Inhibition of Aluminium Alloy AA2024-T3 pitting corrosion by copper complexing compounds

Wavebreakers in excitable systems and possible applications for corrosion mitigation

Traveling waves of excitation arise from the spatial coupling of local nonlinear events by transport processes. In corrosion systems, these electro-dissolution waves relay local perturbations across large portions of the metal surface, significantly amplifying overall damage. For the example of the magnesium alloy AZ31B exposed to sodium chloride solution, we report experimental results suggesting the existence of a vulnerable zone in the wake of corrosion waves where local perturbations can induce a unidirectional wave pulse or segment. The evolution of these segments, combined with the absence of rotating spiral waves, imply subexcitable dynamics for which the segments' open ends tangentially retract. Using a simple excitable reaction-diffusion model, we identify parameters that replicate these experimental observations. Under these conditions, small protected disks act as wavebreakers, disrupting continuous fronts, which then shrink and disappear. We further explore different placement schemes of these wavebreakers to optimize potential corrosion mitigation. For constant surface coverage, many small wavebreakers prove more effective than a few large ones. A comparison of triangular, square, rectangular, hexagonal, aperiodic Penrose, and random lattice geometries indicates that triangular placements of wavebreakers are generally the optimal choice, while rectangular and random lattices perform poorly. Although wavebreakers were not demonstrated experimentally in this study, these findings provide concrete design guidance for the protection of alloy surfaces prone to wave-mediated corrosion.

Morphogenic Modeling of Corrosion Reveals Complex Effects of Intermetallic Particles

Corrosion processes are often discussed as stochastic events. Here, it is shown that some of these seemingly random processes are not driven by nanoscopic fluctuations but rather by the spatial distribution of micrometer-scale heterogeneities that trigger fast reactions associated with corrosion. Using a novel excitable reaction-diffusion model, corrosion waves traveling over the metal surface and the associated material loss are described. This resulting nonuniform corrosion penetration, seen as a height loss in modeling, exposes buried intermetallic particles, which depending on the local electrochemical state of the surface trigger or block new waves. Informed by quantitative experimental data for the Mg-Al-Zn alloy AZ31B, wave speeds, wave widths, and average material loss are accurately captured. Morphogenic mitigation based on wave-breaking microparticles is also simulated. While AZ31B corrosion is identified as a process driven by rare-wave events, this study predicts several other corrosion regimes that proceed via spots or patchy patterns, opening the door for new protection, design, and prediction strategies.

Design of New Ecofriendly Schiff Base Inhibitors for Carbon Steel Corrosion Protection in Acidic Solutions: Electrochemical, Surface, and Theoretical Studies

Corrosion poses a significant problem for several industrial sectors, inducing continuous research and development of corrosion inhibitors for use across a wide range of industrial applications. Here, we report the effectiveness of three newly developed Schiff bases derived from amino acids and 4-aminoacetophenone, namely, AIP, AMB, and AImP, as environmentally friendly corrosion inhibitors for Q235 steel in hydrochloric acid using electrochemical and surface analyses, in addition to theoretical techniques. The electrochemical findings of potentiodynamic polarization (PDP) demonstrated that the explored compounds serve as mixed-type inhibitors and can effectively suppress steel corrosion, with maximal protection efficiencies of 93.15, 96.01, and 77.03% in the presence of AIP, AMB, and AImP, respectively, at a concentration of 10 mM. The electrochemical impedance spectroscopy (EIS) and polarization results confirmed the growth of a durable protective barrier on the steel surface in the existence of the inhibitors, which is responsible for decreasing the metallic dissolution. Results were further supported by scanning electron microscopy (SEM), energy-dispersive X-ray spectroscopy (EDS), UV-vis, and Fourier transform infrared (FTIR), which ascribed the development of inhibitor-adsorption films on the steel surface. The results of EDS and XPS analyses demonstrated the existence of the distinctive elements of the inhibitors on the metallic surface. Furthermore, density functional theory (DFT) calculations and Monte Carlo (MC) simulations showed the electronic structure of the examined inhibitors and their optimized adsorption configurations on the steel surface, which helped in explaining the anticorrosion mechanism. Finally, the theoretical and experimental findings exhibit a high degree of consistency.

Synthesis and Corrosion Inhibition Potential of Cerium/Tetraethylenepentamine Dithiocarbamate Complex on AA2024-T3 in 3.5% NaCl

In this work, a cerium/tetraethylenepentamine dithiocarbamate complex was synthesized and evaluated for the corrosion inhibition capability on an AA2024-T3 Al alloy in a 3.5% NaCl medium. The synthesized compounds were characterized via spectroscopic techniques. The corrosion inhibition behaviour of the complex was elucidated by electrochemical measurements and surface analysis techniques. Based on electrochemical test results, the corrosion inhibition efficiency of the complex increases with the immersion time of aluminium alloy in the test solution. The corrosion inhibition reaches 96.80% when the aluminium is immersed in a 3.5% NaCl solution containing a corrosion inhibitor for 120 h. The potentiodynamic polarization test results show that the complex acts as a mixed-type corrosion inhibitor and the passive range is widened. The surface analysis methods reveal that the corrosion inhibition ability of the complex originated from the formation of a protective layer on the Al surface. This film is created from the physisorption and chemisorption of cerium ions and organic parts simultaneously released from the complex molecules.

Evolution and stability of 2-mercaptobenzimidazole inhibitor film upon Al alloy 6061

Organic corrosion inhibitors have become competent alternatives to hazardous chrome conversion coatings due to their rapid adsorption over metal surfaces in corrosive environments. Literature suggests a wide range of organic corrosion inhibitors with high inhibition efficiency, barrier properties, and adsorption mechanisms. However, the long-term durability and protectiveness of an organic inhibitor film need to be understood with in-depth insights on its interaction with heterogenous alloy surfaces like AA6xxx, reduction of galvanic activities and time-resolved degradation due to ionic diffusion. The present article is focused on the time-resolved adsorption and degradation of 2-mercaptobenzimidazole (2-MBI)-induced inhibitor layer/film over AA6061 in 0.1 M NaCl solution. Electrochemical and surface analysis data indicate that the presence of 2-MBI drives the rapid formation of a 20–30 nm thick protective film comprised of constitutional elements of C, S, and N from 2-MBI upon the surface of AA6061 substrate. This film mitigated the corrosion cells associated with nano- and micro-sized Fe and Si-rich intermetallic particles (IMPs) in AA6061. XPS reveals two distinguished bonding states of S and N in the inhibitor film and chemical interactions between 2-MBI and the surface of AA6061. The protective film maintained 65% inhibiting efficiency after 1 day, which progressively degraded due to electrolyte ingress and eventually with a drop in inhibition efficiency down to 21% after 14 days. Inhibitor-induced film over AA6061 reduced the corrosion susceptibility of Fe, and Si-rich IMPs up to 1 day given the subsequent adsorption by S and N heteroatoms. However, this film became thick and defective after 1 day, which undermined its barrier properties against ingress of aggressive ions and facilitated water adsorption.

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Biopolymeric Anticorrosion Coatings from Cellulose Nanofibrils and Colloidal Lignin Particles

This study presents a process for preparation of cellulose-lignin barrier coatings for hot-dip galvanized (HDG) steel by aqueous electrophoretic deposition. Initially, a solution of softwood kraft lignin and diethylene glycol monobutyl ether was used to prepare an aqueous dispersion of colloidal lignin particles (CLPs) via solvent exchange. Analysis of the dispersion showed that it comprised submicron particles (D = 146 nm) with spherical morphologies and colloidal stability (ζ-potential = -40 mV). Following successful formation, the CLP dispersion was mixed with a suspension of TEMPO-oxidized cellulose nanofibers (TOCN, 1 and 2 g·L^-1) at a fixed volumetric ratio (1:1, TOCN-CLPs), and biopolymers were deposited onto HDG steel surfaces at different potentials (0.5 and 3 V). The effects of these variables on coating formation, dry adhesion, and electrochemical properties (3.5% NaCl) were investigated. The scanning electron microscopy results showed that coalescence of CLPs occurs during the drying of composite coatings, resulting in formation of a barrier layer on HDG steel. The scanning vibrating electrode technique results demonstrated that the TOCN-CLP layers reduced the penetration of the electrolyte (3.5% NaCl) to the metal-coating interface for at least 48 h of immersion, with a more prolonged barrier performance for 3 V-deposited coatings. Additional electrochemical impedance spectroscopy studies showed that all four coatings provided increased levels of charge transfer resistance (R_ct)-compared to bare HDG steel-although coatings deposited at a higher potential (3 V) and a higher TOCN concentration provided the maximum charge transfer resistance after 15 days of immersion (13.7 cf. 0.2 kΩ·cm² for HDG steel). Overall, these results highlight the potential of TOCN-CLP biopolymeric composites as a basis for sustainable corrosion protection coatings.

Corrosion Inhibition at Scribed Locations in Coated AA2024-T3 by Cerium- and DMTD-Loaded Natural Silica Microparticles under Continuous Immersion and Wet/Dry Cyclic Exposure

Earlier studies on cerium-loaded naturally occurring silica microparticles (i.e., diatomaceous earth) demonstrated the potential to efficiently protect small scratches in epoxy-coated AA2024-T3 panels during relatively short immersion times. The current work investigates the potential of such inhibitor-loaded microparticles to protect wide and deep scribes (up to 1 mm wide) in long-time immersion testing and during cyclic (wet/dry) conditions. For this, cerium nitrate and 2,5-dimercaptothiadiazole (DMTD) were used as inorganic and organic corrosion inhibitors. The corrosion protection was evaluated using a hyphenated real-time optics/electrochemistry method and two individual local techniques measuring oxygen concentration and electrochemical impedance (LEIM) inside the scribe. SEM/EDS was used to analyze the samples after exposure. The results show significant levels of corrosion protection at damaged locations at low cerium concentrations (3.7 wt % Ce³⁺ relative to the total coating mass) during 30 days of immersion in salt solution. However, for a given scribe geometry, the protection was found to be dependent on the electrolyte volume with larger electrolyte/exposed metal ratios leading to short protection time. A partial replacement of the Ce³⁺ by DMTD in the microcarriers resulted in a higher degree of passivation than when DMTD was used alone. Wet/dry cyclic exposure tests showed that cyclic conditions can increase the buildup of stable inhibitor-containing layers in the case of cerium-loaded silica microparticles. This underlines the need for more research using wet/dry exposure conditions.

Locally Condensed Water as a Solution for In Situ Wet Corrosion Electron Microscopy

In microstructural corrosion studies, knowledge on the initiation of corrosion on an nm-scale is lacking. In situ transmission electron microscope (TEM) studies can elucidate where/how the corrosion starts, provided that the proper corrosive conditions are present during the investigation. In wet corrosion studies with liquid cell nanoreactors (NRs), the liquid along the electron beam direction leads to strong scattering and therefore image blurring. Thus, a quick liquid removal or thickness control of the liquid layer is preferred. This can be done by the use of a Peltier element embedded in an NR. As a prelude to such in situ work, we demonstrate the local wetting of a TEM sample, by creating a temperature decrease of 10 ± 2°C on the membrane of an NR with planar Sb/BiSb thermoelectric materials for the Peltier element. TEM samples were prepared and loaded in an NR using a dual-beam focused ion beam scanning electron microscope. A mixture of water vapor and carrier gas was passed through a chamber, which holds the micro-electromechanical system Peltier device and resulted in quick formation of a water layer/droplets on the sample. The TEM analysis after repeated corrosion of the same sample (ex situ studies) shows the onset and progression of O2 and H2S corrosion of the AA2024-T3 alloy and cold-rolled HCT980X steel lamellae.

Cerium/diethyldithiocarbamate complex as a novel corrosion inhibitive pigment for AA2024-T3

In this work, cerium-diethyldithiocarbamate (Ce-DEDTC) complex was synthesized as a novel anti-corrosion pigment. The structure of the synthesized pigment was characterized by employing Fourier transfer infrared spectroscopy, X-ray diffraction, thermogravimetric analysis, inductively coupled plasma optical emission spectroscopy, and ultraviolet-visible spectroscopy. All of the characterization techniques showed that the Ce-DEDTC pigment was successfully produced. The electrochemical tests were used to investigate the subsequence effect of the synthesized complex on the corrosion behavior of the AA2024-T3. AA2024-T3 showed a wide passive range in the presence of the Ce-DEDTC pigment. Scanning electron microscopy, optical microscopy, X-ray photoelectron spectroscopy, and contact angle tests were employed to investigate the effect of the synthesized pigment on aluminum surface properties. The result illustrated that the existence of the Ce-DEDTC complex led to the creation of a thin film on the AA2024-T3 surface, which was significantly inhibited the localized corrosion of the aluminum alloy.

Nanometre to micrometre length-scale techniques for characterising environmentally-assisted cracking: An appraisal

The appraisal is strongly focussed on challenges associated with the nuclear sector, however these are representative of what is generally encountered by a range of engineering applications. Ensuring structural integrity of key nuclear plant components is essential for both safe and economic operation. Structural integrity assessments require knowledge of the mechanical and physical properties of materials, together with an understanding of mechanisms that can limit the overall operating life. With improved mechanistic understanding comes the ability to develop predictive models of the service life of components. Such models often require parameters which can be provided only by characterisation of processes occurring in situ over a range of scales, with the sub-micrometre-scale being particularly important, but also challenging. This appraisal reviews the techniques currently available to characterise microstructural features at the nanometre to micrometre length-scale that can be used to elucidate mechanisms that lead to the early stages of environmentally-assisted crack formation and subsequent growth. Following an appraisal of the techniques and their application, there is a short discussion and consideration for future opportunities.

Sealing porous anodic layers on AA2024-T3 with a low viscosity benzoxazine resin for corrosion protection in aeronautical applications

In this paper, a 4-ethylphenol-para-phenylenediamine (4EP-pPDA) benzoxazine has been applied and cured on previously anodized AA2024-T3 substrates. The porous surface oxide layers obtained from sulfo-tartaric anodizing appeared to be highly impregnated by the benzoxazine resin, sealing the anodic films. Through rheological, morphological and chemical characterization, the curing process has been identified to be the key step for the impregnation to occur, related to the low viscosity of the 4EP-pPDA benzoxazine attained during thermal curing. Moreover, the typical surface porosity of the anodic layer reappeared after curing, offering a good anchoring to possible top coats. Finally, high and enduring barrier properties of this hybrid organic–inorganic layer have been highlighted through Electrochemical Impedance Spectroscopy (EIS) and correlated with recent results obtained by Molecular Dynamics Simulations (MDS). These barrier properties appeared to be strongly influenced by the curing process parameters, as has been assessed using alternative curing cycles limiting their duration and lowering the curing temperature. Consequently, adapting the curing process enables the optimization of the barrier properties of the system while respecting the dependence of the mechanical properties of the AA2024-T3 substrate on thermal treatment at high temperatures.

In this paper, a 4-ethylphenol-para-phenylenediamine (4EP-pPDA) benzoxazine has been applied and cured on previously anodized AA2024-T3 substrates.

Controlling factors in localised corrosion morphologies observed for magnesium immersed in chloride containing electrolyte

The early stages of localised corrosion affecting magnesium (Mg) surfaces when immersed in aqueous sodium chloride (NaCl) solutions involves the propagation of dark regions, within which both anodic metal dissolution and cathodic hydrogen evolution occur. For nominally “pure” Mg, these dark areas can either take the form of discs which expand radially with time, or filiform-like tracks which lengthen with time. For Mg surfaces which display disc-form corrosion features in concentrated NaCl electrolyte, a transition to filiform corrosion (FFC) is observed as the concentration is decreased, indicating ohmic constraints on radial propagation. A similar effect is observed when Mg specimens of different iron impurity are immersed in a fixed, high concentration NaCl solution, where disc-form corrosion is observed on samples having ≥280 ppm Fe, but FFC predominates at ≤80 ppm Fe. An in situ scanning vibrating electrode technique (SVET) is used to determine current density distributions within the propagating corrosion features. Cathodic current density values of between −100 and −150 A m⁻² measured in central areas of disc-like features are sufficient to sustain the radial growth of a local anode at the perimeter of the discs. However, for high purity Mg specimens (≤80 ppm Fe), cathodic current densities of −10 A m⁻² or less are measured over FFC affected regions, indicating that linear propagation arises when there is insufficient cathodic current produced on the corroded surface to sustain radial growth. The results are consistent with surface control of localised corrosion propagation in concentrated electrolyte, but ohmic control in dilute, lower conductivity NaCl solution.