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Corrosion and Corrosion Protection of Metals/Alloys

A Special Issue of Materials (ISSN 1996-1944) belonging to the section "Corrosion".

Deadline for manuscript submissions: 20 September 2026 | Viewed by 4118

Editor

Dr. Zbigniew Brytan

E-Mail Website1 Website2
Guest Editor
Department of Engineering Materials and Biomaterials, Mechanical Engineering Faculty, Silesian University of Technology, ul. Konarskiego, 18a, 44-100 Gliwice, Poland
Interests: stainless steels; duplex stainless steel; heat-resistant steels; creep-resistant steels; corrosion; powder metallurgy; additive manufacturing; surface engineering; laser processing of metals; electrochemical impedance spectroscopy
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

The corrosion of metals and alloys remains one of the most critical challenges in materials engineering. It affects the durability, safety, and performance of products and systems in a range of industries, including energy, construction, transport, and biomedical applications. Despite significant advances in alloy design, protective coatings, and surface engineering, the complex mechanisms of corrosion in different environments and operating conditions require ongoing research. This Special Issue, entitled “Corrosion and Corrosion Protection of Metals/Alloys”, aims to provide a platform for researchers and engineers to share recent advances in our understanding of corrosion phenomena and in the development of innovative protection strategies. Topics include fundamental studies of electrochemical processes, environmental degradation, localised corrosion, and stress corrosion cracking, as well as advanced approaches such as nanostructured coatings, corrosion inhibitors, surface modifications, and sustainable corrosion protection technologies. Contributions addressing modelling, testing methods, and case studies from industrial applications are also encouraged. By bringing together theoretical, experimental, and applied perspectives, this Special Issue seeks to promote knowledge exchange and highlight practical solutions for extending the service life of metallic materials. Potential authors are invited to submit original research articles, reviews, or case reports that contribute to advancing corrosion science and protective technologies.

Dr. Zbigniew Brytan
Guest Editor

Manuscript Submission Information

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Keywords

  • corrosion mechanisms
  • corrosion protection
  • metallic alloys
  • surface engineering
  • protective coatings
  • corrosion inhibitors
  • stress corrosion cracking
  • localized corrosion
  • electrochemical methods
  • service life extension

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Published Papers (6 papers)

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Research

23 pages, 28033 KB  
Article
Active Dissolution and Localized Corrosion Behavior of AISI 316L Stainless Steel in Concentrated Hydrochloric Acid
by Citlalli Gaona-Tiburcio, Erick Maldonado-Bandala, Jesús Manuel Jáquez-Muñoz, Demetrio Nieves-Mendoza, Ce Tochtli Méndez-Ramírez, Jose Cabral-Miramontes, Laura Landa-Ruiz, Miguel Ángel Baltazar-Zamora, Luis Daimir Lopez-Leon, Javier Olguin-Coca and Facundo Almeraya-Calderón
Materials 2026, 19(16), 3386; https://doi.org/10.3390/ma19163386 - 9 Aug 2026
Viewed by 299
Abstract
AISI 316L austenitic stainless steel is extensively used in petrochemical storage and processing equipment because of its excellent corrosion resistance. However, exposure to concentrated hydrochloric acid severely destabilizes its passive film, promoting active dissolution and localized corrosion. This work investigates the corrosion behavior [...] Read more.
AISI 316L austenitic stainless steel is extensively used in petrochemical storage and processing equipment because of its excellent corrosion resistance. However, exposure to concentrated hydrochloric acid severely destabilizes its passive film, promoting active dissolution and localized corrosion. This work investigates the corrosion behavior of AISI 316L stainless steel in hydrochloric acid solutions of 7.2, 9.6, and 12 M at room temperature. Cyclic potentiodynamic polarization (CPP) tests were performed according to ASTM G61, and the corrosion morphology was characterized using optical microscopy (OM), scanning electron microscopy (SEM), energy-dispersive spectroscopy (EDS), and metallographic cross-sections. The electrochemical results revealed an active dissolution regime characterized by the absence of a stable passive region and positive hysteresis loops in all HCl solutions, indicating irreversible surface damage and poor repassivation. The corrosion current density increased from the order of 10−1 mA cm−2 in 7.2 and 9.6 M HCl to the order of 101 mA cm−2 in 12 M HCl, demonstrating a significant acceleration of the corrosion kinetics. SEM and cross-sectional analyses confirmed the development of localized pitting corrosion, with pit depths reaching approximately 0.87 mm. The results demonstrate that concentrated hydrochloric acid promotes the coexistence of generalized active dissolution and localized pitting corrosion, while increasing HCl concentration modifies the morphology and propagation mode of the pits. Full article
(This article belongs to the Special Issue Corrosion and Corrosion Protection of Metals/Alloys)
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15 pages, 22518 KB  
Article
Effect of Al Content on Corrosion Properties in Die-Cast AZXW Alloys
by Hongxiu Liu, Bong-Sun You, Jun-Ho Bae and Jae-Yeon Kim
Materials 2026, 19(13), 2760; https://doi.org/10.3390/ma19132760 - 29 Jun 2026
Viewed by 247
Abstract
This study evaluates the corrosion behavior of high-pressure die-casting AZXW alloys, focusing on the influence of Al content (6, 9, 11, and 13 wt.%). The Al effect on corrosion resistance is characterized by a dual effect. The corrosion rates initially increase as Al [...] Read more.
This study evaluates the corrosion behavior of high-pressure die-casting AZXW alloys, focusing on the influence of Al content (6, 9, 11, and 13 wt.%). The Al effect on corrosion resistance is characterized by a dual effect. The corrosion rates initially increase as Al content reaches 9 wt.%, which is attributed to a higher fraction of isolated β phases acting as micro-galvanic cathodes. Conversely, further increasing the Al content to 13 wt.% promotes the development of continuous network β phases, which serve as an efficient physical barrier that stops corrosion propagation. Furthermore, the Volta potential difference (VPD) between the α-Mg and β-phase decreases with rising Al concentrations, alleviating galvanic corrosion, further lowering the corrosion rate. Full article
(This article belongs to the Special Issue Corrosion and Corrosion Protection of Metals/Alloys)
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25 pages, 4335 KB  
Article
Synthesis, Characterization, and Corrosion Inhibition Properties of a Novel Quaternary Ammonium Salt Containing Dual-Imidazoline Rings for N80 Carbon Steel Under CO2 Corrosion Conditions
by Xiaoping Qin, Xi Chen, Peng Tang, Cuixia Li, Yangyang Yu, Wei Liu, Guanglin Zhou, Wenzhong Tian, Guangliang Lu, Song Qing and Haiyang Tian
Materials 2026, 19(10), 1934; https://doi.org/10.3390/ma19101934 - 8 May 2026
Viewed by 697
Abstract
A novel dual-imidazoline ring quaternary ammonium salt corrosion inhibitor (TN-IM) was rationally synthesized via a three-step sequential reaction, using hydroxyethyl ethylenediamine and tetradecanedioic acid as starting materials, with benzyl chloride as the quaternizing reagent. The synthetic process involved amidation at 160 °C for [...] Read more.
A novel dual-imidazoline ring quaternary ammonium salt corrosion inhibitor (TN-IM) was rationally synthesized via a three-step sequential reaction, using hydroxyethyl ethylenediamine and tetradecanedioic acid as starting materials, with benzyl chloride as the quaternizing reagent. The synthetic process involved amidation at 160 °C for 4 h, cyclization at 220 °C for 3 h, and quaternization at 70 °C for 3 h, respectively. Fourier transform infrared spectroscopy and proton nuclear magnetic resonance were employed to characterize the chemical structure of TN-IM, confirming its successful synthesis. The corrosion inhibition performance of TN-IM was evaluated by the static weight loss method and electrochemical measurements, while the corrosion products and surface morphology of N80 carbon steel were analyzed via energy-dispersive X-ray spectroscopy and scanning electron microscopy. Static weight loss tests conducted in 3.5 wt% of a NaCl solution saturated with 0.6 MPa CO2 at 60 °C for 24 h revealed that TN-IM at a concentration of 0.15 mmol/L exhibited a corrosion inhibition efficiency 1.86% higher than that of a single-imidazoline ring quaternary ammonium salt inhibitor. Potentiodynamic polarization measurements demonstrated that TN-IM functions as a mixed-type corrosion inhibitor, with a predominant inhibitory effect on the anodic reaction on N80 steel. Electrochemical impedance spectroscopy results indicated that TN-IM molecules can adsorb onto the active sites of the N80 surface, thereby retarding the corrosion process by suppressing the charge transfer step in the electrochemical corrosion reaction. This study establishes a new paradigm for the synthesis of high-efficiency imidazoline-based CO2 corrosion inhibitors with multiple adsorption sites, holding significant implications for corrosion control in harsh industrial environments. Full article
(This article belongs to the Special Issue Corrosion and Corrosion Protection of Metals/Alloys)
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29 pages, 2140 KB  
Article
Optimization of the Passivation Process for AM 350 and CUSTOM 450 Stainless Steels Using Taguchi Methodology and Gray Relational Analysis
by Facundo Almeraya-Calderon, Jose Cabral-Miramontes, Miguel Villegas-Tovar, Demetrio Nieves-Mendoza, Erick Maldonado-Bandala, María Lara-Banda, Brenda Paola Baltazar-Garcia, Oliver Samaniego-Gamez, Ce Tochtli Méndez-Ramírez, Javier Olguin-Coca and Citlalli Gaona-Tiburcio
Materials 2026, 19(9), 1846; https://doi.org/10.3390/ma19091846 - 30 Apr 2026
Viewed by 598
Abstract
This study presents research on optimizing the parameters of the passivation process for precipitation-hardening stainless steels (PHSS) to improve the corrosion resistance of AM350 and CUSTOM 450 alloys, which are extensively utilized in the aerospace and aviation sectors, since, as this is a [...] Read more.
This study presents research on optimizing the parameters of the passivation process for precipitation-hardening stainless steels (PHSS) to improve the corrosion resistance of AM350 and CUSTOM 450 alloys, which are extensively utilized in the aerospace and aviation sectors, since, as this is a complex process, it requires the implementation of a robust methodological approach that allows for multi-response optimization. Experiments were designed using the Taguchi method, which offered a strong framework for examining the impact of material, type of passivation solution, concentration, temperature, and passivation process time on the corrosion resistance of both PHSS alloys. To confirm the ideal PHSS passivation process parameters and measure the significance of each component, gray relational analysis (GRA) and analysis of variance (ANOVA) were also employed. The combined use of the Taguchi/GRA represents a robust and efficient methodological approach to the multi-response optimization of complex processes, overcoming the limitations inherent in the individual application of each technique. It was determined that the optimized parameters were a PHSS AM 350, a solution composed of a combination of citric acid and oxalic acid, acid concentration of 25% v/v, temperature of 50 °C, and time of 120 min. This combination of parameters resulted in significant improvements of up to 55% in corrosion resistance in the H2SO4 and NaCl evaluation solutions, demonstrating the effectiveness of the optimized conditions. This work emphasizes the efficacy of integrating Taguchi, GRA, and ANOVA techniques to significantly reduce the corrosion rate of PHSS undergoing the passivation process using alternatives to nitric acid. The integration of the Taguchi methodology with GRA enables the normalization and combination of responses with different scales and performance criteria into a single gray relational index, facilitating the overall evaluation of the system. Full article
(This article belongs to the Special Issue Corrosion and Corrosion Protection of Metals/Alloys)
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14 pages, 3313 KB  
Article
Computer Vision-Based Corrosion Detection and Feature Extraction for Rock Bolts
by Shucan Lu, Saisai Wu, Xinxin Ma, Shuisheng Yu, Zunyi Zhang and Xuewen Song
Materials 2026, 19(2), 392; https://doi.org/10.3390/ma19020392 - 19 Jan 2026
Cited by 2 | Viewed by 937
Abstract
To address the challenges posed by rock bolt corrosion to engineering safety and service life, this study focuses on corrosion detection through integrated image processing, deep learning, and feature extraction methods. An automatic corrosion identification model was constructed based on computer-vision object-detection algorithms. [...] Read more.
To address the challenges posed by rock bolt corrosion to engineering safety and service life, this study focuses on corrosion detection through integrated image processing, deep learning, and feature extraction methods. An automatic corrosion identification model was constructed based on computer-vision object-detection algorithms. By incorporating a Feature Pyramid Network, the model’s multi-scale object-detection capability was significantly enhanced. The corrosion features were extracted via image binarization and grayscale matrix analysis. The binary image method accurately quantified pitting density, revealing an initial increase followed by a decrease over time. The corrosion morphology was simulated using a Fractional Brownian Motion model, validating the accuracy of fractal feature calculations. The fractal dimension increased significantly with prolonged corrosion time, which not only characterize surface roughness evolution and corrosion rate, but also provide a reliable quantitative indicator for metal corrosion assessment. This research offers a technical framework integrating image processing, deep learning, and fractal theory for rock bolt corrosion monitoring and maintenance. Full article
(This article belongs to the Special Issue Corrosion and Corrosion Protection of Metals/Alloys)
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26 pages, 18739 KB  
Article
ZnO Thin Films as Promising Corrosion Protection on Mg-Based Alloys
by Aneta Kania, Magdalena M. Szindler, Marek Szindler, Zbigniew Brytan, Monika Kciuk, Wojciech Pakieła, Łukasz Reimann and Paweł M. Nuckowski
Materials 2025, 18(24), 5568; https://doi.org/10.3390/ma18245568 - 11 Dec 2025
Cited by 1 | Viewed by 759
Abstract
The present study examined the microstructure and corrosion characteristics of MgCa4Zn1Gd1 and MgCa2Zn1Gd3 alloys that were coated with ZnO thin films, which were deposited by atomic layer deposition (ALD). Coatings of different thicknesses (42.5, 95.4 and 133.7 nm for 500, 1000, and 1500 [...] Read more.
The present study examined the microstructure and corrosion characteristics of MgCa4Zn1Gd1 and MgCa2Zn1Gd3 alloys that were coated with ZnO thin films, which were deposited by atomic layer deposition (ALD). Coatings of different thicknesses (42.5, 95.4 and 133.7 nm for 500, 1000, and 1500 cycles, respectively) were characterized using X-ray diffraction (XRD), Raman spectroscopy, SEM/EDS, AFM (atomic force microscope), and FTIR (Fourier transform infrared spectroscopy). XRD and Raman analyses were conducted to verify the formation of crystalline zinc oxide (ZnO) with a homogeneous granular morphology. Surface roughness decreased with increasing coating thickness, reaching the lowest values for the 1500-cycle ZnO layer on MgCa2Zn1Gd3 (Ra = 7.65 nm, Rs = 9.8 nm). Potentiodynamic and immersion tests in Ringer solution at 37 °C revealed improved corrosion resistance for thicker coatings, with the lowest hydrogen evolution (20.89 mL·cm−2) observed for MgCa2Zn1Gd3 coated after 1500 cycles. Analysis of corrosion products by FTIR identified Mg(OH)2 and MgCO3 as dominant and then MgO and ZnO. Phase analysis also indicated the presence of ZnO coating after 100 h of immersion. The ZnO film deposited after 1500 ALD cycles on MgCa2Zn1Gd3 provides the most effective corrosion protection and is a promising solution for biodegradable magnesium implants. Full article
(This article belongs to the Special Issue Corrosion and Corrosion Protection of Metals/Alloys)
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