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Crystals
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Corrosion Phenomena in Metals
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Corrosion Phenomena in Metals

A special issue of Crystals (ISSN 2073-4352). This special issue belongs to the section "Crystalline Metals and Alloys".

Deadline for manuscript submissions: 20 June 2025 | Viewed by 10654

Special Issue Editors

Dr. Jijo Christudasjustus

E-Mail Website
Guest Editor
Physical and Computational Sciences Directorate, Pacific Northwest National Laboratory, Richland, WA 99352, USA
Interests: localized corrosion; corrosion mechanisms; advanced characterization; advanced engineering materials; surface film; TEM; nanocrystalline alloys; high-entropy alloy
Dr. Rajeev Gupta

E-Mail Website
Guest Editor
Department of Material Science and Engineering, North Carolina State University, Raleigh, NC 27606, USA
Interests: corrosion science and engineering; materials design; alloys; advanced manufacturing; electrochemistry
Dr. Mohammad Umar Farooq Khan

E-Mail Website
Guest Editor
Materials in High Temperature Extreme Environment (MiHTEE) Lab, University of Michigan, Ann Arbor, MI 48109, USA
Interests: materials science; electrochemistry and corrosion; oxidation; advanced engineering materials and manufacturing; nanostructured alloys; EAC; molten salt corrosion; failure mechanisms; coatings
Dr. Ulises Martin Diaz

E-Mail Website
Guest Editor
Department of Materials Science and Engineering, Texas A&M University, College Station, TX 77843, USA
Interests: corrosion; materials science; SCC; additive manufacturing; stainless steel; simulation

Special Issue Information

Dear Colleagues,

Crystals is launching a Special Issue on “Corrosion Phenomena in Metals” to highlight scientific advances in fundamental and applied research on the degradation of metallic materials. As it is known, the damage caused by corrosion can manifest in several ways, including through the loss of material strength, the formation of cracks and fractures, the impairment of surface finishes, and the overall degradation of structural integrity. Consequently, the economic impact of corrosion is substantial, as it necessitates costly repairs, maintenance, and the replacement of corroded materials and equipment. Therefore, the present Special Issue is brought about to emphasize the impact of corrosion and provide a path to mitigate degradation. We welcome submissions of original research articles, short-communication articles, and critical reviews of experimental studies involving advanced characterization and electrochemical techniques to understand the structure and material properties. The topics of interest include, but are not limited to:

  • Stress corrosion cracking and environment-assisted cracking;
  • Localized corrosion that initiates by means of pitting or intergranular corrosion;
  • Influence of corrosion inhibitor in improving the surface resistance or expediting repassivation;
  • Corrosion mechanisms that explore the science behind the dissolution initiation and impedance;
  • Microstructure/Nanostructure changes in metals influencing corrosion behavior or corrosion rate;
  • Relationship between the electrochemical and mechanical properties, and their degradation due to corrosion;
  • High-temperature oxidation and hot corrosion;
  • Emerging corrosion-resistant material processing and design approaches, such as high-entropy alloys, additively manufactured alloys, and far-from-equilibrium microstructures;
  • Corrosion protection via surface modification, such as metallic coating and surface hardening;
  • Service lifetime prediction of metallic parts under an aggressive environment;
  • External factors affecting corrosion phenomena including, but not limited to, radiation or biofouling.

Dr. Jijo Christudasjustus
Dr. Rajeev Gupta
Dr. Mohammad Umar Farooq Khan
Dr. Ulises Martin Diaz
Guest Editors

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 100 words) can be sent to the Editorial Office for announcement on this website.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Crystals is an international peer-reviewed open access monthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2100 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

  • stress corrosion cracking
  • environment-assisted cracking
  • localized corrosion
  • corrosion inhibitor
  • high-entropy alloys
  • additively manufactured alloys
  • transmission electron microscopy
  • potentiodynamic polarization test
  • high-temperature oxidation
  • nanocrystalline alloys
  • electrochemical impedance spectroscopy
  • secondary phases
  • metallic coating
  • immersion test
  • failure initiation and propagation mechanism
  • corrosion mitigation
  • semiconductive properties
  • passive film
  • modeling
  • service lifetime prediction

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Further information on MDPI's Special Issue policies can be found here.

Published Papers (7 papers)

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Research

22 pages, 11041 KiB  
Article
Effect of Dynamic Corrosion and Degradation on Fatigue Life of an AA2024-T3 Aircraft Profile: Experimental, Statistical, and Numerical Analyses
by Gilberto Daniel Conejo Magaña, Víctor García García, Daniel Cahue Díaz, Nicolás Herrera-Sandoval and Orlando Hernández Cristóbal
Crystals 2025, 15(1), 66; https://doi.org/10.3390/cryst15010066 - 11 Jan 2025
Viewed by 701
Abstract
The effect of parameters such as angle of attack, flow velocity, and electrolyte concentration (saline solution) on the extent of material degradation, as well as the morphology and depth of corrosion pits in an airfoil made of 2024-T3 aluminum alloy, was studied in [...] Read more.
The effect of parameters such as angle of attack, flow velocity, and electrolyte concentration (saline solution) on the extent of material degradation, as well as the morphology and depth of corrosion pits in an airfoil made of 2024-T3 aluminum alloy, was studied in detail. An orthogonal L9 design of experiments (Taguchi method) was applied to promote high pitting corrosion through the quality characteristic “the higher the better”. Potentiodynamic curves of the three experiments with low, medium, and high saline concentration were obtained through the CorrTest CS350 equipment. The above allowed the determination of the electrochemical corrosion parameters under static test conditions. The corroded airfoils were analyzed using light optical microscopy (LOM). In addition, the roughness measurements correlated with the extent of the degraded surface. A complete pit shape and depth characterization was obtained by applying mechanical ground, surface wear level monitoring (every 0.01 mm), and LOM observations. Pitting defects (depth and morphology) and mechanical strength reduction were considered by a finite element (FE) model to simulate the airfoil fatigue behavior. Numerical results helped to determine the contribution of pitting and the extent of degradation on sudden airfoil failure. Full article
(This article belongs to the Special Issue Corrosion Phenomena in Metals)
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18 pages, 16446 KiB  
Article
Effect of Zr, Zn, and Cu on Corrosion Resistance of As-Extruded Mg-3Sn-1Ca Alloy
by Zheng Jia, Sichao Du and Xiaowei Niu
Crystals 2024, 14(12), 1098; https://doi.org/10.3390/cryst14121098 - 20 Dec 2024
Viewed by 595
Abstract
TX31 (Mg-3Sn-1Ca) is an alloy with promising future applications. This study enhances the corrosion resistance of the TX31 alloy through the addition of Zr and Zn and compares the effects of individual Cu addition and Zn/Cu composite addition on the corrosion resistance of [...] Read more.
TX31 (Mg-3Sn-1Ca) is an alloy with promising future applications. This study enhances the corrosion resistance of the TX31 alloy through the addition of Zr and Zn and compares the effects of individual Cu addition and Zn/Cu composite addition on the corrosion resistance of the TX31 alloy. This study investigates the corrosion properties of TX31 alloys, focusing on the effects of the grain size, second phase, corrosion product film, and texture intensity. The addition of Zr and Zn changed the second-phase area fraction, while Cu introduced a new Mg2Cu phase. The TXZ311 alloy (Mg-3Sn-1Ca-1Zn) exhibited the best corrosion resistance, with a corrosion rate as low as 1.68 mm·year−1, a significant reduction compared to other alloys. This improvement is attributed to its higher fraction of high-angle grain boundaries (HAGBs) and the enhanced stability of the corrosion product film. The TXK311 alloy (Mg-3Sn-1Ca-1Zr) showed superior corrosion resistance, with a rate of 2.97 mm·year−1, due to its uniform and fine grain structure. In contrast, the TX31 alloy had the poorest corrosion resistance, with a corrosion rate of 3.66 mm·year−1, due to its bimodal microstructure. The addition of Cu in the TXC311 (Mg-3Sn-1Ca-1Cu) and TXCZ3111 (Mg-3Sn-1Ca-1Cu-1Zn) alloys resulted in micro-galvanic corrosion between α-Mg and Mg2Cu, which decreased the corrosion resistance. Full article
(This article belongs to the Special Issue Corrosion Phenomena in Metals)
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16 pages, 5676 KiB  
Article
Chitosan–Alginate Nanocontainers with Caffeine as Green Corrosion Inhibitors for Protection of Galvanized Steel
by Kamelia Kamburova, Nelly Boshkova, Tsetska Radeva, Maria Shipochka and Nikolai Boshkov
Crystals 2024, 14(7), 660; https://doi.org/10.3390/cryst14070660 - 19 Jul 2024
Cited by 4 | Viewed by 1518
Abstract
The introduction of new regulations needs to develop eco-friendly systems to prevent corrosion. In this work, a natural corrosion inhibitor caffeine (CAF) was encapsulated in polysaccharide-based nanoparticles, capable of the responsive release of CAF during corrosion. The nanoparticles were prepared using electrostatic complexation [...] Read more.
The introduction of new regulations needs to develop eco-friendly systems to prevent corrosion. In this work, a natural corrosion inhibitor caffeine (CAF) was encapsulated in polysaccharide-based nanoparticles, capable of the responsive release of CAF during corrosion. The nanoparticles were prepared using electrostatic complexation between two natural polysaccharides which are oppositely charged—chitosan (CHI) and sodium alginate (ALG), crosslinked by tripolyphosphate (TPP). The particle size distribution and zeta potential were evaluated using dynamic light scattering and laser Doppler velocimetry. The encapsulation efficiency and release of CAF from nanocontainers was evaluated with UV-spectroscopy. The nanoparticles were incorporated via electrodeposition into the zinc coating on low-carbon steel to ensure self-healing. Cyclic voltammetry demonstrated the cathodic and anodic processes in the starting electrolytes. Surface hydrophobicity was investigated by water contact angle (WCA). The corrosion resistance of the coatings was estimated with polarization resistance (Rp) measurements and potentiodynamic polarization (PDP) curves. The study of the chemical composition of the coatings was carried out with X-ray photoelectron spectroscopy. The data obtained confirm the indisputable influence of the nanoparticles/nanocontainers on the protective feature of the hybrids—the latter have about twice-higher Rp values compared to the ordinary zinc. Full article
(This article belongs to the Special Issue Corrosion Phenomena in Metals)
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12 pages, 3560 KiB  
Article
Environmentally Assisted Cracking of Duplex and Lean Duplex Stainless Steel Reinforcements in Alkaline Medium Contaminated with Chlorides
by Ulises Martin and David M. Bastidas
Crystals 2024, 14(7), 651; https://doi.org/10.3390/cryst14070651 - 16 Jul 2024
Cited by 1 | Viewed by 1093
Abstract
Herein, the corrosion performance of different stainless steel (SS) reinforcing bar grades in alkaline solution is presented, including UNS S32205 duplex stainless steel (DSS), UNS S32304 and UNS S32001 lean DDS (LDSS). The electrochemical dissolution kinetics were studied by potentiodynamic polarization and the [...] Read more.
Herein, the corrosion performance of different stainless steel (SS) reinforcing bar grades in alkaline solution is presented, including UNS S32205 duplex stainless steel (DSS), UNS S32304 and UNS S32001 lean DDS (LDSS). The electrochemical dissolution kinetics were studied by potentiodynamic polarization and the Tafel slope method. The environmentally assisted cracking (EAC) mechanisms of the different SS grades in the presence of Cl− were revealed with the slow strain rate test (SSRT). The higher activation of the anodic branch and the loss of toughness were related to the austenite-to-ferrite phase ratio. UNS S32205 DSS presented the slowest anodic dissolution kinetics, mainly due to the higher austenite content compared to the other LDSS; however, it suffered a more severe EAC than the UNS S32304 LDSS. In the case of UNS S32001 LDSS, even while having the lowest Ni content (i.e., large ferrite α-phase ratio), it experienced the least decrease in elongation as well as low anodic dissolution kinetics for Cl− contents up to 8 wt.%, where the Cl− threshold was reached. Full article
(This article belongs to the Special Issue Corrosion Phenomena in Metals)
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21 pages, 20941 KiB  
Article
Effect of Corrosion and Post-Weld Treatment on the Fatigue Behavior of Multipass Robot GMAW Welds of S700MC Steel
by Stefania Spyropoulou, Emmanouil Christofilis and Anna D. Zervaki
Crystals 2024, 14(7), 609; https://doi.org/10.3390/cryst14070609 - 30 Jun 2024
Viewed by 1676
Abstract
High-strength steel is a candidate material for offshore structures, which are currently being constructed with regular-strength steel. These structures are constantly exposed to harsh environmental conditions and experience cyclic loadings, which can lead to premature failure due to the synergistic effects of corrosion [...] Read more.
High-strength steel is a candidate material for offshore structures, which are currently being constructed with regular-strength steel. These structures are constantly exposed to harsh environmental conditions and experience cyclic loadings, which can lead to premature failure due to the synergistic effects of corrosion and fatigue. In this regard, the current study aims to investigate the effects of corrosion and High-Frequency Mechanical Impact (HFMI) treatment on the fatigue behavior of welded joints made of S700MC steel. Multipass butt-welded joints were fabricated via the Robot GMAW method at an optimally selected heat input of 0.7405 kJ/mm. The microstructure of the weldments was studied using light optical microscopy. Tensile and Vickers microhardness tests were performed to evaluate the mechanical properties of the welded joints. To simulate marine environment corrosion in the laboratory, the as-welded samples were exposed to salt fog spray for 720 h. Subsequently, specimens were subjected to cyclic loading to evaluate their fatigue strength, while SEM and stereomicroscopy were used to analyze the fractured surfaces, providing a comprehensive understanding of the fracture mode. The findings suggest that although corrosion led to increased surface roughness and the formation of corrosion pits, its influence on the fatigue behavior of the weldments might be less significant compared to other geometrical factors, at least for the exposure time employed in the study. Full article
(This article belongs to the Special Issue Corrosion Phenomena in Metals)
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14 pages, 9807 KiB  
Article
Influence of Spatter on Porosity, Microstructure, and Corrosion of Additively Manufactured Stainless Steel Printed Using Different Island Size
by Venkata Bhuvaneswari Vukkum, Taylor Sanborn, John Shepherd, Sourabh Saptarshi, Rakesh Basu, Timothy Horn and Rajeev Kumar Gupta
Crystals 2024, 14(4), 328; https://doi.org/10.3390/cryst14040328 - 30 Mar 2024
Cited by 1 | Viewed by 1663
Abstract
Specimens of 316 L stainless steel were printed using laser powder bed fusion (LPBF), a popular metal additive manufacturing (AM) technique, with varying island sizes. Not many researchers have considered the impact of spatter while optimizing LPBF printing parameters. In this research, the [...] Read more.
Specimens of 316 L stainless steel were printed using laser powder bed fusion (LPBF), a popular metal additive manufacturing (AM) technique, with varying island sizes. Not many researchers have considered the impact of spatter while optimizing LPBF printing parameters. In this research, the influence of spatter was considered while also investigating the effect of varied island size on the microstructure, surface roughness, microhardness, and corrosion resistance of LPBF-316 L. No correlation was observed between surface roughness or microhardness and minor variations in island size. However, a correlation was drawn between varied island sizes and porosity in LPBF-316 L. The specimens associated with larger island sizes showed significantly enhanced corrosion resistance due to fewer manufacturing defects and reduced porosity, attributed to the minimal influence of the spatter. Based on analysis, the LPBF parameters were revised, which lead to superior corrosion resistance of LPBF-316 L, attributed to high density and reduced porosity. Full article
(This article belongs to the Special Issue Corrosion Phenomena in Metals)
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15 pages, 5271 KiB  
Article
Effect of Additive and Current Density on Microstructures and Corrosion Behavior of a Multi-Component NiFeCoCu Alloy Prepared by Electrodeposition
by Ying Wang, Bingyang Ma, Wei Li, Peter K. Liaw, Songpu Yang and Ning Zhong
Crystals 2024, 14(2), 171; https://doi.org/10.3390/cryst14020171 - 8 Feb 2024
Cited by 4 | Viewed by 1849
Abstract
High-entropy alloys (HEAs) have been attracting growing interest for decades due to their unique properties. Electrodeposition provides a low-cost and convenient route for producing classified types of HEAs, compared to other synthesis techniques, making it an attention-grabbing method. However, fabricating high-quality HEAs through [...] Read more.
High-entropy alloys (HEAs) have been attracting growing interest for decades due to their unique properties. Electrodeposition provides a low-cost and convenient route for producing classified types of HEAs, compared to other synthesis techniques, making it an attention-grabbing method. However, fabricating high-quality HEAs through electrodeposition in aqueous electrolytes remains a great challenge. In this study, the effects of additives and current densities on the compositions, surface morphologies, microstructures, and corrosion behavior of the electrodeposited NiFeCoCu alloy are studied. The results indicate that saccharin plays a key role in achieving a flat and bright surface for NiFeCoCu coatings, while also relieving the internal stress and improving anti-corrosion properties. Electrodeposition under a current density of 20–40 mA/cm2 results in a uniform and dense deposit with favorable properties. The present work provides a low-cost and feasible industrial solution for the preparation of HEA coatings, which holds great potential for innovation in the field of HEA coatings through electrodeposition. Full article
(This article belongs to the Special Issue Corrosion Phenomena in Metals)
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