Epoxy coating as effective anti-corrosive polymeric material for aluminum alloys: Formulation, electrochemical and computational approaches

Electrochemical and DFT Studies of the Pistacia Integerrima Gall Extract: An Eco-friendly Approach towards the Corrosion of Steel in Acidic Medium

A novel application of the Pistacia integerrima gall extract as an environmentally friendly corrosion inhibitor is reported in this study. The major phytochemicals present in the gall extract, namely pistagremic acid, β-sitosterol, pistiphloroglucinyl ether, pistaciaphenyl ester, naringenin, and 5,7-dihydroxy-2-(4-hydroxyphenyl)-2,3-dihydrochromen-4-one, play key roles in its anticorrosive behavior on steel in aggressive media. Several approaches were used to study the corrosion prevention activity of steel in 1 M H2SO4, including weight loss analysis, scanning electron microscopy (SEM), electrochemical impedance spectroscopy (EIS), potentiodynamic polarization (PDP), and density functional theory (DFT). At 2000 mg L-1, the highest efficiency of 92.19% was observed in 1 M H2SO4. An SEM study was conducted to validate the surface coverage of the metal surface. DFT studies revealed several nucleophilic regions present in the phytochemicals of the inhibitor, which supported the favorable nucleophilicity. Corrosion studies have not been performed on this sample. Phytochemicals make it an effective corrosion inhibitor, and its extraction process utilizes distilled water, making it better than other inhibitors. It has been proven that the obtained values of ΔEInhDFT for pistiphloroglucinyl, pistaciaphenyl ether, and naringenin organic compounds were very low, confirming the high reactivity of these corrosion inhibitors. The order of the values of ΔEInhDFT is as follows: pistaciaphenyl ether > pistiphloroglucinyl ether > naringenin organic compound; this suggests that pistaciaphenyl ether is more reactive than the other compounds. In this study, P. integerrima gall extract emerges as a novel and highly effective corrosion resistance agent in 1 M H2SO4, chosen for its relevance to acid pickling and cleaning processes.

Electrochemical, surface morphological and computational evaluation on carbohydrazide Schiff bases as corrosion inhibitor for mild steel in acidic medium

Anticorrosion and adsorption behaviour of synthesized carbohydrazide Schiff bases, namely (Z)-N'-(4-hydroxy-3-methoxybenzylidene)-6-methyl-2-oxo-4-phenyl-1,2,3,4-tetrahydropyrimidine-5-carbohydrazide(MBTC) and (Z)-N'-(3,4-dichlorobenzylidene)-6-methyl-2-oxo-4-phenyl-1,2,3,4-tetrahydropyrimidine-5-carbohydrazide (CBTC) was examined for mild steel (MS) in 15% HCl medium. The corrosion inhibition study was performed by using gravimetric, thermodynamic, electrochemical and theoretical studies including density functional theory (DFT), molecular dynamic simulation (MDS) and Monte Carlo simulations (MCS). The outcomes in terms of corrosion inhibition efficiency using electrochemical impedance spectroscopy (EIS) method at 303 K and 150 ppm concentration were 96.75% for MBTC and 95.14% for CBTC. Both inhibitors adsorbed on the MS surface through physical as well as chemical adsorption and followed the Langmuir isotherm. The mixed-type nature of both inhibitors was identified by polarization results. Surface analysis was done using FESEM, EDX, AFM and XPS studies and results showed that a protective layer of inhibitor molecules was developed over the surface of MS. The results of DFT, MCS and MDS are in accordance with experimental results obtained by weight loss and electrochemical methods.

Insight into the corrosion mitigation performance of three novel benzimidazole derivatives of amino acids for carbon steel (X56) in 1 M HCl solution

Three new organic molecules having a benzimidazole base were synthesized and used for the protection of carbon steel (X56) against corrosion in 1.00 M HCl solution. The protection against corrosion was assessed by electrochemical frequency modulation (EFM), electrochemical impedance spectroscopy (EIS) and potentiodynamic polarization (PDP). In addition, the electronic and molecular structure of the synthesized molecules were computationally investigated and correlated to corrosion inhibition. Global reactivity descriptors, molecular orbitals (FMO and NBO) and local reactivity descriptors (molecular electrostatic potential map and Fukui functions) were discussed. The results showed a maximum protective efficiency range between 95% and 98% indicating high corrosion inhibition. Moreover, all molecules were able to combat the cathodic as well as anodic reaction simultaneously, revealing a mixed-type resistance. SEM and EDX verified effective adhering film formation to the metal surface. In accordance, the theoretical calculations showed effective electron reallocation from the organic film to the X56 c-steel surface. Furthermore, the adsorption annealing calculations revealed that structural layers of these molecules hold parallel and close to the metal surface with adsorption energy from 249.383 to 380.794 kcal mol^-1, showing strong inhibitor-metal contact.

Eco-Friendly AMPS-Doped Polyaniline/Urethane-Methacrylate Coating as a Corrosion Protection Coating: Electrochemical, Surface, Theoretical, and Thermodynamic Studies

In this study, 2-acrylamido-2-methylpropanesulfonic acid (AMPS)-doped polyaniline (PANI) fibers were used as polymerizable smart anticorrosive agents to prepare eco-friendly UV-curable anticorrosive coatings. For this purpose, AMPS-doped PANI fibers were synthesized through chemical oxidative interfacial polymerization. The size and chemical structure of the prepared conducting fibers were characterized by scanning electron microscopy, ¹H NMR, and Fourier transform infrared (FTIR) analyses. As a binder for the prepared conducting fibers, an eco-friendly fluorinated urethane-methacrylate dispersion was synthesized and fully characterized using FTIR analysis. Subsequently, various amounts of the synthesized fibers were mixed with the fluorinated binder to prepare UV-curable anticorrosive coatings. The physicochemical interactions between the PANI fibers and UV-curable binder were studied thoroughly using differential scanning calorimetry and thermogravimetric analyses and measurement of the gel contents and adhesion strength of the prepared composite coatings. The corrosion resistance performance of the prepared coatings was evaluated using electrochemical impedance spectroscopy analysis, and the obtained results revealed that the presence of 2 wt % of the AMPS-doped PANI fibers significantly enhanced the corrosion resistance of the obtained coating. In addition, the corrosion layers of the coatings were analyzed using X-ray photoelectron spectroscopy, which indicated that the AMPS-doped PANI fibers changed the composition of the corrosion product layer. To expand these attempts, this study also explores the interaction of AMPS-doped PANI fibers with the Fe(100) surface using density functional theory as well as atom in molecule calculations. All of the obtained results proved that the outstanding corrosion protection performance of the prepared composite coatings originated from exceptional chemical interactions between the unsaturated doping agents of the prepared PANI fibers and the UV-cured polymer.

Essential Oil of Origanum vulgare as a Green Corrosion Inhibitor for Carbon Steel in Acidic Medium

In this study, Oregano (Origanum vulgare) leaf essential oil was studied as an environmental-friendly anticorrosion agent for carbon steel in aggressive hydrochloric acid. The corrosion inhibition of O. vulgare was characterized by surface morphology, electrochemical, weight loss, theoretical and computational methods. It was found that the highest inhibition performance of O. vulgare was 85.64% at 2 g/l in 1 M HCl. The results of Langmuir isotherm and adsorption thermodynamics investigation demonstrated that the O. vulgare inhibitor adsorbed on the metal surface by the formation of rigid covalent bonds. The adsorption and inhibition centers of the selected inhibitor were studied by the computational methods, resulting in that the hydroxyl functional groups and benzoyl rings are mainly responsible for the high inhibition efficiency.

Superior Anticorrosion Performance of Well-Dispersed MXene-Polymer Composite Coatings Enabled by Covalent Modification and Ambient Electron-Beam Curing

MXene-reinforced composite coatings have recently shown promise for metal anticorrosion due to their large aspect ratio and antipermeability; however, the challenges of the poor dispersion, oxidation, and sedimentation of MXene nanofillers in a resin matrix that are often encountered in the existing curing methods have greatly limited practical applications. Herein, we reported an efficient, ambient, and solvent-free electron beam (EB) curing technology to fabricate PDMS@MXene filled acrylate-polyurethane (APU) coatings for anticorrosion of 2024 Al alloy, a common aerospace structural material. We showed that the dispersion of MXene nanoflakes modified by PDMS-OH was dramatically improved in EB-cured resin and enhanced the water resistance through the additional water-repellent groups of PDMS-OH. Moreover, the controllable irradiation-induced polymerization enabled a unique high-density cross-linked network, presenting a large physical barrier against corrosive media. The newly developed APU-PDMS@MX₁ coatings achieved excellent corrosion-resistance with the highest protection efficiency of 99.9957%. The coating filled with uniformly distributed PDMS@MXene promoted the corrosion potential, corrosion current density, and corrosion rate to be -0.14 V, 1.49 × 10^-9 A/cm², and 0.0004 mm/year, respectively, and the impedance modulus was increased by 1-2 orders of magnitude compared to that of APU-PDMS coating. This work combining 2D material with EB curing technology broadens the avenue for designing and fabricating composite coatings for metal corrosion protection.

Coco Monoethanolamide Surfactant as a Sustainable Corrosion Inhibitor for Mild Steel: Theoretical and Experimental Investigations

Recent studies indicate that surfactants are a relatively new and effective class of corrosion inhibitors that almost entirely meet the criteria for a chemical to be used as an aqueous phase corrosion inhibitor. They possess the ideal hydrophilicity to hydrophobicity ratio, which is crucial for effective interfacial interactions. In this study, a coconut-based non-ionic surfactant, namely, coco monoethanolamide (CMEA), was investigated for corrosion inhibition behaviour against mild steel (MS) in 1 M HCl employing the experimental and computational techniques. The surface morphology was studied employing the scanning electron microscope (SEM), atomic force microscope (AFM), and contact measurements. The critical micelle concentration (CMC) was evaluated to be 0.556 mM and the surface tension corresponding to the CMC was 65.28 mN/m. CMEA manifests the best inhibition efficiency (η%) of 99.01% at 0.6163 mM (at 60 °C). CMEA performs as a mixed-type inhibitor and its adsorption at the MS/1 M HCl interface followed the Langmuir isotherm. The theoretical findings from density functional theory (DFT), Monte Carlo (MC), and molecular dynamics (MD) simulations accorded with the experimental findings. The MC simulation's assessment of CMEA's high adsorption energy (-185 Kcal/mol) proved that the CMEA efficiently and spontaneously adsorbs at the interface.

Study of the Corrosion of Nickel-Chromium Alloy in an Acidic Solution Protected by Nickel Nanoparticles

This study uses nickel nanoparticles coated on the nickel-chromium (Ni-Cr) alloy by the electrodeposition technique to protect the alloy against corrosion. An open-circuit potential and potentiodynamic and linear polarization resistance in a 1 M H₂SO₄ solution saturated with carbon dioxide were used to study the anticorrosion performance of nanoparticle coatings. When coated with nanomaterials, the corrosion rate of Ni-Cr alloy was lower than when it was bare, and the potential for corrosion increased from -0.433 V for uncoated Ni-Cr alloy to -0.103 V when the electrodes were exposed to saturated calomel. Electrochemical experiments show that nickel-coated Ni-Cr alloy corrosion in sulfuric acid media has high protective characteristics, with an efficiency of 83.69% at 0.165 mA/cm² current density when pH = 1 is used. As demonstrated by the results of this research, the nickel-chromium alloy can be protected from corrosion in acidic media by a low-acidity bath coating layer. Surface morphologies have shown that coatings at different acidic scales may be able to resist an acid attack because of their excellent adherence to the nickel-chromium alloy surface. Measures for determining and studying the composition of the alloy surface's protective covering were improved using X-ray diffraction (XRD).

An Experimental and Theoretical Investigation of the Efficacy of Pantoprazole as a Corrosion Inhibitor for Mild Steel in an Acidic Medium

The corrosion behavior of mild steel in a 1 M aqueous sulfuric acid medium in the presence and absence of the drug Pantoprazole was investigated using potentiodynamic polarization and quantum chemical calculations as well as Monte Carlo and molecular dynamic simulations. The potentiodynamic experiments indicated that this molecule, as a result of its adsorption on a mild steel surface, functioned as a mixed inhibitor. The goal of the study was to use theoretical calculations to acquire a better understanding of how inhibition works. The adsorption behavior of the examined compounds on the Fe (1 1 0) surface was calculated using a Monte Carlo simulation. Furthermore, the molecules were studied using density functional theory (DFT), especially the PBE functional, to determine the relationship between the molecular structure and the corrosion inhibition behavior of the chemical under research. The adsorption energies of Pantoprazole (in its three different protonation states) iron were calculated more precisely using molecular mechanics with periodic boundary conditions (PBC). The predicted theoretical parameters were found to be in agreement with the experimental data, which was a considerable help in understanding the corrosion inhibition mechanism displayed by this chemical.

Alleviation of Iron Corrosion in Chloride Solution by N,N′-bis[2-Methoxynaphthylidene]amino]oxamide as a Corrosion Inhibitor

The alleviation of iron corrosion in 3.5% NaCl sodium chloride solution using N,N′-bis[2-methoxynaphthylidene]amino]oxamide (MAO) as a corrosion inhibitor has been reported. The work was achieved using various investigation techniques. Potentiodynamic cyclic polarization (PCP) displayed a powerful inhibition for the corrosion via reducing the iron’s cathodic and anodic reactions. This was reflected in reduced corrosion currents and increased polarization resistances in the presence and upon the increase of MAO concentration. The electrochemical impedance spectroscopy results indicated that MAO molecules provoke the corrosion resistance via increasing polarization resistance. The power of MAO on decreasing pitting attack was also investigated through measuring the change of current with time at −0.475 V(Ag/AgCl). Scanning electron microscopy images were taken of the surface after the current–time measurements were performed in the absence and presence of MAO. The current-time experiments indicated that MAO highly mitigates the corrosion of iron. The energy dispersive X-ray analyzer reported the products found on the tested surfaces. The effect of extending the exposure time from 1 h to 48 h was also tested and was found to alleviate the corrosion of iron, whether MAO molecules are absent or present.