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Corrosion and Formation of Surface Films on Metals and Alloys

A special issue of Materials (ISSN 1996-1944). This special issue belongs to the section "Corrosion".

Deadline for manuscript submissions: closed (20 May 2025) | Viewed by 6846

Special Issue Editors


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Guest Editor
School of Chemical and Metallurgical Engineering, University of the Witwatersrand, Johannesburg ZA-2050, South Africa
Interests: corrosion; electrochemistry; electrowinning; water treatment
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Guest Editor
School of Chemical and Metallurgical Engineering, University of the Witwatersrand, Johannesburg 2000, South Africa
Interests: titanium alloys; dental alloys; welding
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Guest Editor Assistant
School of Chemical and Metallurgical Engineering, Unversity of the Witwatersrand, Johannesburg 2050, South Africa
Interests: corrosion; additive manufacturing; WC hard metals

Special Issue Information

Dear Colleagues,

Corrosion is a multifaceted degradation phenomenon with wide-ranging consequences in many industries and environments. The corrosion behavior of materials in corrosive media depends critically on the nature of the passive film and corrosion products formed during the corrosion process. This Special Edition will emphasize these passive films and corrosion products that form during the aqueous media's corrosion process. Mild and stainless steel are popular materials in several industries and applications, and their corrosion behavior is often reported. However, a wide variety of other non-ferrous metals and alloys find application in numerous products and processes. The focus in this Special Edition will be on these different alloys and metals, e.g., titanium, magnesium, and aluminum alloys, copper, brass, and bronze alloys, cermet and metal matrix composites, high-entropy alloys, and any materials and the nature and composition of passive film and corrosion products formed on them during any aqueous corrosion process. Information obtained by any surface analysis technique, or combination thereof, which can provide such information and is utilized as part of the study, can be described.

Prof. Dr. Herman Potgieter
Dr. Michael Oluwatosin Bodunrin
Guest Editors

Dr. David Whitefield
Guest Editor Assistant

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Keywords

  • passive layer
  • corrosion layer composition
  • SEM-EDS
  • XRD
  • XPS
  • Raman spectroscopy
  • corrosion surface
  • corrosion products

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Published Papers (5 papers)

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Research

18 pages, 19325 KiB  
Article
Corrosion Behaviour of S32101 (1.4162—X2CrMnNiN21-5-1) Stainless Steel in Pulping Liquors
by Banele Siyabonga Kheswa, David Whitefield, Herman Potgieter and Michael Bodunrin
Materials 2025, 18(9), 1921; https://doi.org/10.3390/ma18091921 - 24 Apr 2025
Viewed by 220
Abstract
The corrosion behaviour of lean duplex S32101 (1.4162—X2CrMnNiN21-5-1) stainless steel was assessed in various corrosive environments relevant to the pulp and paper industry. Electrochemical techniques, including open-circuit potential measurements and cyclic polarisation, were used to evaluate the corrosion resistance of S32101 stainless steel [...] Read more.
The corrosion behaviour of lean duplex S32101 (1.4162—X2CrMnNiN21-5-1) stainless steel was assessed in various corrosive environments relevant to the pulp and paper industry. Electrochemical techniques, including open-circuit potential measurements and cyclic polarisation, were used to evaluate the corrosion resistance of S32101 stainless steel in various acidic, saline, and industrial liquors such as black, green, and white liquors, as well as dissolved chlorine dioxide bleaching solutions. To evaluate the extent of damage and corrosion mechanisms, post-exposure surface analysis was conducted using scanning electron microscopy (SEM). The results showed that S32101 experienced pitting corrosion in chloride-containing solutions, particularly in salt and acidified-salt environments. Corrosion rates increased with rising temperatures across all solutions. The highest corrosion rate of 3.17 mm/yr was observed in the highly alkaline white liquor at 50 °C, whilst chlorine dioxide induced the least aggressive effects at all temperatures. The suitability of S32101 stainless steel in handling pulp and paper liquors is shown in its corrosion resistance against the bleaching medium and low-temperature saline solutions, but it is not recommended for prolonged exposure to high alkaline liquors or chloride-rich solutions. Full article
(This article belongs to the Special Issue Corrosion and Formation of Surface Films on Metals and Alloys)
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14 pages, 9070 KiB  
Article
Behavior of YSZ (High Y2O3 Content) Layer on Inconel to Electro-Chemical Corrosion
by Ionut Adomniței, Ramona Cimpoeșu, Daniela Lucia Chicet, Margareta Coteață, Fabian Cezar Lupu, Costică Bejinariu, Liviu Andrușcă, Petronela Paraschiv, Mihai Axinte, Gheorghe Bădărău and Nicanor Cimpoeșu
Materials 2025, 18(2), 400; https://doi.org/10.3390/ma18020400 - 16 Jan 2025
Cited by 1 | Viewed by 716
Abstract
The high yttria content of a stabilized zirconia (YSZ) (38 wt% Y2O3) coating was deposited by atmospheric plasma spraying (APS) from Metco 207 powders on an Inconel 718 (Ni-based superalloy) substrate. As a metal coating connection, a layer of [...] Read more.
The high yttria content of a stabilized zirconia (YSZ) (38 wt% Y2O3) coating was deposited by atmospheric plasma spraying (APS) from Metco 207 powders on an Inconel 718 (Ni-based superalloy) substrate. As a metal coating connection, a layer of cermet powder (Ni-20% Al—410NS) was used before the ceramic layer deposition. The electro-chemical corrosion resistance of these materials was tested using Inconel cylinders with a diameter of 10 mm and a thickness of 1 mm, with and without the ceramic layer. Linear and cyclic measurements were obtained in H2SO4 electrolyte media at pH = 2. Electro-impedance spectroscopy (EIS) experiments were performed on the sample covered with the ceramic layer to evaluate the interface behavior. Scanning electron microscopy (SEM), along with equipment to determine chemical composition, and an energy dispersive spectrometry (EDS) detector were used to characterize the material surface before and after corrosion tests. It was observed that the corrosion resistance of Inconel was influenced by the bonding layer and the ceramic coating. Full article
(This article belongs to the Special Issue Corrosion and Formation of Surface Films on Metals and Alloys)
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17 pages, 15401 KiB  
Article
Investigation of Oxide Layer Development of X6CrNiNb18-10 Stainless Steel Exposed to High-Temperature Water
by Georg Veile, Radhika Hirpara, Simon Lackmann and Stefan Weihe
Materials 2024, 17(18), 4500; https://doi.org/10.3390/ma17184500 - 13 Sep 2024
Cited by 1 | Viewed by 1135
Abstract
The oxide layer development of X6CrNiNb18-10 (AISI 347) during exposure to high-temperature water has been investigated. Stainless steels are known to form a dual oxide layer in corrosive environments. The secondary Fe-rich oxide layer has no significant protective effect. In contrast, the primary [...] Read more.
The oxide layer development of X6CrNiNb18-10 (AISI 347) during exposure to high-temperature water has been investigated. Stainless steels are known to form a dual oxide layer in corrosive environments. The secondary Fe-rich oxide layer has no significant protective effect. In contrast, the primary Cr-rich oxide layer is known to reach a stabilized state, protecting the base metal from further oxidation. This study’s purpose was to determine the development of oxide layer dimensions over exposure time using SEM, TEM and EDX line scans. While a parabolic development of Cr in the protective primary layer and Fe in the secondary layer was observed, the dimensions of the Ni layer remained constant. Ni required the presence of a pronounced Fe-rich secondary layer before being able to reside on the outer secondary layer. With increasing immersion time, the Ni element fraction surpassed the Cr element fraction in the secondary layer. Oxide growth on the secondary layer could be observed. After 480 h, nearly the entire surface was covered by the outer oxide layer. In the metal matrix, no depletion of Cr or Ni could be observed over time; however, an increased presence of Cr and Ni in the primary layer was found at the expense of Fe content. The Nb-stabilized stainless steel was subject to the formation of Niobium pentoxide (Nb2O5), with the quantity and magnitude of element fraction increasing over exposure time. Full article
(This article belongs to the Special Issue Corrosion and Formation of Surface Films on Metals and Alloys)
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18 pages, 9312 KiB  
Article
Corrosion of an Additively Manufactured Ti6Al4V Alloy in Saline and Acidic Media
by Hugo Mora-Sanchez, Miguel Collado-Vian, Marta Mohedano, Raúl Arrabal and Endzhe Matykina
Materials 2024, 17(3), 712; https://doi.org/10.3390/ma17030712 - 2 Feb 2024
Cited by 3 | Viewed by 1414
Abstract
The present work aims to provide corrosion performance data for an additively manufactured Ti6Al4V alloy in saline and polluted environments. The as-received additively manufactured material underwent heat treatment at 850 °C for 3 h to transform the acicular α’ microstructure into a lamellar [...] Read more.
The present work aims to provide corrosion performance data for an additively manufactured Ti6Al4V alloy in saline and polluted environments. The as-received additively manufactured material underwent heat treatment at 850 °C for 3 h to transform the acicular α’ microstructure into a lamellar α microstructure. Comparative corrosion assessments were conducted between the heat-treated substrates, the as-received condition, and a conventionally mill-annealed alloy. Potentiodynamic polarization experiments were carried out in saline (3.5 wt.% NaCl) and acid aqueous media ((NH4)2SO4 containing Harrison’s solution). The corrosion performance of additively manufactured substrates matched or surpassed that of the conventional alloy in Harrison’s solutions while remaining inferior in saline medium, despite forming a thicker passive film. Overall, the XY plane showed better corrosion performance, particularly after the elimination of the acicular α’ martensite by the applied heat treatment. The results also suggested that the presence of the coarse β phase was beneficial in 3.5 wt.% NaCl solution and detrimental in Harrison’s solutions, more so in acidified and fluorinated conditions. Full article
(This article belongs to the Special Issue Corrosion and Formation of Surface Films on Metals and Alloys)
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15 pages, 3370 KiB  
Article
Effect of Sulfide and Chloride Ions on Pitting Corrosion of Type 316 Austenitic Stainless Steel in Groundwater Conditions Using Response Surface Methodology
by Jin-Seok Yoo, Nguyen Thuy Chung, Yun-Ho Lee, Yong-Won Kim and Jung-Gu Kim
Materials 2024, 17(1), 178; https://doi.org/10.3390/ma17010178 - 28 Dec 2023
Cited by 5 | Viewed by 1813
Abstract
This study investigates the corrosion resistance of Type 316 stainless steel as a candidate material for radioactive waste disposal canisters. The viability of stainless steel is examined under groundwater conditions with variations in pH, bisulfide ions (HS), and chloride ions (Cl [...] Read more.
This study investigates the corrosion resistance of Type 316 stainless steel as a candidate material for radioactive waste disposal canisters. The viability of stainless steel is examined under groundwater conditions with variations in pH, bisulfide ions (HS), and chloride ions (Cl) concentrations. Utilizing response surface methodology, correlations between corrosion factors and two crucial response variables, passive film breakdown potential and protection potential, are established. Cyclic potentiodynamic polarization tests and advanced analytical techniques provide detailed insights into the material’s behavior. This research goes beyond, deriving an equation through response surface methodology that elucidates the relationship between the factors and breakdown potential. HS weakens the passive film and reduces the pitting corrosion resistance of the stainless steel. However, this study highlights the inhibitory effect of HS on pitting corrosion when Cl concentrations are below 0.001 M and at equivalent concentrations of HS. Under these conditions, immediate re-passivation occurs from the destroyed passive film to metal sulfides such as FeS2, MoS2, and MoS3. As a result, no hysteresis loop occurs in the cyclic polarization curve in these conditions. This research contributes to the understanding of Type 316 stainless-steel corrosion behavior, offering implications for the disposal of radioactive waste in geological repositories. Full article
(This article belongs to the Special Issue Corrosion and Formation of Surface Films on Metals and Alloys)
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