Marine Atmospheric Corrosion of Carbon Steel: A Review

Recent advances in emerging integrated anticorrosion and antifouling nanomaterial-based coating solutions

The rapid progress in the marine industry has resulted in notable challenges related to biofouling and surface corrosion on underwater infrastructure. Conventional coating techniques prioritise individual protective properties, such as offering either antifouling or anticorrosion protection. Current progress and innovations in nanomaterials and technologies have presented novel prospects and possibilities in the domain of integrated multifunctional coatings. These coatings can provide simultaneous protection against fouling and corrosion. This review study focuses on the potential applications of various nanomaterials, such as carbon-based nanostructures, nano-metal oxides, polymers, metal-organic frameworks, and nanoclays, in developing integrated multifunctional nano-based coatings. These emerging integrated multifunctional coating technologies recently developed and are currently in the first phases of development. The potential opportunities and challenges of incorporating nanomaterial-based composites into multifunctional coatings and their future prospects are discussed. This review aims to improve the reader's understanding of the integrated multifunctional nano-material composite coating design and encourage valuable contributions to its development.

Iron-fortified water: a new approach for reducing iron deficiency anemia in resource-constrained settings

A new approach for fortification of drinking water is presented for combating iron deficiency anemia (IDA) worldwide. The idea is to leach Fe from a bed containing granular metallic iron (Fe0), primarily using ascorbic acid (AA). AA forms very stable and bioavailable complexes with ferrous iron (FeII). Calculated amounts of the FeII-AA solution can be added daily to the drinking water of households or day-care centers for children and adults (e.g. hospitals, kindergartens/schools, refugee camps) to cover the Fe needs of the populations. Granular Fe0 (e.g., sponge iron) in filters is regarded as a locally available Fe carrier in low-income settings, and, AA is also considered to be affordable in low-income countries. The primary idea of this concept is to stabilize FeII from the Fe0 filter by using an appropriate AA solution. An experiment showed that up to 12 mg Fe can be daily leached from 1.0 g of a commercial sponge iron using a 2 mM AA solution. Fe fortification of safe drinking water is a practicable, affordable and efficient method for reducing IDA in low-income communities.

Physics-Informed, Data-Driven Model for Atmospheric Corrosion of Carbon Steel Using Bayesian Network

Atmospheric corrosion is a significant challenge faced by the aviation industry as it considerably affects the structural integrity of an aircraft operated for long periods. Therefore, an appropriate corrosion deterioration model is required to predict corrosion problems. However, practical application of the deterioration model is challenging owing to the limited data available for the parameter estimation. Thus, a high uncertainty in prediction is unavoidable. To address these challenges, a method of integrating a physics-based model and the monitoring data on a Bayesian network (BN) is presented herein. Atmospheric corrosion is modeled using the simulation method, and a BN is constructed using GeNie. Moreover, model calibration is performed using the monitoring data collected from aircraft parking areas. The calibration approach is an improvement over existing models as it incorporates actual environmental data, making it more accurate and applicable to real-world scenarios. In conclusion, our research emphasizes the importance of precise corrosion models for predicting and managing atmospheric corrosion on carbon steel. The study results open new avenues for future research, such as the incorporation of additional data sources to further improve the accuracy of corrosion models.

New Accelerated Corrosion Test Method Simulating Atmospheric Corrosion of Complex Phase Steel Combining Cyclic Corrosion Test and Electrochemically Accelerated Corrosion Test

The automobile industry commonly uses cyclic corrosion tests (CCTs) to evaluate the durability of materials. However, the extended evaluation period required by CCTs can pose challenges in this fast-paced industry. To address this issue, a new approach that combines a CCT with an electrochemically accelerated corrosion test has been explored, to shorten the evaluation period. This method involves the formation of a corrosion product layer through a CCT, which leads to localized corrosion, followed by applying an electrochemically accelerated corrosion test using an agar gel electrolyte to preserve the corrosion product layer as much as possible. The results indicate that this approach can achieve comparable localized corrosion resistance, with similar localized corrosion area ratios and maximum localized corrosion depths to those obtained through a conventional CCT in half the time.

Correlation between Laboratory-Accelerated Corrosion and Field Exposure Test for High-Strength Stainless Steels

Equipment in a long-term marine atmosphere environment is prone to corrosion failure. Natural field exposure tests usually require a long time to obtain corrosion information. This study worked out a laboratory-accelerated corrosion test method that has a strong correlation with the natural environment test in Wanning, Hainan, and can be used as the basis for life assessment and the prediction of two high-strength stainless-steel materials. The mathematical model of corrosion weight loss of two high-strength stainless steels (3Cr13 and 00Cr12Ni10MoTi) was established by a field exposure test and a laboratory-accelerated corrosion test. Then, the correlation between the field exposure test and the laboratory-accelerated corrosion test was evaluated using qualitative and quantitative methods, and the acceleration ratio was calculated using the accelerated switching factor (ASF) method. The results show that: (1) The corrosion morphology of the two stainless steels after 15 days of laboratory-accelerated corrosion testing is similar to that obtained after two years of field exposure. (2) The value of gray correlation between the laboratory-accelerated corrosion test and the field exposure test is not less than 0.75. (3) The acceleration ratio of both stainless steels increases with the corrosion test time in the laboratory. The corrosion prediction models for the two stainless steels are T_3Cr13 = 6.234 t^1.634 and T_{00Cr12Ni10MoTi} = 55.693 t^1.322, respectively.

Enhanced chloride-free snow-melting agent generation from organic wastewater by integrating bioconversion and synthesis

In this study, a new process for producing chloride-free snow-melting agents (CSAs) was proposed. Organic wastewater was converted to total volatile fatty acids (TVFA) by anaerobic acidogenic fermentation. The experiments for acid generation showed that the maximum TVFA concentration of 45.9 g/L was obtained at an organic loading rate of 5 g chemical oxygen demand /(L·d), and the proportion of acetic acid reached 78.8 %. Forward osmosis was used for concentrating the TVFA solution. The obtained CSAs, after evaporation and crystallization, had a better ice-melting capacity and less corrosion on metal and concrete than NaCl and CaCl₂. Additionally, the damage caused by CSAs to the germination of plant seeds was significantly lesser than that caused by chloride salts. This study proposed a feasible method for the high-value conversion of organic wastewater, providing a new direction for the reuse of organic wastewater.

Research on the Corrosion Behavior of Q235 Pipeline Steel in an Atmospheric Environment through Experiment

Low-carbon steel pipelines are frequently used as transport pipelines for various media. As the pipeline transport industry continues to develop in extreme directions, such as high efficiency, long life, and large pipe diameters, the issue of pipeline reliability is becoming increasingly prominent. This study selected Q235 steel, a typical material for low-carbon steel pipelines, as the research object. In accordance with the pipeline service environment and the accelerated corrosion environment test spectrum, cyclic salt spray accelerated corrosion tests that simulated the effects of the marine atmosphere were designed and implemented. Corrosion properties, such as corrosion weight loss, morphology, and product composition of samples with different cycles, were characterized through appearance inspection, scanning electron microscopy analysis, and energy spectrum analysis. The corrosion behavior and mechanism of Q235 low-carbon steel in the enhanced corrosion environment were studied, and the corrosion weight loss kinetics of Q235 steel was verified to conform to the power function law. During the corrosion process, the passivation film on the surface of the low-carbon steel and the dense and stable α-FeOOH layer formed after the passivation film was peeled off played a role in corrosion resistance. The passivation effect, service life, and service limit of Q235 steel were studied and determined, and an evaluation model for quick evaluation of the corrosion life of Q235 low-carbon steel was established. This work provides technical support to improve the life and reliability of low-carbon steel pipelines. It also offers a theoretical basis for further research on the similitude and relevance of cyclic salt spray accelerated corrosion testing.

Experimental Parametric Study of a Functional-Magnetic Material Designed for the Monitoring of Corrosion in Reinforced Concrete Structures

The presence of aggressive agents (such as chloride ions brought by seawater) in reinforced concrete structures is responsible for the corrosion of the steel rebars. A Structural Health Monitoring technology is developed as a new passive preventive method that would allow for the detection of and for the ability to follow the presence of chloride ions in the cover concrete of reinforced concrete. This technology, referenced as Functional Magnetic Material (FMM), consists on the measurement with an external interrogator of a Magnetic Observable (MO), partially shielded by a patch and corrodible by chloride ions. This paper presents the results of a parametric experimental study, allowing the validation of the concept of this technology, by highlighting the variation of the MO while considering the geometry and the corrosion level of the patch (based on its Relative Mass Loss—RML), as well as the distance between the samples and the interrogator. The results show that the MO of the FMM significantly varies with the increase in the RML of the patch. A 10%-RML for the patch is sufficient for detecting a variation of the MO of the FMM, and the relative variations of the MO are strongly dependent on the distance between the FMM and the magnetometer, as well as the patch’s thickness.

Study on corrosion behavior and mechanism of AISI 4135 steel in marine environments based on field exposure experiment

The application of high-strength steels in marine engineering is gaining importance because of their high performance and ability to help save resources. However, detailed and systematic information about the corrosion behavior of high-strength steels in different marine corrosion zones is still limited. This study aimed to investigate and compare the corrosion behavior of AISI 4135 high-strength steel in marine atmospheric, splash, tidal, and immersion zones, focusing on rust layer characteristics, corrosion form and electrochemical corrosion behavior. Corrosion exposure experiments were performed in a specific sea area, and the recovered steel samples were characterized by Raman spectroscopy, confocal laser scanning microscopy, nitrogen adsorption analysis, etc. Results showed that the rust layer formed on the surface of the steel in all corrosion zones had component delamination. The steel samples in the atmospheric, splash, and tidal zones were characterized by pitting corrosion, where the average depths of the corrosion pits were 56.1 ± 4.7 μm, 199.5 ± 12.6 μm, 108.1 ± 11.0 μm, respectively, whereas those in the immersion zone were characterized by general corrosion. Meanwhile, electrochemical tests were performed on the electrode samples during exposure. Results showed that the corrosion of the steel progressed from slow to fast in the atmospheric, splash, and tidal zones, whereas it was relatively steady in the immersion zone. Differentiated models of the corrosion evolution of steel under wet-dry cycle and immersion conditions were presented. This discrepancy is related to the varying degrees of accumulation of ionic corrosion products at the metal/oxide interface, which are determined by the mean pore access diameter of the rust layer and the corrosion environment. This study is highly significant for the design of marine engineering considering the safety applications of high-strength steel structures in harsh marine environments.

Electrochemical Characterization of Polymeric Coatings for Corrosion Protection: A Review of Advances and Perspectives

The development of anti-corrosion polymeric coatings has grown exponentially in the fields of material science, chemistry, engineering, and nanotechnology during the last century and has prompted the evolution of efficient characterization techniques. Nowadays, polymeric coatings represent a well-established protection system that provides a barrier between a metallic substrate and the environment. However, the increase in complexity and functionality of these coatings requires high-precision techniques capable of predicting failures and providing smart protection. This review summarizes the state of the art for the main electrochemical techniques, emphasizing devices that track the anti-corrosion properties of polymeric coatings from the macroscale to the nanoscale. An overview of the advances in accelerated corrosion testing and the electrochemical characterization of coatings is explored, including insights into their advantages and limitations. In addition, the challenges and potential applications of the theoretical approaches are summarized based on current knowledge. Finally, this work provides the reader with the trends and challenges of designing future technologies and models capable of tracking corrosion and predicting failures.

Evolution and Evaluation of Aesthetic Properties in Weathering Steel Accelerated Patinas: The Role of Lepidocrocite

Weathering steels are widely used in civil engineering, architecture and contemporary art due to their mechanical properties, their enhanced resistance to atmospheric corrosion as well as their aesthetic properties. Artists and blacksmiths often apply chemical treatments to obtain the appealing colors of a patina in a shorter period of time. However, the development of an accelerated patina may have an effect on the final appearance and color of the surface. With the aim of evaluating differences in color and studying the evolution of the surface, eight accelerated patinas were made and exposed to the atmosphere for periods of time of up to 24 months and were compared to a natural patina. The characterization studies showed the presence of lepidocrocite on the surface. A close inspection of the X-ray diffraction patterns showed the displacement of the (020) lepidocrocite reflection and asymmetric broadening of selective lines of this phase that were associated to stacking and twins faults, respectively. These faults decrease with the exposure time and are related to a maximum at 630 nm in the reflectance spectrum and the stabilization of the b* coordinate (yellow color). The colors of the accelerated patinas differ from the natural patina at short exposure times. However, they tend to converge at longer exposure times.

Metallic Iron for Water Remediation: Plenty of Room for Collaboration and Convergence to Advance the Science

Scientific collaboration among various geographically scattered research groups on the broad topic of “metallic iron (Fe0) for water remediation” has evolved greatly over the past three decades. This collaboration has involved different kinds of research partners, including researchers from the same organization and domestic researchers from non-academic organizations as well as international partners. The present analysis of recent publications by some leading scientists shows that after a decade of frank collaboration in search of ways to improve the efficiency of Fe0/H2O systems, the research community has divided itself into two schools of thought since about 2007. Since then, progress in knowledge has stagnated. The first school maintains that Fe0 is a reducing agent for some relevant contaminants. The second school argues that Fe0 in-situ generates flocculants (iron hydroxides) for contaminant scavenging and reducing species (e.g., FeII, H2, and Fe3O4), but reductive transformation is not a relevant contaminant removal mechanism. The problem encountered in assessing the validity of the views of both schools arises from the quantitative dominance of the supporters of the first school, who mostly ignore the second school in their presentations. The net result is that the various derivations of the original Fe0 remediation technology may be collectively flawed by the same mistake. While recognizing that the whole research community strives for the success of a very promising but unestablished technology, annual review articles are suggested as an ingredient for successful collaboration.

Experimental and Statistical Approach to Detect the Corrosion Rate and Influencing Profiles for Enhancing Corrosion Rate of High-Voltage Insulator Materials

The influence of temperature, pollutant, and pH on the local corrosion rate of insulators installed in industrial, marine, and rural installation sites is investigated based on experimental and statistical investigations. The tensile load test confirms that corroded insulator specimens collected from industrial sites aged more than 10 years represent a minimum fracture load, 19,892 lbs. It was further observed that more than 91.24% and 64.62% corroded insulator specimens suffered from shell break and pin detachment, respectively. The microstructural and XRF analysis reveal that insulator specimens collected from industrial sites (age > 10 years), represented the highest wt% of O (19.2) and lowest wt% of Zn (0.34) among industrial, marine, and rural installation sites. The 3D stationery mechanical simulation reveals that insulator specimens aged > 10 years experienced maximum stress (600 MPa) in the pin-cement interface. Using full two-level factorial designs, temperature, concentration of pollutants, and pH were found significant factors for corrosion rate. The immersion test results further confirm the above-mentioned factors significant for the dissolution behavior of galvanized coating of insulator pin. Following immersion test results, the industrial region shows the highest corrosion rate (5.58-12 µm/year) among all installation sites.

Investigating the Fe0/H2O systems using the methylene blue method: Validity, applications, and future directions

An innovative approach to characterize the reactivity of metallic iron (Fe⁰) for aqueous contaminant removal has been in use for a decade: The methylene blue method (MB method). The approach considers the differential adsorptive affinity of methylene blue (MB) for sand and iron oxides. The MB method characterizes MB discoloration by sand as it is progressively coated by in-situ generated iron corrosion products (FeCPs) to deduce the extent of iron corrosion. The MB method is a semi-quantitative tool that has successfully clarified some contradicting reports on the Fe⁰/H₂O system. Moreover, it has the potential to serve as a powerful tool for routine tests in the Fe⁰ remediation industry, including quality assurance and quality control (QA/QC). However, MB is widely used as a 'molecular probe' to characterize the Fe⁰/H₂O system, for instance for wastewater treatment. Thus, there is scope to avoid confusion created by the multiple uses of MB in Fe⁰/H₂O systems. The present communication aims at filling this gap by presenting the science of the MB method, and its application and limitations. It is concluded that the MB method is very suitable for Fe⁰ material screening and optimization of operational designs. However, the MB method only provides semi-quantitative information, but gives no data on the solid-phase characterization of solid Fe⁰ and its reaction products. In other words, further comprehensive investigations with microscopic and spectroscopic surface and solid-state analyses are needed to complement results from the MB method.

Unravelling the Role of Nitrogen in Surface Chemistry and Oxidation Evolution of Deep Cryogenic Treated High-Alloyed Ferrous Alloy

The role of nitrogen, introduced by deep cryogenic treatment (DCT), has been investigated and unraveled in relation to induced surface chemistry changes and improved corrosion resistance of high-alloyed ferrous alloy AISI M35. The assumptions and observations of the role of nitrogen were investigated and confirmed by using a multitude of complementary investigation techniques with a strong emphasis on ToF-SIMS. DCT samples display modified thickness, composition and layering structure of the corrosion products and passive film compared to a conventionally heat-treated sample under the same environmental conditions. The changes in the passive film composition of a DCT sample is correlated to the presence of the so-called ghost layer, which has higher concentration of nitrogen. This layer acts as a precursor for the formation of green rust on which magnetite is formed. This specific layer combination acts as an effective protective barrier against material degradation. The dynamics of oxide layer build-up is also changed by DCT, which is elucidated by the detection of different metallic ions and their modified distribution over surface thickness compared to its CHT counterpart. Newly observed passive film induced by DCT successfully overcomes the testing conditions in more extreme environments such as high temperature and vibrations, which additionally confirms the improved corrosion resistance of DCT treated high-alloyed ferrous alloys.

Corrosion Behavior and Mechanical Properties of 30CrMnSiA High-Strength Steel under an Indoor Accelerated Harsh Marine Atmospheric Environment

In this work, the corrosion behavior and mechanical properties of 30CrMnSiA high-strength steel under a harsh marine atmosphere environment were systematically studied using accelerated test technology, along with corrosion kinetic analysis, microstructure and phase composition analysis, electrochemical measurements, and mechanical property tests. The influence of corrosion time on corrosion kinetics was characterized by the weight loss method. The corrosion layer and its product evolution were analyzed by SEM, EDS, XRD, and XPS. The corrosion behavior of steel was studied by a potentiodynamic polarization curve and EIS. Finally, the influence of corrosion on mechanical properties was studied by tensile and fatigue tests. The results show that 30CrMnSiA high strength steel has good corrosion resistance in a harsh marine atmosphere environment. Its corrosion behavior is cyclical: the outer rust layer exfoliated, the inner rust layer became the outer rust layer, and the matrix became inner rust due to the attack by the corrosive medium. The rust layer had a great protective effect on the matrix. The mechanical properties of 30CrMnSiA high-strength steel were reduced under the corrosive environment, and corrosion had a significant effect on its fatigue resistance.

Assessment of potential benefits of traffic and urban mobility reductions during COVID-19 lockdowns: dose-response calculations for material corrosions on built cultural heritage

Air pollution, particularly in urban areas, puts human health in danger and has adverse impacts on the built environment. It can accelerate the natural corrosion rate of cultural heritages and monuments, leading to premature aging and lowering their aesthetic value. Globally, at the beginning of 2020, to tackle the spread of novel COVID-19, the lockdown was enforced in the most hard-hit countries. Therefore, this study assesses, as a first time, the plausible benefits of traffic and urban mobility reductions on the natural process of deterioration of materials during COVID-19 lockdown in twenty-four major cities on five continents. The potential risk is estimated based on exceeding the tolerable degradation limits for each material. The notable impact of COVID-19 mobility restrictions on air quality was evidenced in 2020 compared to 2019. The introduced mobility restrictions in 2020 could decrease the surface recession rate of materials. Extremely randomized trees analysis showed that PM10 was the main influencing factor for corrosion of portland, copper, cast bronze, and carbon steel with a relative importance of 0.60, 0.32, 0.90, and 0.64, respectively, while SO2 and HNO3 were mainly responsible for corrosion of sandstone and zinc with a relative importance of 0.60 and 0.40, respectively. The globally adverse governed meteorological conditions in 2020 could not positively influence the movement restrictions around the world in air quality improvements. Our findings can highlight the need for additional policies and measures for reducing ambient pollution in cities and the proximity of sensitive cultural heritage to avoid further damage.

Water as a probe for pH measurement in individual particles using micro-Raman spectroscopy

Atmospheric aerosol acidity impacts numerous physicochemical processes, but the determination of particle pH remains a significant challenge due to the nonconservative nature of the H⁺ concentration ([H⁺]). Traditional measurements have difficulty in describing the practical state of an aerosol because they comprise chemical components or hypotheses that change the nature of the particles. In this work, we present a direct pH measurement that uses water as a general probe to detect [H⁺] in individual particles by micro-Raman spectroscopy. Containing the vibrational bands of ions and water influenced by ions, the spectra of hydrated ion were decomposed from the solution spectra as standard spectra by multivariate curve resolution analysis. Meanwhile, ratios of hydrated ions were calculated between the Raman spectra and standard spectra to evaluate concentration profiles of each ion. It demonstrated that good quantitative models between the ratio and concentration for all ions including H⁺ can be built with correlation coefficients (R²) higher than 0.95 for the solutions. The method was further applied to individual particle pH measurement. The pH value of sulfate aerosol particles was calculated, and the standard error was 0.09 using pH values calculated from the [HSO₄^-]/[SO₄^2-] as a reference. Furthermore, the applicability of the method was proven by detecting the pH value of chloride particles. Therefore, utilizing water, the most common substance, as the spectroscopic probe to measure [H⁺] without restriction of the ion system, this method has potential to measure the pH value of atmospheric particles with various compounds, although more work needs to be done to improve the sensitivity of the method.

Influence of the Deep Cryogenic Treatment on AISI 52100 and AISI D3 Steel's Corrosion Resistance

The effect of deep cryogenic treatment (DCT) on corrosion resistance of steels AISI 52100 and AISI D3 is investigated and compared with conventional heat-treated counterparts. DCT's influence on microstructural changes is subsequently correlated to the corrosion resistance. DCT is confirmed to reduce the formation of corrosion products on steels' surface, retard the corrosion products development and propagation. DCT reduces surface cracking, which is considered to be related to modified residual stress state of the material. DCT's influence on each steel results from the altered microstructure and alloying element concentration that depends on steel matrix and type. This study presents DCT as an effective method for corrosion resistance alteration of steels.

Research status and development trends in the field of marine environment corrosion: a new perspective

Corrosion had aroused extensive concern and attention because it was an unavoidable problem for marine equipment and facilities in service. However, the current status and development trend of marine environment corrosion research had seldom been systematically studied. Therefore, it was encouraged to use bibliometrics and information visualization analysis methods to conduct bibliometric analysis of related publications in the field of marine environment corrosion based on HistCite, CiteSpace, and VOSviewer software programs. Compared with the traditional comments of researchers in this field, this research provided a direction for the development of quantitative analysis and visualization of marine environment corrosion on a large scale. The results showed that the overall focus of research in the field of marine environment corrosion continued to increase from 1900 to 2019. China had the highest publication productivity, the USA had the highest h-index value and the second highest average citations per item value, Materials Science was the most popular subject category, Corrosion Science was the main journal and Melchers RE was the author with the most output contributions. This research also exhibited four hot spots in this field. In addition, this work could help new researchers to find research directions and identify research trends and frontiers in the field of marine environment corrosion by tracing the research hotspots of topic categories, countries, institutions, journals, authors, and publications in recent years.

Inhaled Water and Salt Suppress Respiratory Droplet Generation and COVID-19 Incidence and Death on US Coastlines

Dry air alters salt and water balance in the upper airways and increases the risks of COVID-19 among other respiratory diseases. We explored whether such upper airway variations in salt and water balance might alter respiratory droplet generation and potentially contribute to observed impacts of airway hydration on respiratory disease. In a randomized 4-arm study of 21 healthy human subjects we found that the breathing of humid air, the wearing of cotton masks, and the delivery of (sodium, calcium, and magnesium chloride) salt droplets sized to deposit in the nose, trachea, and main bronchi similarly reduce the exhalation of respiratory droplets by approximately 50% ([Formula: see text] < 0.05) within 10 minutes following hydration. Respiratory droplet generation returns to relatively high baseline levels within 60–90 minutes on return to dry air in all cases other than on exposure to divalent (calcium and magnesium) salts, where suppression continues for 4–5 hours. We also found via a preliminary ecological regression analysis of COVID-19 cases in the United States between January 2020 and March 2021 that exposure to elevated airborne salt on (Gulf and Pacific) US coastlines appears to suppress by approximately 25%–30% ([Formula: see text] < 0.05) COVID-19 incidence and deaths per capita relative to inland counties — accounting for ten potential confounding environmental, physiological, and behavioral variables including humidity. We conclude that the hydration of the upper airways by exposure to humidity, the wearing of masks, or the breathing of airborne salts that deposit in the upper airways diminish respiratory droplet generation and may reduce the risks of COVID-19 incidence and symptoms.

Effect of Cr on Aqueous and Atmospheric Corrosion of Automotive Carbon Steel

This study investigated the effect of Cr alloying element on the corrosion properties of automotive carbon steel (0.1C, 0.5Si, 2.5Mn, Fe Bal., composition given in wt.%) in aqueous and atmospheric conditions using electrochemical measurement and cyclic corrosion tests. Three steels with 0, 0.3, and 0.5 wt.% Cr were studied by electrochemical impedance spectroscopy. Polarization resistance (R_p) of 0.3 Cr and 0.5 Cr steels was higher than that of 0 Cr steel, and the R_p also increased as the Cr content increased. Therefore, Cr increases the corrosion resistance of automotive carbon steel immersed in a chloride ion (Cl⁻)-containing aqueous solution. In the cyclic corrosion test results, Cl⁻ was concentrated at the metal/rust interface in all of the steels regardless of Cr content. The Cl⁻ was uniformly concentrated and distributed on the 0 Cr steel, but locally and non-uniformly concentrated on the Cr-added steels. The inner rust layer consisted of β-FeOOH containing Cl⁻ and Cr-goethite, while the outer rust layer was composed of amorphous iron oxyhydroxide mixed with various types of rust. FeCl₂ and CrCl₃ are formed from the Cl⁻ nest developed in the early stage, and the pitting at CrCl₃-formed regions are locally accelerated because Cr is strongly hydrolyzed to a very low pH.

The Effect of Tropical Environment on Fatigue Failure in Royal Malaysian Airforce (RMAF) Aircraft Structure and Operational Readiness

The environmental condition in which the Royal Malaysian Airforce is currently operating its aircraft is prone to corrosion. This is due to the high relative humidity and temperature. With most of its aircraft being in the legacy aircraft era, the aircraft’s main construction consists of the aluminium 2024 material. However, this material is prone to corrosion, thus reducing fatigue life and leading to fatigue failure. Using the concept of either Safe Life or Damage Tolerance as its fatigue design philosophy, the RMAF adopts the Aircraft Structure Integrity Program (ASIP) to monitor its structural integrity. With the current problem of not having the structural limitation on corrosion-damaged structure, the RMAF has embarked on its fatigue testing method. Finite Element (FE) studies and flight tests were conducted, and the outcome is summarized. The conclusion is that the longeron tested on the aircraft can withstand the operational load, and its yield strength is below the ultimate yield strength of the material. These research outcomes will also enhance the ASIP for other aircraft platforms in the RMAF fleet for its structure life assessment or service life extension program.

Uncovering the superior corrosion resistance of iron made via ancient Indian iron-making practice

Ancient Indian iron artefacts have always fascinated researchers due to their excellent corrosion resistance, but the scientific explanation of this feature remains to be elucidated. We have investigated corrosion resistance of iron manufactured according to traditional metallurgical processes by the Indian tribes called ‘Agaria’. Iron samples were recovered from central India (Aamadandh, Korba district, Chhattisgarh). Iron artefacts are investigated using a range of correlative microscopic, spectroscopic, diffraction and tomographic techniques to postulate the hidden mechanisms of superlative corrosion resistance. The importance of manufacturing steps, ingredients involved in Agaria’s iron making process, and post-metal treatment using metal-working operation called hot hammering (forging) is highlighted. This study also hypothesizes the probable protective mechanisms of corrosion resistance of iron. Findings are expected to have a broad impact across multiple disciplines such as archaeology, metallurgy and materials science.

Mapping the susceptibility of UNESCO World Cultural Heritage sites in Europe to ambient (outdoor) air pollution

Air pollution, particularly in urban areas, is a concern for its negative effects on the materials of the built environment. Cities are also home to a large part of our cultural heritage. Air pollution accelerates the natural processes of deterioration of the materials of historic buildings and monuments, causing premature aging and reducing their aesthetic value. The present paper aims to assess the current potential damage due to air pollution on different materials through Europe. Several corrosion and soiling maps were produced by applying widely used dose-response functions. One of the priorities of this study was to provide an estimate of the effects of air pollution on UNESCO World Heritage cultural sites throughout Europe. The potential risk for cultural heritage monuments was estimated on the basis of exceeding tolerable degradation thresholds suggested for each material. The results show that, despite the significant improvements in air quality in Europe over the past few decades, air pollution is still considerable and continues to be an important agent of degradation of cultural heritage, particularly in anthropized areas. Although the methodology used in this study provides a simplified assessment of the likelihood of damage to UNESCO's cultural heritage in Europe from air pollution, it provides a unique perspective and the potential risk is assessed on a common basis. The results obtained contribute to a better understanding of the existing risk deriving from atmospheric pollution and to highlighting those sites, generally located in areas where anthropogenic activity is relevant, that need particular attention. The present paper can serve as a basis for stimulating additional studies and site-specific analyzes, as well as highlighting the need for further measures and policies for atmospheric pollution reduction in cities and in the surroundings of sensitive historic buildings and monuments to prevent further damage.

Microstructure and Corrosion Behavior of Cold-Sprayed Zn-Al Composite Coating

A Zn–Al composite coating was successfully deposited on Q235 steel by cold spray technology for the corrosion protection in the marine atmosphere. The microstructure and corrosion behavior of the prepared coating was studied byScanning Electron Microscope (SEM), X-ray Diffraction (XRD), salt spray test and electrochemical experiments. A 2400-h neutral salt spray corrosion test (with a corrosion medium of 3.5% sodium chloride solution) showed that the prepared cold-sprayed Zn-Al composite coating has excellent anti-corrosion properties. Based on the microstructure evolution and corrosion products analysis, droplets’ flow-driven ‘synergistic corrosion effect’ was proposed to explain the co-corrosion behavior of Zn and Al particles in the composite coating.

The empirical prediction of weight change and corrosion rate of low-carbon steel

Understanding the corrosion rate of metallic building materials is very important to maximize their beneficial use of public facilities. Direct measurements of the weight change and corrosion rate would be time consuming and expensive. This study aims to develop new empirical models based on the experimental data of testing 25 specimens immersed in five different environments for predicting the weight change and corrosion rate of the low-carbon steel. Using the equation developed based on the correlation between corrosion rate and chloride ion concentration is able to predict the corrosion rate of low-carbon steel at the limited chloride ion concentration. An increase in the trend lines of plotting the modeled and measured weight change of low-carbon steel versus immersion time is very similar to each other and progressively increase with increasing of the NaCl concentration. The corrosion rate of low-carbon steel increases from 0.202 to 0.286 mm/y with increasing of the NaCl concentration from 0 to 5% (w/w) in aqueous solution. The weight change and corrosion rate of the steel material are predicted using the new empirical models to contribute to the most reliable applications of low-carbon steel building materials in the future.

Corrosion rate prediction and influencing factors evaluation of low-alloy steels in marine atmosphere using machine learning approach

The empirical modeling methods are widely used in corrosion behavior analysis. But due to the limited regression ability of conventional algorithms, modeling objects are often limited to individual factors and specific environments. This study proposed a modeling method based on machine learning to simulate the marine atmospheric corrosion behavior of low-alloy steels. The correlations between material, environmental factors and corrosion rate were evaluated, and their influences on the corrosion behavior of steels were analyzed intuitively. By using the selected dominating factors as input variables, an optimized random forest model was established with a high prediction accuracy of corrosion rate (R² values, 0.94 and 0.73 to the training set and testing set) to different low-alloy steel samples in several typical marine atmospheric environments. The results demonstrated that machine learning was efficient in corrosion behavior analysis, which usually involves a regression analysis of multiple factors.

High Corrosion Protection Performance of a Novel Nonfluorinated Biomimetic Superhydrophobic Zn-Fe Coating with Echinopsis multiplex-like Structure

A simple, low-cost, fluorine-free, and ecofriendly method was applied to prepare a novel superhydrophobic Zn-Fe alloy coating on the surface of carbon steel. First of all, the Zn-Fe coating was obtained in an alkaline glycerol non-cyanide Zn-Fe plating solution. Then tetradecanoic acid was grafted onto the Zn-Fe coating by a coordination reaction, leading to a superhydrophobic surface. The water contact angle was up to 166° and the sliding angle was 4°. The as-prepared superhydrophobic coating exhibited high performances, such as strong adhesion to the substrate, impact resistance, self-cleaning, antifouling, and anticorrosion. Importantly, until now, few reports focus on the use of a non-cyanide alkaline glycerol plating bath for electrodeposition, which is green, composition-stable, and corrosion-free for devices. In addition, the growth mechanism of the Echinopsis multiplex-like hierarchical micro/nanostructure of the superhydrophobic surface was studied in detail.

Corrosion Processes on Weathering Steel Bridges Influenced by Deposition of De-Icing Salts

The safety and durability of bridges designed from weathering steels are conditioned by the development of a sufficiently protective layer of corrosion products. Air pollution, microclimate around the bridge, time of wetness, structural solution of the bridge, and the position and orientation of the surface within the bridge structure all influence the development of protective layers on the surface of the weathering steel. In this article, attention is focused mainly on the microclimatic effects resulting from the road traffic under the bridge. The influence of chloride deposition on the development of corrosion products is evaluated using experimental in situ testing. Two neighboring bridges made of weathering steel and crossing different types of obstacles were selected for this experiment. Relations and dependences between the measured parameters (deposition rate of chlorides, corrosion rates, thickness of corrosion products and the amount of chlorides in corrosion products) are evaluated and discussed.

Using an Engineered Galvanic Redox System to Generate Positive Surface Potentials that Promote Osteogenic Functions

Successful osseointegration of orthopaedic and orthodontic implants is dependent on a competition between osteogenesis and bacterial contamination on the implant-tissue interface. Previously, by taking advantage of the highly interactive capabilities of silver nanoparticles (AgNPs), we effectively introduced an antimicrobial effect to metal implant materials using an AgNP/poly(dl-lactic- co-glycolic acid) (PLGA) coating. Although electrical forces have been shown to promote osteogenesis, creating practical materials and devices capable of harnessing these forces to induce bone regeneration remains challenging. Here, we applied galvanic reduction-oxidation (redox) principles to engineer a nanoscale galvanic redox system between AgNPs and 316L stainless steel alloy (316L-SA). Characterized by scanning electron microscopy , energy-dispersive X-ray spectroscopy, atomic force microscopy, Kelvin probe force microscopy, and contact angle measurement, the surface properties of the yield AgNP/PLGA-coated 316L-SA (SNPSA) material presented a significantly increased positive surface potential, hydrophilicity, surface fractional polarity, and surface electron accepting/donating index. Importantly, in addition to its bactericidal property, SNPSA's surface demonstrated a novel osteogenic bioactivity by promoting peri-implant bone growth. This is the first report describing the conversion of a normally deleterious galvanic redox reaction into a biologically beneficial function on a biomedical metal material. Overall, this study details an innovative strategy to design multifunctional biomaterials using a controlled galvanic redox reaction, which has broad applications in material development and clinical practice.

Effect of Alternating Current on the Cathodic Protection and Interface Structure of X80 Steel

This study employs potential-monitoring techniques, cyclic voltammetry tests, alternating current (AC) voltammetry methods, and surface characterization to investigate the AC corrosion of cathodically protected X80 pipeline steel. In a non-passive neutral solution at pH 7.2, a sufficiently negative potential completely protects steel at an AC current density of 100 A/m². In an alkaline solution at pH 9.6, more serious AC corrosion occurs at more negative cathodic protection (CP) potential, whereas without CP the steel suffers negligible corrosion. In addition, the interface capacitance increases with AC amplitude. Based on these results, the AC corrosion mechanisms that function under various conditions are analyzed and described.