mg-8.5Li-6.5Zn-1.2Y alloy following solid solution processing for 4 h is 1.98 × 10⁻⁵, which is the lowest density. These results indicate that solid solution treatment can significantly improve the corrosion resistance of the Mg-8.5Li-6.5Zn-1.2Y alloy. The I-phase and the α-Mg phase are the primary elements influencing the corrosion resistance of the Mg-8.5Li-6.5Zn-1.2Y alloy. The existence of the I-phase and the border dividing the α-Mg phase and β-Li phase easily form galvanic corrosion. Although the I-phase and the boundary between the α-Mg phase and β-Li phase will be corrosion breeding sites, they are more effective in inhibiting corrosion. Full article

(This article belongs to the Special Issue Corrosion Mechanism and Protection Technology of Metallic Materials)

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