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Corrosion Science and Engineering: Recent Research, Insights, and Challenges

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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: closed (31 March 2024) | Viewed by 19718

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Dr. Reza Parvizi

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Guest Editor

School of Engineering, Faculty of Science, Engineering and Built Environment, Deakin University, Geelong Waurn Ponds Campus, Waurn Ponds, VIC 3216, Australia
Interests: applied electrochemistry; corrosion engineering; advanced characterization of corrosion morphologies; corrosion in additive manufacturing; surface science and engineering; corrosion prevention and remediation

Dr. Anthony Hughes

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Guest Editor

Institute of Frontier Materials, Deakin University, Geelong Waurn Ponds Campus, Waurn Ponds, Geelong, VIC 3216, Australia
Interests: advanced characterization; corrosion in additive manufacturing; surface science and engineering; corrosion prevention and remediation
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Special Issue Information

Dear Colleagues,

For decades, the corrosion and degradation of metals has been found to be one of the most detrimental and challenging issues to key industries such as construction, oil and gas, aircraft or automotive. The corrosion performance of metals and alloys is dependent on various factors including their microstructure and chemical composition, chemistry, and characteristics of the corrosive medium to name few, which could potentially, in the worst case, pose fatal hazards if they are not monitored and remediated effectively. The vibrant advancement of those industries, together with the fast-growing manufacturing market, justifies the demand for the design and development of corrosion-resistant alloys and protection technologies. Such generative progress in new materials engineering, such as additive manufacturing, will drive fundamental investigation and the revisitation/revision of corrosion mechanisms, protections scenarios, and eventually the testing and evaluation methodologies and standards. Henceforth, it will be quite challenging for the manufacturing industries and the consumers in the market to reach a full compromise between the demanded corrosion properties and economical parameters related to the design and production of these precisely engineered systems.

The Special Issue “Corrosion Science and Engineering: Recent Research, Insights and Challenges” aims to focus on original research and critical reviews on the mechanistic investigation of corrosion/degradation of high-performance and advanced manufactured alloys, novel corrosion monitoring and characterization methodologies, and corrosion protection and surface treatment technologies, such as smart anti-corrosion coatings with diverse applications in both science and industry.

We look forward to receiving your contributions.

Dr. Reza Parvizi
Prof. Dr. Anthony Hughes
Guest Editors

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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.

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Keywords

Corrosion mechanisms and fundamentals
Multiscale interfacial electrochemical processes
Corrosion of additively manufactured parts
Hydrogen embrittlement in metals
Advanced characterization of localized corrosion
Review of recent advances in corrosion science and engineering
Corrosion remediation via surface treatment
Corrosion monitoring and protection
Recent advances in corrosion measurement methodologies
Erosion breakdown in metallic infrastructures

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Published Papers (10 papers)

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Research

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16 pages, 6111 KiB

Open AccessArticle

Effect of Nitrogen on the Corrosion Resistance of 6Mo Super Austenitic Stainless Steel

by Haiyu Tian, Jian Wang, Zhiqiang Liu and Peide Han

Metals 2024, 14(4), 391; https://doi.org/10.3390/met14040391 - 26 Mar 2024

Cited by 1 | Viewed by 1223

Abstract

6Mo super austenitic stainless steel (SASS) with nitrogen contents of 0.2 and 0.4 (wt.%) was melted, and solution treatments at 1100, 1180, and 1250 °C for 30 min were performed. The effects of nitrogen on the microstructure and pitting resistance of the two steels that signed as 0.2N and 0.4N samples were investigated. At a heat-treatment temperature of 1180 °C, the alloy demonstrates the highest corrosion resistance, attributed to the combined effects of grain size and precipitates. The structure of the passivation film changes with increasing nitrogen content, with the Cr/Fe ratio is significantly higher in the 0.4N sample compared to the 0.2N sample. Moreover, the increase in nitrogen content results in thicker Cr and Mo oxide layers and higher levels of NH₃ and NH₄⁺, thereby improving the corrosion resistance of the stainless steel. Full article

(This article belongs to the Special Issue Corrosion Science and Engineering: Recent Research, Insights, and Challenges)

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23 pages, 46172 KiB

Open AccessArticle

Experimental Investigation and Modeling: Considerations of Simultaneous Surface Steel Droplets’ Evaporation and Corrosion

by Marius Ciprian Ilie, Timur Vasile Chiş, Ioana Maior, Cristian Eugen Răducanu, Iuliana Mihaela Deleanu, Tănase Dobre and Oana Cristina Pârvulescu

Metals 2023, 13(10), 1733; https://doi.org/10.3390/met13101733 - 12 Oct 2023

Cited by 2 | Viewed by 890

Abstract

The present work focuses on the problem of steel surface corrosion as a kinetic expression when water droplets are repeatedly deposited and evaporated on/from its surface. This process, together with the rainwater film corrosion process, belongs to the theoretical foundations of the problem of atmospheric corrosion. It was considered that the formation of water droplets on surfaces is a random but repetitive process, as well as the fact that experimental and theoretical observations show that the droplet corrosion front of a metal surface is located in its zone circumference. We thus aimed to establish how the corrosion process evolves on a steel plate when many drops are deposited and removed repeatedly. An experimental setup and working procedure were used to obtain data characterizing the simultaneous process of steel surface corrosion and water droplet evaporation. For natural convection conditions with a variable relative humidity and temperature environment, an extensive data set consisting of the dynamics of individual droplet evaporation coupled simultaneously with the corrosion of the steel surface under the droplet was obtained. The mathematical models for evaporation and corrosion under the droplet have the same dynamic transfer surface for water evaporation and oxygen supply in the droplet. An approach for determining this surface depending on the momentary droplet mass was considered. Several simultaneous measurements of evaporation–corrosion dynamics were used to calibrate the coupled models, which were then used to show their compatibility with experimental data. Full article

(This article belongs to the Special Issue Corrosion Science and Engineering: Recent Research, Insights, and Challenges)

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21 pages, 9606 KiB

Open AccessArticle

Probing Localised Corrosion Inhibition of AA2024-T3 by Integrating Electrode Array, SVET, SECM, and SEM-EDS Techniques

by Reza Parvizi, Anthony E. Hughes, Maria Forsyth and Mike Y. Tan

Metals 2023, 13(10), 1703; https://doi.org/10.3390/met13101703 - 6 Oct 2023

Cited by 1 | Viewed by 1126

Abstract

This work demonstrates an approach towards the understanding of multi-scale and open-circuit localised electrochemical processes of AA2024-T3 in the presence and absence of an environmentally friendly rare-earth inhibitor; cerium diphenyl phosphate (Ce(dpp)₃). At high temporal resolution, a wire bean electrode (WBE) made from 100 identical AA2024-T3 wires revealed sudden increases in galvanic anodic and cathodic activities immediately after dosing of 50 and 100 ppm of the inhibitor and an overall suppression of macro-scale activities by increasing the inhibitor concentration to 200 ppm, suggesting it as a fast-screening tool for inhibitors and measuring inhibition efficiency. At high spatial resolutions, scanning probe electrochemical techniques confirmed local activation of corroding microstructures on individual AA2024-T3 wires similarly by dosing the inhibitor up to 100 ppm. In agreement with WBE findings, the effective shutdown of both anodic and cathodic activities occurred after increasing the inhibitor concentration to 200 ppm confirming the optimal concentration of the Ce(dpp)₃ and the mixed mode inhibition mechanism of this selected inhibitor on AA2024-T3. Full article

(This article belongs to the Special Issue Corrosion Science and Engineering: Recent Research, Insights, and Challenges)

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22 pages, 6808 KiB

Open AccessArticle

Experimental Investigation and Modeling of Film Flow Corrosion

by Marius Ciprian Ilie, Ioana Maior, Cristian Eugen Raducanu, Iuliana Mihaela Deleanu, Tanase Dobre and Oana Cristina Parvulescu

Metals 2023, 13(8), 1425; https://doi.org/10.3390/met13081425 - 9 Aug 2023

Cited by 1 | Viewed by 986

Abstract

The paper focuses on the experimental investigation and mathematical modeling of the corrosion of steel when a film of water flows over its surface. The experimental monitoring of corrosion dynamics in the flowing film was carried out using a laboratory pilot model, exploited in such a way as to obtain data necessary to identify some characteristic parameters of the mathematical model of this problem. The mathematical model of the case takes into account the transfer of oxygen through the liquid film flowing on the surface of the corroding plate where the chemical surface processes characteristic of corrosion occur (dissolution of Fe, oxidation of Fe²⁺ to Fe³⁺, formation of surface deposit, etc.). Experimental measurements were used to identify the parameters of the mathematical model, especially the reaction constant of the Fe dissolution rate and the surface oxidation yield of Fe²⁺ to Fe³⁺. Calculation of the correlation coefficients for the apparent constant surface reaction rate and process factors showed that they correlate strongly and non-linearly with the Reynolds number (Re) of the film flow, with the cumulative flow duration, and with the cumulative standby time of the experiments. Using the dynamics of the resistance to the transfer of oxygen through the rust film and the dynamics of its thickness resulting from the specific flow of rust deposition, the apparent oxygen diffusion coefficient through the rust film formed on the plate was expressed. Full article

(This article belongs to the Special Issue Corrosion Science and Engineering: Recent Research, Insights, and Challenges)

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13 pages, 9271 KiB

Open AccessArticle

Effect of Ca and Sb on the Corrosion Resistance of E690 Steel in Marine Atmosphere Environment

by Jianbo Jiang, Nannan Li, Qinglin Li, Zaihao Jiang, Bingqin Wang, Yinyin He, Fangfang Liu and Chao Liu

Metals 2023, 13(5), 826; https://doi.org/10.3390/met13050826 - 23 Apr 2023

Cited by 4 | Viewed by 1824

Abstract

This study investigates the impact of Ca and Sb elements on the corrosion resistance of E690 steel in a simulated marine environment. Electrochemical testing and dry/wet cyclic corrosion testing were conducted on prepared E690 steel specimens. The eroded specimens’ microstructure was observed under a scanning electron microscope, and the inclusion morphology was analyzed using an energy-dispersive spectrometer (EDS). The simulating liquid was designed to emulate the severe marine atmospheric environment in Xisha. Results showed that the addition of Ca and Sb elements effectively enhances the corrosion resistance of E690 steel in the simulated marine environment. The corrosion rates of E690 steel specimens with Ca and Sb additions were lower than those without, and the corrosion morphology was more uniform. These findings suggest that the addition of Ca and Sb elements can improve the corrosion resistance of E690 steel in simulated marine environments and have potential for use in marine engineering applications. Full article

(This article belongs to the Special Issue Corrosion Science and Engineering: Recent Research, Insights, and Challenges)

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15 pages, 6857 KiB

Open AccessArticle

Corrosion Behavior of Mg-xGd-1Zn-0.4Zr Alloys with Different Gd Additions for Biomedical Application

by Xue Geng, Jiahao Jiang and Xiaobo Zhang

Metals 2022, 12(10), 1763; https://doi.org/10.3390/met12101763 - 20 Oct 2022

Cited by 10 | Viewed by 1725

Abstract

In recent years, Mg alloys have attracted increased attention for biomedical application owing to their good biodegradability, biocompatibility, and biomechanical properties. However, rapid corrosion is still one of the most common limitations for their implanted application. In this work, the microstructure and corrosion behavior of the solution- and aging-treated Mg-xGd-1Zn-0.4Zr (x = 3, 6, and 9 wt%, denoted as GZ31K, GZ61K, and GZ91K, respectively) alloys were studied using optical microscope (OM), scanning electron microscope (SEM), immersion tests, electrochemical tests, and quasi in situ corrosion method. The results show that block Gd-rich precipitates and needle-like Zr-Zn-rich precipitates are formed as well as α-Mg matrix. With the increase in Gd content, the precipitates increase and the grain size first reduces and then increases. Corrosion experiment results show that the GZ61K alloy has the best corrosion resistance and the GZ91K alloy shows the highest corrosion rate among the three alloys in simulated body fluid (SBF). It is found that α-Mg is preferentially corroded and the precipitates have better corrosion resistance as compared to the α-Mg matrix. The GZ61K alloy with the corrosion rate of 0.23 mm/y in SBF shows a promising prospect for biomedical application. Full article

(This article belongs to the Special Issue Corrosion Science and Engineering: Recent Research, Insights, and Challenges)

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12 pages, 4091 KiB

Open AccessArticle

Electrochemical Behaviour and Direct Cell Viability Analysis of Hybrid Implants Made of Ti-6Al-4V Lattices Infiltrated with a Bioabsorbable Zn-Based Alloy

by Noa Gabay Bass, Galit Katarivas Levy, Tomer Ron, Razi Vago, Jeremy Goldman, Amnon Shirizly and Eli Aghion

Metals 2022, 12(10), 1735; https://doi.org/10.3390/met12101735 - 16 Oct 2022

Cited by 1 | Viewed by 1886

Abstract

Biodegradable metals are being developed for biomedical implants or components of implants. Biodegradable zinc-based materials, in particular, have been shown to promote bone regeneration in orthopaedic applications. Here, we investigated the potential of a hybrid Ti-Zn system, comprising a Ti-6Al-4V biostable lattice produced by additive manufacturing (AM) infiltrated by a bioabsorbable Zn-2%Fe alloy, to serve as an osseointegrated implant for dental and orthopaedic applications. The osseointegration of implants can be enhanced by a porous implant structure that facilitates bone ingrowth to achieve superior bonding between the bone tissue and the implant. The hybrid material was evaluated in terms of microstructure and localized chemical composition using scanning and transmission electron microscopy with special attention to the interface between the Ti-based lattice and the biodegradable alloy. The electrochemical behaviour of the Ti-Zn system was analysed in a simulated physiological environment in terms of open circuit potential test and cyclic potentiodynamic polarization. Cytotoxicity was evaluated using direct cell viability tests. The results demonstrate desirable properties of the hybrid Ti-Zn system as a non-cytotoxic material with an acceptable corrosion rate. Full article

(This article belongs to the Special Issue Corrosion Science and Engineering: Recent Research, Insights, and Challenges)

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11 pages, 5530 KiB

Open AccessFeature PaperArticle

Effect of Nanosized Precipitates on Corrosion Resistance of Nb-Microalloyed Steels

by Irina Rodionova, Nataliya Arutyunyan, Andrey Amezhnov, Dmitrii D’yakonov, Yuliya Gladchenkova, Sergey Dunaev and Irina Vasechkina

Metals 2022, 12(4), 636; https://doi.org/10.3390/met12040636 - 7 Apr 2022

Cited by 3 | Viewed by 1917

Abstract

High-strength cold-rolled low-carbon microalloyed steels are widely used in the automotive industry. Preference is generally given to microalloying with niobium, since its effect on the mechanical properties of steel is most pronounced due to both precipitation hardening and a reduction in the ferrite grain size. For the operation of a car, the corrosion resistance of metal parts is an important factor, since, along with other properties of the material, it determines its service life. The study of the effect of the structural state of cold-rolled sheet low-carbon Nb-microalloyed steels, processed in continuous annealing units, on their corrosion resistance has been carried out. Methods of optical, scanning and transmission electron microscopy, mechanical and corrosion tests were used. It is shown that one of the main structural factors that determine the corrosion resistance of rolled products is the size of nanosized NbC precipitates. The influence of the temperature parameters of hot rolling and annealing on their formation has been established. An increase in the temperatures of the hot rolling end and coiling, as well as annealing, leads to an increase in their average size in the rolled stock after annealing, which increases the corrosion resistance of the steels under consideration. Full article

(This article belongs to the Special Issue Corrosion Science and Engineering: Recent Research, Insights, and Challenges)

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Review

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15 pages, 1866 KiB

Open AccessReview

Research Progress in Corrosion Protection Technology for Electronic Components

by Qixin Zhao, Xiangyi Liu, Hanbing Wang, Yongqiang Zhu, Yang An, Dazhao Yu and Jiantao Qi

Metals 2023, 13(9), 1508; https://doi.org/10.3390/met13091508 - 22 Aug 2023

Cited by 3 | Viewed by 3456

Abstract

As a necessary part of all electronic devices, equipment and systems, electronic components play a vital role in the global economy. Since the corrosion of a single electronic component may directly affect the normal operation of the entire electronic system, the failure of electronic components has now become the most important cause of electrical system failure and has become a major obstacle to China’s transformation into a scientific and technological power. Therefore, it is urgent to study the corrosion failure process of electronic components and the means of effective protection. In this paper, starting from the corrosion types and influencing factors of electronic components, especially chips, we introduce the influence of humidity, temperature, salt spray, and environmental particles, as well as the device’s own surface roughness, material adhesion, semiconductor materials, metal coupling system, and lead-free solder system on corrosion performance in the environment. Subsequently, this paper summarizes how to protect electronic components during processing, and sums up the types of electronic component protections, and the specific corrosion protection process for the three commonly used types of chips, namely, the indium antimonide InSb chip, the IC chip, and the Sn–Zn solder chip, for reference. Finally, future development trends in the corrosion protection of electronic components are anticipated and summarized. Full article

(This article belongs to the Special Issue Corrosion Science and Engineering: Recent Research, Insights, and Challenges)

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18 pages, 3802 KiB

Open AccessReview

Research Progress on Laser Cladding Alloying and Composite Processing of Steel Materials

by Tengfei Han, Kexin Zhou, Zhongyu Chen and Yuesheng Gao

Metals 2022, 12(12), 2055; https://doi.org/10.3390/met12122055 - 29 Nov 2022

Cited by 12 | Viewed by 2890

Abstract

Laser cladding technology is a reliable and efficient surface modification technology, which has been widely used in surface alloying and composite processing of steel materials. Firstly, the characteristics of laser cladding technology were introduced, and the effects of process control and the material system on the geometric shape, size, microstructure, and properties of cladding coating were analyzed by summarizing the research results of laser cladding on steel surfaces. The results show that with the increase of laser power, the dilution rate and width of the cladding coating increase, and the grain becomes coarse. Thus, the wear resistance deteriorates. Compared with alloy cladding coating, composite cladding coating exhibits better wear and corrosion resistance, but the plastic toughness is worse than alloy cladding coating. The research progress of surface alloying and composite processing of steel worldwide was analyzed from various aspects. Current results suggest that laser cladding alloying and compounding can enhance the wear resistance and corrosion resistance of steel materials. Based on the summary of the current research results, the development prospect and planning of laser cladding technology in the field of surface alloying and composite processing of steel are further pointed out. Full article

(This article belongs to the Special Issue Corrosion Science and Engineering: Recent Research, Insights, and Challenges)

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