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Corrosion and Tribocorrosion Behavior of Metals and Alloys

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A special issue of Lubricants (ISSN 2075-4442).

Deadline for manuscript submissions: closed (31 December 2022) | Viewed by 25181

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Dr. Mobin Salasi

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Curtin Corrosion Centre, Curtin University, Bentley, WA 6102, Australia
Interests: mechanically assisted corrosion; localised corrosion; tribocorrosion
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Dr. Christina Schultz

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Future Industries Institute, University of South Australia, Mawson Lakes Campus, SA 5000, Australia
Interests: corrosion; tribocorrosion; thermal spray coatings

Dr. Jean Geringer

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École des Mines de Saint-Étienne, 158 cours Fauriel, 42023 Saint-Etienne, France
Interests: corrosion; tribocorrosion; fretting corrosion
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Prof. Dr. Mariano Iannuzzi

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Guest Editor

Curtin Corrosion Centre, Curtin University, Bentley, WA 6102, Australia
Interests: mechanically assisted corrosion; localised corrosion; environmentally-assisted cracking
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

Tribocorrosion, a form of mechanically assisted corrosion, has been defined as the science of conjoint action of mechanical wear (abrasive or erosive) and (electro)chemical corrosion. The process involves a tribological contact occurring in a corrosive environment. The tribocontact disturbs (electro-)chemical reactions on the surface of the material (passive or actively corroding), resulting in complex degradation phenomena.

Research in tribocorrosion has gained attention due to its practical importance across many industries and applications, as well as its potential economic benefits, especially in the resource industry, or its automotive and biomedical applications. Despite the growing interest and significant progress in tribocorrosion studies, the testing methodologies are still largely non-standardized.

Currently, the only available standard method is the ASTM G119, which has several limitations.

This Special Issue aims to share the latest investigations focused on tribocorrosion and the associated localized corrosion of engineering alloys in challenging environments.

Dr. Mobin Salasi
Dr. Christina Schultz
Dr. Jean Geringer
Prof. Dr. Mariano Iannuzzi
Guest Editors

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Keywords

corrosion
fretting corrosion
tribocorrosion
abrasion corrosion
erosion corrosion

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Published Papers (11 papers)

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Research

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41 pages, 21136 KiB

Open AccessArticle

Tribocorrosive Aspects of Tungsten Carbide, Silicon Nitride, and Martensitic Steel under Fretting-like Conditions

by Markus Kronberger and Josef Brenner

Lubricants 2023, 11(5), 195; https://doi.org/10.3390/lubricants11050195 - 27 Apr 2023

Cited by 1 | Viewed by 1917

Abstract

Water-based lubrication faces the common challenge of component lifetime extension which is impaired by tribocorrosion due to material surface depassivation. However, such mechanisms in a pH-neutral and low-halide electrolyte require additional understanding. A ball-on-flat configuration study of hard-phase materials in a low amplitude–high frequency sliding contact against martensitic chromium steel with contact pressures around 200 MPa is presented. Under lubrication by purified water, tungsten carbide-based metal matrix composite (MMC) with NiCr binder and silicon nitride-based ceramic (SiAlON) against DIN/EN 1.4108 steel yielded coefficients of friction above unity. Wear scar enlargement led to fretting-like conditions with adhesion becoming the fundamental wear mechanism. A tribocorrosion-induced depletion of tungsten carbide and nickel was determined for MMC. SiAlON materials suffered extreme wear under the formation of abrasive SiO₂, while heat-treated DIN/EN 1.4125 steel showed lower friction and wear, but also showed signs of hydrogen embrittlement. Results from accompanying single-material corrosion experiments could not satisfactorily explain the phenomena. Including galvanic interaction and the influence of contact geometry, a new tribocorrosion model for fretting conditions is proposed. It describes an expanding anodic belt located at the inner-most crevice position of an otherwise cathodically polarized material. Low conductivity of the electrolyte is seen as a key player in this process, while the galvanic situation between two materials in contact was shown to invert when water was substituted by a wet organic phase. Full article

(This article belongs to the Special Issue Corrosion and Tribocorrosion Behavior of Metals and Alloys)

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13 pages, 5415 KiB

Open AccessArticle

Study of Effect of Nickel Content on Tribocorrosion Behaviour of Nickel–Aluminium–Bronzes (NABs)

by C. Berlanga-Labari, A. Claver, M. V. Biezma-Moraleda and José F. Palacio

Lubricants 2023, 11(2), 43; https://doi.org/10.3390/lubricants11020043 - 28 Jan 2023

Cited by 1 | Viewed by 1863

Abstract

The simultaneous existence of mechanical erosion and electrochemical corrosion is a common scenario for engineering alloys used in marine environments, such as pump impellers and valves. Nickel–aluminium–bronzes (NABs) are widely used alloys in these environments due to their combination of high corrosion resistance and effective mechanical properties. However, NAB alloys are increasingly cast with reduced nickel content due to its high price and low availability. In this study, we examined the tribocorrosion behaviour of two nickel–aluminium bronzes (C95500 and C95400) with different nickel contents (4.8% and 1.0%, respectively) by means of a pin-on-disk device combined with in situ electrochemistry under 1 M NaCl solution. We conducted tests for pure wear in distilled water, pure corrosion using in situ electrochemistry under 1 M NaCl solution, and a combination of wear and corrosion, called tribocorrosion, to understand the overall synergism that exists between the two. We analysed our results using gravimetric as well as volumetric analysis; in addition, we defined the friction coefficient to compare the effect of open-circuit potential (OCP). We also applied the Tafel method and compared corrosion rates for the different scenarios. We employed confocal microscopy to delimitate the impact of the surface topography of pure wear and its synergistic effect with corrosion, and used an optical microscope to study the materials’ microstructures as cast conditions. We also utilised XRD in the Bragg–Brentano configuration to determine the chemical composition of corrosion products. From the experiments conducted, we concluded that an important synergistic effect existed between the wear and corrosion of both NABs, which was associated with corrosion-induced wear. We found NAB C95400 to be more susceptible to erosion under both conditions compared with NAB C95500 due to the chemical composition and lubricant effect of corrosion products formed during the tribocorrosion tests, which were supported by the enriched Ni corrosion products, particularly the presence of nickel-rich copper chloride, 3Cu₃(CuNi)(OH)₆CuCl₂, in the C95500 alloy. We concluded that, because it increased the nickel content, the NAB alloy offered better wear and corrosion behaviour in sea water conditions due to its protective film nature. Full article

(This article belongs to the Special Issue Corrosion and Tribocorrosion Behavior of Metals and Alloys)

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12 pages, 5635 KiB

Open AccessArticle

Microstructure and Performance of Fe₅₀Mn₃₀Cr₁₀Ni₁₀ High-Entropy Alloy Produced by High-Efficiency and Low-Cost Wire Arc Additive Manufacturing

by Xibin Zhang, Yonggang Tong, Yongle Hu, Xiubing Liang, Yongxiong Chen, Kaiming Wang, Mingjun Zhang and Jiaguo Xu

Lubricants 2022, 10(12), 344; https://doi.org/10.3390/lubricants10120344 - 2 Dec 2022

Cited by 4 | Viewed by 1939

Abstract

High-entropy alloys exhibiting superior properties have great potential applications in various fields. The ability to achieve efficient and economical production of large size and complex structures of high-entropy alloy is of great significance to promoting its engineering application. Additive manufacturing is the key method to produce the complex component; however, the current trend in additive manufacturing of high-entropy alloys focuses on laser additive manufacturing, which is expensive and time-consuming. Herein, we developed a wire arc additive manufacturing (WAAM) method with high-efficiency and a low-cost Fe₅₀Mn₃₀Cr₁₀Ni₁₀ high-entropy alloy was successfully produced. The as-produced alloy was composed of face-centered cubic (FCC) phase with minor σ phase. Its microstructure mainly exhibited dendritic and cytosolic dendritic crystals. Mechanical strength of the additive manufactured alloy reached about 448 MPa with a high fracture elongation up to 80%. The additive manufactured alloy had good corrosion resistance with a protecting layer formed on the surface after corrosion testing, which was much better than 45 steel. Additionally, the frictional performance of the additive manufactured alloy was characterized against the grinding parts of steel and Al₂O₃ balls, and the corresponding friction mechanism was discussed. Full article

(This article belongs to the Special Issue Corrosion and Tribocorrosion Behavior of Metals and Alloys)

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8 pages, 2063 KiB

Open AccessArticle

Effects of Hot Isostatic Pressing on the Properties of Laser-Powder Bed Fusion Fabricated Water Atomized 25Cr7Ni Stainless Steel

by Arulselvan Arumugham Akilan, Ravi K Enneti, Vamsi Krishna Balla and Sundar V. Atre

Lubricants 2022, 10(12), 340; https://doi.org/10.3390/lubricants10120340 - 1 Dec 2022

Cited by 2 | Viewed by 1636

Abstract

25Cr7Ni stainless steel (super duplex stainless steels) exhibits a duplex microstructure of ferrite and austenite, resulting in an excellent combination of high strength and corrosion resistance. However, Laser-Powder Bed Fusion fabrication of a water-atomized 25Cr7Ni stainless steel of novel chemical composition resulted in a purely ferritic microstructure and over 5% porosity. The current study investigated the effects of two hot isostatic pressing parameters on the physical, mechanical, and corrosion properties as well as microstructures of water-atomized 25Cr7Ni stainless steel of novel composition fabricated by L-PBF for the first time in the literature. The corrosion behaviour was studied using linear sweep voltammetry in a 3.5% NaCl solution. The Hot Isostatic Pressing-treated sample achieved over 98% densification with a corresponding reduction in porosity to less than 0.1% and about 3~4% in annihilation of dislocation density. A duplex microstructure of ferrite 60% and austenite 40%was observed in the X-Ray Diffraction and etched metallography of the HIP-treated samples from a purely ferritic microstructure prior to the HIP treatment. With the evolution of austenite phase, the HIP-treated samples recorded a decrease in Ultimate Tensile Strength, yield strength, and hardness in comparison with as-printed samples. The variation in the morphology of the evolved austenite grains in the HIP-treated samples was observed to have a significant effect on the elongation. With a reduction in porosity and the evolution of the austenite phase, the HIP-treated samples showed a higher corrosion resistance in comparison with the as-printed samples. Full article

(This article belongs to the Special Issue Corrosion and Tribocorrosion Behavior of Metals and Alloys)

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15 pages, 3428 KiB

Open AccessArticle

Corrosion Behavior of AZ31B Magnesium Alloy Anode by Sulfate-Reducing Prokaryotes in the Tidal Flat Mud with Different Water Contents

by Jinrong Li, Ruiyong Zhang, Wolfgang Sand, Qingjun Zhu, Xin Liu, Jizhou Duan, Baorong Hou and Jie Zhang

Lubricants 2022, 10(11), 293; https://doi.org/10.3390/lubricants10110293 - 2 Nov 2022

Cited by 1 | Viewed by 1703

Abstract

At present, there are few studies on microbial corrosion of magnesium anode materials that provide protection for oil pipelines in tidal flat environment. In view of an abnormal failure of magnesium anodes in oil pipelines in a tidal flat mud environment, the influence of the change in water content in the beach mud on the corrosion of AZ31B magnesium anode by sulfate-reducing prokaryote (SRP) was investigated by electrochemical methods, weight loss and surface analysis techniques. SRP can grow well in a tidal flat mud environment and cause microbial corrosion of magnesium alloy. The results show that with the increase in water content, the number of SRP cells in the mud increased, that the corrosivity of tidal flat muds was enhanced and that the corrosion rate of AZ31B magnesium anode was accelerated: compared with the corrosion rate of 0.554 mm/y in 40% water content, the corrosion rate of magnesium alloy samples in 60% water content is as high as 1.38 mm/y. Full article

(This article belongs to the Special Issue Corrosion and Tribocorrosion Behavior of Metals and Alloys)

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13 pages, 5551 KiB

Open AccessArticle

Study on the Performance and Corrosion Failure Process of Porous Titanium-Based Coated Electrodes

by Jiamin Li, Linhui Chang, Buming Chen, Hui Huang and Zhongcheng Guo

Lubricants 2022, 10(11), 282; https://doi.org/10.3390/lubricants10110282 - 28 Oct 2022

Cited by 1 | Viewed by 1418

Abstract

Titanium-based coated electrodes are considered to be a substitute for Pb-based anodes because of their lower weights and lower energy consumption; however, their properties and service lives are affected by the matrix structure. Herein, the metal oxide coating was prepared via the thermal oxidation decomposition of a 5 μm-porous titanium plate. The scanning electron microscope (SEM) showed that the metal oxide coating on the porous titanium plate was strengthened in each layer that had pores. The inner coating of the particles are sized using nanometers, with a diameter of 22–64 nm and a compact structure. The electrochemical test results show that, compared with the flat titanium plate, the coating attached to the porous titanium plate has a better catalytic performance in the chlorine evolution reaction, (the chlorine evolution potential decreases by 121 mV), and the service life is increased by 3.78 times. Through a SEM, XRD, and EDS analysis of the coating composition after corrosion failure, the corrosion mechanism of the surface oxide coating was discussed. Full article

(This article belongs to the Special Issue Corrosion and Tribocorrosion Behavior of Metals and Alloys)

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10 pages, 1208 KiB

Open AccessArticle

Structure–Phase Transformations in the Modified Surface of Al-20%Si Alloy Subjected to Two-Stage Treatment

by Yulia Shliarova, Dmitrii Zaguliaev, Yurii Ivanov, Victor Gromov and Alexander Prudnikov

Lubricants 2022, 10(7), 133; https://doi.org/10.3390/lubricants10070133 - 22 Jun 2022

Viewed by 1519

Abstract

The paper describes the two-stage modification of the surface layer of hypereutectic Al-20%Si alloy that combines electroexplosive alloying by an Al-Y₂O system with subsequent irradiation by pulsed electron beam. It is shown that irrespective of the modification mode, a multilayer structure is formed consisting of the following layers: a surface layer and an intermediate layer. The surface layer is a multiphase material, the thickness of which varies within 1 µm. The intermediate layer, the thickness of which varies within 40 µm, is made up of rapid solidification cells formed due to the rapid cooling of molten layer of Al-20%Si alloy. The cells are divided by thin interlayers mostly formed by silicon nanoparticles. Full article

(This article belongs to the Special Issue Corrosion and Tribocorrosion Behavior of Metals and Alloys)

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18 pages, 10624 KiB

Open AccessArticle

Influence of the Nitrided Layer Structure on the Micro-Pitting and Wear Behavior of Slow-Running Nitrided External Gears

by Stefanie Hoja, Michael Geitner, Bernd Zornek, Franz Hoffmann, Thomas Tobie, Karsten Stahl and Rainer Fechte-Heinen

Lubricants 2022, 10(5), 88; https://doi.org/10.3390/lubricants10050088 - 6 May 2022

Cited by 10 | Viewed by 2701

Abstract

Nitriding can significantly increase the load carrying properties of gears. While the diffusion layer is primarily responsible for improving the tooth root and flank load carrying capacity, the compound layer mainly determines the tribological properties of the gear surface. In the present work, the influence of the compound layer on the tribological load carrying capacity of nitrided gears in the N/N pairing was investigated. For this purpose, compound layers with different thickness, porosity and phase composition were produced and their micro-pitting and wear behavior were investigated in load stage and speed stage tests. The test results confirm that the properties of the compound layer are decisive for the micro-pitting and wear resistance of nitrided gears. For a high micro-pitting resistance, the presence of pores in the near-surface area of the compound layer is of high importance, since no micro-pitting occurred as long as pores were present. With regard to the wear behavior, no dependence on the compound layer thickness or the porous zone thickness was found while the phase composition of the compound layer shows a decisive influence. Full article

(This article belongs to the Special Issue Corrosion and Tribocorrosion Behavior of Metals and Alloys)

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12 pages, 2256 KiB

Open AccessArticle

In Silico Approaches for Some Sulfa Drugs as Eco-Friendly Corrosion Inhibitors of Iron in Aqueous Medium

by Soukaina Alaoui Mrani, Nadia Arrousse, Rajesh Haldhar, Abdellatif Ait Lahcen, Aziz Amine, Taoufiq Saffaj, Seong-Cheol Kim and Mustapha Taleb

Lubricants 2022, 10(3), 43; https://doi.org/10.3390/lubricants10030043 - 15 Mar 2022

Cited by 18 | Viewed by 2960

Abstract

This paper addresses the prediction of the adsorption behavior as well as the inhibition capacity of non-toxic sulfonamide-based molecules, also called sulfa drugs, on the surface of mild steel. The study of the electronic structure was investigated through quantum chemical calculations using the density functional theory method (DFT) and the direct interaction of inhibitors with the iron (Fe) metal surface was predicted using the multiple probability Monte Carlo simulations (MC). Then, the examination of the solubility and the environmental toxicity was confirmed using a chemical database modeling environment website. It was shown that the presence of substituents containing heteroatoms able to release electrons consequently increased the electron density in the lowest unoccupied and highest occupied molecular orbitals (LUMO and HOMO), which allowed a good interaction between the inhibitors and the steel surface. The high values of E_HOMO imply an ability to donate electrons while the low values of E_LUMO are related to the ability to accept electrons thus allowing good adsorption of the inhibitor molecules on the steel surface. Molecular dynamics simulations revealed that all sulfonamide molecules adsorb flat on the metal surface conforming to the highly protective Fe (1 1 0) surface. The results obtained from the quantum chemistry and molecular dynamics studies are consistent and reveal that the order of effectiveness of the sulfonamide compounds is P7 > P5 > P6 > P1 > P2 > P3 > P4. Full article

(This article belongs to the Special Issue Corrosion and Tribocorrosion Behavior of Metals and Alloys)

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17 pages, 5935 KiB

Open AccessArticle

Weight Loss, Thermodynamics, SEM, and Electrochemical Studies on N-2-Methylbenzylidene-4-antipyrineamine as an Inhibitor for Mild Steel Corrosion in Hydrochloric Acid

by Israa Abd Alkadir Aziz, Makarim H. Abdulkareem, Iman Adnan Annon, Mahdi M. Hanoon, Mohammed H. H. Al-Kaabi, Lina M. Shaker, Ahmed A. Alamiery, Wan Nor Roslam Wan Isahak and Mohd S. Takriff

Lubricants 2022, 10(2), 23; https://doi.org/10.3390/lubricants10020023 - 9 Feb 2022

Cited by 26 | Viewed by 3920

Abstract

The use of N-2-methylbenzylidene-4-antipyrineamine as an acid corrosion inhibitor for mild steel surfaces in hydrochloric acid is discussed in this article by means of weight loss, electrochemical impedance spectroscopy (EIS), and scanning electron microscopy (SEM) methods. The experimental findings exhibited that N-2-methylbenzylidene-4-antipyrineamine is a significant corrosion inhibitor for the mild steel in 1.0 M HCl solution and that its protection efficiency touches the peak at 5 × 10^–4 M, exhibiting 91.8% for N-2-methylbenzylidene-4-antipyrineamine. The inhibitory efficiency increases as the inhibitor concentration rises and reduces as the temperature rises. Temperature has a significant impact on corrosion and blocking activities, which is extensively examined and explained. According to the gravimetric results, the examined inhibitor inhibits mild steel surface corrosion by providing a barrier at the metal–hydrochloric acid medium interface. Thermodynamic characteristics were combined with a quantum chemistry investigation using density functional theory to provide more insight into the inhibitory effect mechanism. The tested inhibitor adsorbs on the mild steel surface based on Langmuir’s adsorption isotherm method. Full article

(This article belongs to the Special Issue Corrosion and Tribocorrosion Behavior of Metals and Alloys)

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Review

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27 pages, 5259 KiB

Open AccessReview

Improved In Vitro and In Vivo Corrosion Resistance of Mg and Mg Alloys by Plasma Ion Implantation and Deposition Techniques—A Mini-Review

by MOHAMMED-IBRAHIM Jamesh

Lubricants 2022, 10(10), 255; https://doi.org/10.3390/lubricants10100255 - 13 Oct 2022

Cited by 5 | Viewed by 1979

Abstract

Enhanced in vitro corrosion resistance, cytocompatibility, in vitro antibacterial activities, in vivo antibacterial activities, in vivo corrosion resistance and in vivo stimulation of bone formation on plasma-modified biodegradable Mg and its alloys are reviewed, where the plasma modification includes plasma ion implantation (PII), plasma immersion ion implantation (PIII), or plasma immersion ion implantation and deposition (PIII&D) techniques. PII, PIII, and PIII&D are useful surface modification techniques, which can alter the surface properties of the biomaterials while preventing the bulk properties, which is much desirable factor especially for Mg based biomaterials. At first, this paper reviews the improved corrosion resistance by the formation of protective passive surface layer containing Zr-O, Zr-N, N, Si, Al-O, Zn-Al, Cr-O, Ti-O, Ti-N, Fe, Y, Sr, P, Pr, Ce, Nd, Hf, Ta, or C on Mg or its alloys using PII, PIII, or PIII&D techniques. Then, this paper reviews the improved biological properties such as cytocompatibility, in vitro antibacterial activities, and in vivo antibacterial activities on plasma-modified Mg or its alloys. Finally, this paper reviews the improved in vivo corrosion resistance and in vivo stimulation of bone formation on plasma modified Mg alloys. This review suggests that PII, PIII, and PIII&D techniques are effective techniques to improve the in vitro and in vivo corrosion resistance of Mg and its alloys for the development of degradable bio-implants. Full article

(This article belongs to the Special Issue Corrosion and Tribocorrosion Behavior of Metals and Alloys)

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