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 Influence of Graded Amount of Potassium Permanganate on Corrosion of Hot-Dip Galvanized Steel in Simulated Concrete Pore Solutions

This paper evaluates the amount of KMnO₄ in simulated concrete pore solution (pH 12.8) on the corrosion behaviour of hot-dip galvanized steel (HDG). In the range of used MnO₄⁻ (10⁻⁴, 10⁻³, 10⁻² mol·L⁻¹), corrosion behaviour is examined with regard to hydrogen evolution and composition (protective barrier properties) of forming corrosion products. The corrosion behaviour of HDG samples is evaluated using R_p/E_corr and EIS. The composition of corrosion products is evaluated using SEM, XRD, XPS and AAS. The effective MnO₄⁻ ion concentration to prevent the corrosion of coating with hydrogen evolution is 10⁻³ mol·L⁻¹; lower concentrations only prolong the time to passivation (corrosion with hydrogen evolution). The highest used MnO₄⁻ concentration ensures corrosion behaviour without hydrogen evolution but also leads to the formation of less-protective amorphous corrosion products rich in Mn^II/Mn^III phases.     

Corrosion Resistance of AISI 316L Stainless Steel Biomaterial after Plasma Immersion Ion Implantation of Nitrogen

Plasma immersion ion implantation (PIII) of nitrogen is low-temperature surface technology which enables the improvement of tribological properties without a deterioration of the corrosion behavior of austenitic stainless steels. In this paper the corrosion properties of PIII-treated AISI 316L stainless steel surfaces are evaluated by electrochemical impedance spectroscopy (EIS), potentiodynamic polarization (PP) and exposure immersion tests (all carried out in the 0.9 wt. % NaCl solution at 37 ± 0.5 °C) and compared with a non-treated surface. Results of the three performed independent corrosion tests consistently confirmed a significant increase in the corrosion resistance after two doses of PIII nitriding.     

Plasma Electrolytic Polishing—An Ecological Way for Increased Corrosion Resistance in Austenitic Stainless Steels

Plasma electrolytic polishing (PEP) is an environment-friendly alternative to the conventional electrochemical polishing (EP), giving optimal surface properties and improved corrosion resistance with minimum energy and time consumption, which leads to both economic and environmental benefits. This paper is focused on the corrosion behavior of PEP treated AISI 316L stainless steel widely used as a biomaterial. Corrosion resistance of plasma electrolytic polished surfaces without/with chemical pretreatment (acid cleaning) is evaluated and compared with original non-treated (as received) surfaces by three independent test methods: electrochemical impedance spectroscopy (EIS), potentiodynamic polarization (PP), and exposure immersion test. All corrosion tests are carried out in the 0.9 wt.% NaCl solution at a temperature of 37 ± 0.5 °C to simulate the internal environment of a human body. The quality of tested surfaces is also characterized by optical microscopy and by the surface roughness parameters. The results obtained indicated high corrosion resistance of PEP treated surfaces also without chemical pretreatment, which increases the ecological benefits of PEP technology.     

Effect of Solutionizing Duration and Temperature on the Electrochemical Corrosion and Pitting Resistance of Cold-Rolled Super Austenitic Stainless Steel

The solution annealing of cold rolled super austenitic stainless steel UN08029 alloy was carried out to investigate the role of solutionizing duration and temperature on the electrochemical corrosion and pitting resistance of the alloy. Linear polarization, cyclic potentiodynamic, and electrochemical impedance spectroscopy techniques were used to evaluate the electrochemical behavior in 3.5% NaCl solution. The microstructural analysis of the solutionized samples revealed the formation of uniform equiaxed grains from elongated columnar grains, which size increases with duration and temperature. The charge transfer resistance shows an increasing corrosion protectiveness of 46 to 60% with increasing solutionizing duration from 30 to 120 min. Similarly, a 45, 52, 60, and 26% improvement in the corrosion performance was obtained for sample solutionized at 1000, 1100, 1200, and 1300 °C, respectively. In general, the solutionized samples demonstrated improved resistance over the as-received alloy, and this behavior increases with solutionizing duration and temperature. Though the pitting potential drops below that of the as-received alloy, the hysteresis loop revealed that the solutionized samples are less prone to pitting damage, and the sample solutionized at 1200 °C for 120 min exhibited optimum pitting corrosion resistance. The microstructural influence on corrosion was also discussed.     

The Effect of Microstructural Changes on Mechanical and Electrochemical Corrosion Properties of Duplex Stainless Steel Aged for Short Periods

This work reports the effects of Microstructural changes due to the secondary phases, in particular sigma (σ), on the mechanical properties and electrochemical behavior of thermally aged duplex stainless steel (DSS). Structural, morphological, mechanical, and electrochemical characterizations were performed. Sigma phase content increased with increasing aging treatment time. It had a net-like shape, as observed by electron backscatter diffractometry (EBSD). Its presence directly damaged mechanical properties. The corrosion assessment included electrochemical impedance spectroscopy (EIS) in 1 M NaCl solution at temperatures of 25, 40, and 65 °C. EIS results demonstrate that an increase in the σ phase content decreased the corrosion resistance (21.1–0.8, 3.5–0.3, and 3.1–0.2 kΩ cm² at 25, 40, and 60 °C, respectively).     

Corrosion Resistance Measurement of 316L Stainless Steel Manufactured by Selective Laser Melting

Selective laser melting (SLM) technology is ushering in a new era of advanced industrial production of metal components. It is of great importance to understand the relationship between the surface features and electrochemical properties of manufactured parts. This work studied the influence of surface orientation on the corrosion resistance of 316L stainless-steel (SS) components manufactured with SLM. The corrosion resistance of the samples was measured using linear polarization resistance (LPR) and electromechanical noise (EN) techniques under three different environments, H₂O, 3.5 wt.% NaCl, and 20% H₂SO₄, analyzing the horizontal (XY) and vertical (XZ) planes. The microstructure and morphology of the samples were obtained by optical (OM) and scanning electron microscopy (SEM). The obtained microstructure showed the grains growing up from the fusion line to the melt pool center and, via SEM-EDS, the presence of irregular and spherical pores was observed. The highest corrosion rate was identified in the H₂SO₄ solution in the XZ plane with 2.4 × 10⁻² mm/year and the XY plane with 1.31 × 10⁻³ mm/year. The EN technique along with the skewness factor were used to determine the type of corrosion that the material developed. Localized corrosion was observed in the NaCl electrolyte, for the XY and XZ planes (−1.65 and −0.012 skewness factors, respectively), attacking mainly the subgrains of the microstructure and, in some cases, the pores, caused by Cl ions. H₂O and H₂SO₄ solutions presented a uniform corrosion mechanism for the two observed orientations. The morphology identified by SEM was correlated with the results obtained from the electrochemical techniques.     

Formation of Composite Coatings on Galvanized Steel from Organosilane Solutions Using Electrophoresis and Sol–Gel Technology

New hybrid composite coatings (HCCs) on hot-dip galvanized steel (HDGS) were obtained using electrophoresis (cathodic polarization (CP)) and sol–gel technology. For this purpose, a technique for the preparation of a cationic precursor based on TiCl₄ and aminopropyltriethoxysilane was developed. Electrophoresis of the charged particles of the precursor and organosilanes promotes the production of denser sol–gel coatings with improved adhesion. Using scanning electron microscopy (SEM), X-ray photoelectron spectroscopy (XPS) and electrochemical impedance spectroscopy (EIS) methods, the formation mechanism and protective properties of HCC on galvanized steel were investigated.     

Adsorption and Surface Analysis of Sodium Phosphate Corrosion Inhibitor on Carbon Steel in Simulated Concrete Pore Solution

Corrosion of steel-reinforced concrete exposed to marine environments could lead to structural catastrophic failure in service. Hence, the construction industry is seeking novel corrosion preventive methods that are effective, cheap, and non-toxic. In this regard, the inhibitive properties of sodium phosphate (Na₃PO₄) corrosion inhibitor have been investigated for carbon steel reinforcements in 0.6 M Cl⁻ contaminated simulated concrete pore solution (SCPS). Different electrochemical testing has been utilized including potentiodynamic polarization, electrochemical impedance spectroscopy (EIS), and Mott-Schottky plots to test Na₃PO₄ at different concentrations: 0.05, 0.1, 0.3, and 0.6 M. It was found that Na₃PO₄ adsorbs on the surface through a combined physicochemical adsorption process, thus creating insoluble protective ferric phosphate film (FePO₄) and achieving an inhibition efficiency (IE) up to 91.7%. The formation of FePO₄ was elucidated by means of Fourier-transform infrared spectroscopy (FT–IR) and X-ray photoelectron spectroscopy (XPS). Quantum chemical parameters using density functional theory (DFT) were obtained to further understand the chemical interactions at the interface. It was found that PO₄³⁻ ions have a low energy gap (ΔE_gap), hence facilitating their adsorption. Additionally, Mulliken population analysis showed that the oxygen atoms present in PO4³⁻ are strong nucleophiles, thus acting as adsorption sites.     

Corrosion Behavior of CrFeCoNiVx (x = 0.5 and 1) High-Entropy Alloys in 1M Sulfuric Acid and 1M Hydrochloric Acid Solutions

CrFeCoNiV_x high-entropy alloys were prepared by arc-melting, and the microstructures and corrosion properties of these alloys were studied. The CrFeCoNiV_0.5 alloy had a granular structure; the matrix was a face-centered cubic (FCC) structure, and the second phase was a σ phase with a tetragonal structure. The CrFeCoNiV alloy had a dendritic structure; the dendrites in this alloy showed an FCC phase, and the interdendrities had a eutectic structure of FCC and σ phases. Therefore, CrFeCoNiV was much harder than the CrFeCoNiV_0.5 alloy due to the dendritic structures. The potentiodynamic polarization test and electrochemical impedance spectroscopy were used to evaluate the corrosion behavior of the CrFeCoNiV_x high-entropy alloys in deaerated 1M sulfuric acid and 1M hydrochloric acid solutions. The results indicated that the CrFeCoNiV_0.5 alloy had a better corrosion resistance because of the granular structure.     

Combined Electrochemical,Raman Analysis and Machine Learning Assessments of the Inhibitive Properties of an 1,3,4-Oxadiazole-2-Thiol Derivative against Carbon Steel Corrosion in HCl Solution

The inhibiting properties of 5-(4-pyridyl)-1,3,4-oxadiazole-2-thiol (PyODT) on the corrosion of carbon steel in 1.0 M HCl solution were investigated by potentiodynamic polarization, electrochemical impedance spectroscopy, Raman spectroscopy, and SEM-EDX analysis. An approach based on machine learning algorithms and Raman data was also applied to follow the carbon steel degradation in different experimental conditions. The electrochemical measurements revealed that PyODT behaves as a mixed-type corrosion inhibitor, reaching an efficiency of about 93.1% at a concentration of 5 mM, after 1 h exposure to 1.0 M HCl solution. Due to the molecular adsorption and structural organization of PyODT molecules on the C-steel surface, higher inhibitive effectiveness of about 97% was obtained at 24 h immersion. The surface analysis showed a significantly reduced degradation state of the carbon steel surface in the presence of PyODT due to the inhibitor adsorption revealed by Raman spectroscopy and the presence of N and S atoms in the EDX spectra. The combination of Raman spectroscopy and machine learning algorithms was proved to be a facile and reliable tool for an incipient identification of the corrosion sites on a metallic surface exposed to corrosive environments.     

Long-Term Corrosion Behavior of Strong and Ductile High Mn-Low Cr Steel in Acidic Aqueous Environments

To expand the industrial applicability of strong and ductile high Mn-Low Cr steel, a deeper understanding and mechanistic interpretation of long-term corrosion behavior under harsher environmental conditions are needed. From this perspective, the long-term corrosion behaviors of 24Mn3Cr steel under acidic aqueous conditions were examined through a comparison with conventional ferritic steels using the electrochemical measurements (linear polarization resistance and impedance), and immersion test followed by the metallographic observation of corrosion morphologies. In contrast to conventional ferritic steels, 24Mn3Cr steel, which had the lowest corrosion resistance at the early immersion stages (i.e., the highest corrosion current density (i_corr) and lowest polarization resistance (R_p)), showed a gradual increase in corrosion resistance with prolonged immersion. Owing to the slow formation kinetics of (Fe,Cr)-enriched oxide scale, a longer incubation time for ensuring a comparatively higher corrosion resistance is required. On the other hand, conventional ferritic steels had an oxide scale with less densification and a lower elemental enrichment level that did not provide an effective anti-corrosion function. From the results, this study can provide significant insight into the industrial applicability of the high Mn-low Cr steel by providing the mechanistic interpretation of corrosion behaviors in acidic aqueous environments.     

Effect of Chloride Ions Concentrations to Breakdown the Passive Film on Rebar Surface Exposed to L-Arginine Containing Pore Solution

In the present study, 0.115 M L-arginine (LA) has been used as an eco-friendly inhibitor in simulated concrete pore solutions (SP-0) in order to form passive films on a steel rebar–solution interface until 144 h. Hence, 0.51 (SP-1) and 0.85 M NaCl (SP-2) were added in LA containing SP-0 solution to breakdown the passive film and to initiate corrosion reactions. The electrochemical results show that the charge transfer resistance (R_ct) of steel rebar exposed to SP-1 and SP-2 solutions increased with respect to immersion periods. The sample exposed to the SP-2 solution initiated the corrosion reaction at the steel rebar–solution interface after 24 h of NaCl addition and formed pits; on the other hand, the sample without NaCl added, i.e., SP-0, showed agglomeration and dense morphology of corrosion products.     

Sacrificial Dissolution of Zinc Electroplated and Cold Galvanized Coated Steel in Saline and Soil Environments: A Comparison

To protect steel structures, zinc coatings are mostly used as a sacrificial barrier. This research aims to estimate the dissolution tendency of the electroplated and zinc-rich cold galvanized (ZRCG) coatings of a controlled thickness (35 ± 1 μm) applied via brush and dip coating methods on the mild steel. To assess the corrosion behavior of these coated samples in 3.5% NaCl and 10% NaCl containing soil solutions, open circuit potential (OCP), cyclic polarization (CP), and electrochemical impedance spectroscopy (EIS) tests were performed. The more negative OCP and appreciably large corrosion rate of the electroplated and ZRCG coated samples in 3.5% NaCl solution highlighted the preferential dissolution of Zn coatings. However, in saline soil solution, the relatively positive OCP (>−850 mV vs. Cu/CuSO₄) and lower corrosion rate of the electroplated and ZRCG coatings compared to the uncoated steel sample indicated their incapacity to protect the steel substrate. The CP scans of the zinc electroplated samples showed a positive hysteresis loop after 24 h of exposure in 3.5% NaCl and saline soil solutions attributing to the localized dissolution of the coating. Similarly, the appreciable decrease in the charge transfer resistance of the electroplated samples after 24 h of exposure corresponded to their accelerated dissolution. Compared to the localized dissolution of the electroplated and brush-coated samples, the dip-coated ZRCG samples exhibited uniform dissolution during the extended exposure (500 h) salt spray test.     

Effect of Annealing on Microstructure and Corrosion Behavior of Interstitial Free Steel

Interstitial free steels with various grain sizes and textures were prepared by cold-rolling followed by an annealing process. The effect of grain size, crystallographic orientations and stored energy on corrosion behavior of interstitial free steel was investigated. It was found that the deformed microstructure and dislocation boundaries were consumed by recrystallizing grains during annealing. The average grain size increase ranging from 0.61 μm to 11 μm and the volume fraction of recrystallized grains was about 96% after annealing for 64 h; meanwhile, the γ fiber was the dominated recrystallized texture component. The stored energy gradually decreased due to the reduction in dislocation density by annealing. The potentiodynamic polarization and Nyquist plots show that the corrosion potential exhibits a more positive shift and depressed capacitive semicircle radius increase with rising annealing time. The 64 h annealed specimens had the biggest depressed semicircle in the Nyquist plots and the highest positive corrosion potential, which indicates the enhancement of corrosion resistance. Such an improvement of corrosion resistance is attributed to the increase in the volume fraction of the γ fiber and decrease in the stored energy.     

Method of Iterative Determination of the Polarized Area of Steel Reinforcement in Concrete Applied in the EIS Measurements

A new method is proposed for determining the test surface of steel rebar in concrete during polarization measurements of corrosion rate of reinforcement using the method of Electrochemical Impedance Spectroscopy. The methodology was based on the original 3D model of the steel-concrete system, in which traditional equivalent electrical systems were coupled with factors that accounted for the complex geometry of the test reinforced concrete element. The developed method worked with a rectangular counter electrode without a guard ring assist, during an individual impedance measurement. The impact of the counter electrode size on the impedance spectra was verified in the first stage by tests conducted with ten types of counter electrodes. The obtained results in the form of empirical spectra were represented by theoretical spectra using the 3D model and the matching degrees were within a range of 0.96–1.73 at the expected level of 1.00. The obtained results in the form of spectra distribution were accurately represented by simulations with the 3D model. In the second stage, the iterative procedure for determining the polarization area of reinforcement in concrete was positively verified for additional test elements. Electrochemical parameters of the steel-concrete system were determined on the basis of the 3D model with a simultaneous adjustment of the polarization area on the rebar. In this case, the expected matching degree of 1.00 was obtained for each tested system after more than ten iterations starting from matching the model spectra to the empirical spectra at the level of 0.31–0.93.     

Electrochemical Corrosion Behaviour of X70 Steel under the Action of Capillary Water in Saline Soils

In this paper, the electrochemical corrosion behavior of X70 steel in saline soil under capillary water was simulated by a Geo-experts one-dimensional soil column instrument. A volumetric water content sensor and conductivity test were used to study the migration mechanism of water and salt (sodium chloride) under the capillary water. The electrochemical corrosion behavior of the X70 steel in the corrosion system was analyzed by electrochemical testing as well as the macroscopic and microscopic corrosion morphology of the steel. The test results showed that the corrosion behavior of X70 steel was significantly influenced by the rise of capillary water. In particular, the wetting front during the capillary water rise meant that the X70 steel was located at the three-phase solid/liquid/gas interface at a certain location, which worsened its corrosion behavior. In addition, after the capillary water was stabilized, the salts were transported with the capillary water to the top of the soil column. This resulted in the highest salt content in the soil environment and the most severe corrosion of the X70 steel at this location.     

Effect of Sub-Zero Treatments and Tempering on Corrosion Behaviour of Vanadis 6 Tool Steel

Sub-zero treatment of Vanadis 6 steel resulted in a considerable reduction of retained austenite amount, refinement of martensite, enhancement of population density of carbides, and modification of precipitation behaviour. Tempering of sub-zero-treated steel led to a decrease in population density of carbides, to a further reduction of retained austenite, and to precipitation of M₃C carbides, while M₇C₃ carbides precipitated only in the case of conventionally quenched steel. Complementary effects of these microstructural variations resulted in more noble behaviour of sub-zero-treated steel compared to the conventionally room-quenched one, and to clear inhibition of the corrosion rate at the same time.     

Changes in the Structure and Corrosion Protection Ability of Porous Anodic Oxide Films on Pure Al and Al Alloys by Pore Sealing Treatment

It is well known that corrosion protection of pure Al is enormously improved by the formation of porous anodic oxide films and by pore sealing treatment. However, the effects of anodizing and pore sealing on corrosion protection for Al alloys are unclear, because the alloying elements included in Al alloys affect the structure of anodic oxide films. In the present study, porous anodic oxide films are formed on pure Al, 1050-, 3003- and 5052-Al alloys, and pore sealing was carried out in boiling water. Changes in the structure and corrosion protection ability of porous anodic oxide films on pure Al and the Al alloys by pore sealing, were examined by scanning electron microscopy (SEM) and electrochemical impedance spectroscopy (EIS). SEM observation showed that anodic oxide films formed on pure Al have a smooth surface after pore sealing, and that cracks are formed in anodic oxide films on 1050-, 3003- and 5052-aluminum alloys, after pore sealing. Corrosion protection after pore sealing increased with anodizing time on pure Al, but only slightly increased with anodizing time on the Al alloys.     

Role of Coating Processes on the Corrosion Kinetics and Mechanism of Zinc in Artificial Seawater

Zinc (Zn) coating is being used to protect steel structures from corrosion. There are different processes to deposit the coating onto a steel substrate. Therefore, in the present study, a 100 µm thick Zn coating was deposited by arc and plasma arc thermal spray coating processes, and the corrosion resistance performance was evaluated in artificial seawater. Scanning electron microscopy (SEM) results showed that the arc thermal spray coating exhibited splats and inflight particles, whereas plasma arc spraying showed a uniform and dense morphology. When the exposure periods were extended up to 23 d, the corrosion resistance of the arc as well as the plasma arc thermal spray coating increased considerably. This is attributed to the blocking characteristics of the defects by the stable hydrozincite (Zn₅(OH)₆(CO₃)₂).