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Corrosion of Materials: Evaluation, Testing, Protection, and Failure Analysis (2nd Edition)

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

Deadline for manuscript submissions: 20 October 2024 | Viewed by 4809

Special Issue Editors

College of New Materials and Chemical Engineering, Beijing Institute of Petrochemical Technology, Beijing 102617, China
Interests: corrosion; smart coating; nanocontainer; surface treatment
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

The corrosion failure of materials has been a long-term, worldwide issue, causing huge economic losses and accidental disasters. Corrosion protection research comprises an important step towards sustainable actions to protect our environment and to conserve resources. With technical innovations, there have been new corrosion problems arising given the emergence and application of new materials. In this context, the present Special Issue aims to collect state-of-the-art research, providing a forum for discussion on recent advances in corrosion evaluation, testing, protection, and failure analysis.

We welcome high-quality original research and review articles on themes including, but not limited to, the following:

  • Corrosion behaviors and mechanisms;
  • Failure analysis;
  • Surface modification;
  • Advanced coatings;
  • Corrosion inhibitors and smart carriers;
  • Corrosion inhibition mechanism by DFT calculation and molecular dynamics simulation;
  • Electrochemical characterization;
  • New monitoring, evaluation, simulation, and prediction methods.

We look forward to receiving your contributions.

Dr. You Zhang
Dr. Yujie Qiang
Guest Editors

Manuscript Submission Information

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Keywords

  • corrosion
  • failure analysis
  • corrosion inhibitor
  • surface modification
  • advanced coating
  • self-assembled film
  • DFT calculation
  • molecular dynamics simulation
  • active protection
  • electrochemical characterization

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Related Special Issue

Published Papers (6 papers)

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Research

15 pages, 9263 KiB  
Article
Corrosion Behavior of 700L Automotive Beam Steel in Marine Atmospheric Environment
by Younian He, Yuwei Liu, Chuan Wang, Gongwang Cao, Chunlin He and Zhenyao Wang
Materials 2024, 17(20), 4964; https://doi.org/10.3390/ma17204964 - 11 Oct 2024
Abstract
The marine atmospheric corrosion behavior of 700L high-strength automotive beam steel exposed for 36 months was investigated by scanning electron microscopy, energy dispersive spectroscopy, X-ray diffraction, and electrochemical technology. The corrosion kinetics of 700L steel followed the exponential function: D = 4.85t [...] Read more.
The marine atmospheric corrosion behavior of 700L high-strength automotive beam steel exposed for 36 months was investigated by scanning electron microscopy, energy dispersive spectroscopy, X-ray diffraction, and electrochemical technology. The corrosion kinetics of 700L steel followed the exponential function: D = 4.85t1.23. The rust layers were mainly composited of γ-FeOOH, α-FeOOH, γ-Fe2O3, and Fe3O4, regardless of the exposure duration. With an extended exposure time, the porosity, cracking, and spalling of the rust layers increased, and the densification and thickness uniformity decreased. Electrochemical measurements displayed that the corrosion resistance of the rusted 700L steel gradually decreased with increasing exposure time. A good correlation was found between rust layer composition, microstructure, and corrosion resistance. Full article
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0 pages, 8964 KiB  
Article
Long-Term Evaluation of a Ternary Mixture of Molten Salts in Solar Thermal Storage Systems: Impact on Thermophysical Properties and Corrosion
by Mauro Henríquez, Juan Carlos Reinoso-Burrows, Raúl Pastén, Carlos Soto, Carlos Duran, Douglas Olivares, Luis Guerreiro, José Miguel Cardemil, Felipe M. Galleguillos Madrid and Edward Fuentealba
Materials 2024, 17(16), 4053; https://doi.org/10.3390/ma17164053 - 15 Aug 2024
Viewed by 423
Abstract
Solar thermal plants typically undergo trough operational cycles spanning between 20 and 25 years, highlighting the critical need for accurate assessments of long-term component evolution. Among these components, the heat storage media (molten salt) is crucial in plant design, as it significantly influences [...] Read more.
Solar thermal plants typically undergo trough operational cycles spanning between 20 and 25 years, highlighting the critical need for accurate assessments of long-term component evolution. Among these components, the heat storage media (molten salt) is crucial in plant design, as it significantly influences both the thermophysical properties of the working fluid and the corrosion of the steel components in thermal storage systems. Our research focused on evaluating the long-term effects of operating a low-melting-point ternary mixture consisting of 30 wt% LiNO3, 57 wt% KNO3, and 13 wt% NaNO3. The ternary mixture exhibited a melting point of 129 °C and thermal stability above 550 °C. Over 15,000 h, the heat capacity decreased from 1.794 to 1.409 J/g °C. Additionally, saline components such as CaCO3 and MgCO3, as well as lithium oxides (LiO and LiO2), were detected due to the separation of the ternary mixture. A 30,000 h exposure resulted in the formation of Fe2O3 and the presence of Cl, indicating prolonged interaction with the marine environment. This investigation highlights the necessity of analyzing properties under actual operating conditions to accurately predict the lifespan and select the appropriate materials for molten salt-based thermal storage systems. Full article
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18 pages, 6132 KiB  
Article
Turning Waste into Treasure: Invasive Plant Ambrosia trifida L Leaves as a High-Efficiency Inhibitor for Steel in Simulated Pickling Solutions
by Xin Sun, Huiwen Tian, Fangxin Zou, Weihua Li, Yujie Qiang and Baorong Hou
Materials 2024, 17(15), 3758; https://doi.org/10.3390/ma17153758 - 30 Jul 2024
Viewed by 401
Abstract
High toxicity is the main reason for the limited application of traditional corrosion inhibitors. Herein, it is critical to find a green, efficient, and long-term stable alternative substitute for the hazardous and conventional corrosion inhibitor. Ambrosia trifida L is widely distributed in fields [...] Read more.
High toxicity is the main reason for the limited application of traditional corrosion inhibitors. Herein, it is critical to find a green, efficient, and long-term stable alternative substitute for the hazardous and conventional corrosion inhibitor. Ambrosia trifida L is widely distributed in fields and riverside wetlands as an invasive plant in China. According to the concept of turning waste into treasure, the extract of Ambrosia trifida L leaves (ATL) has the potential to address this issue due to its natural origin and abundant presence of heterocyclic organics. Therefore, ATL, as a green corrosion inhibitor, is prepared for the first time via a simple water-based extraction method. FT-IR (Fourier transform infrared spectroscopy) and UV-Vis (UV-visible) indicate that ATL extract contains abundant heterocyclic organics with conjugated structures, which exhibit the potential to become a high-efficiency inhibitor. Notably, the active sites of ATL molecules and their interaction with Q235 steel at the molecular/atomic level are revealed via theoretical calculations. The highest Ebinding value observed for the major components in the ATL extract is 259.66 kcal/mol, implying a significant adsorption capacity. The electrochemical results verify that microdose ATL extract can prominently inhibit steel corrosion, and the highest inhibition efficiency (η) is 97.5% (1000 mg/L). Following immersion for 24 h, the η value is enhanced to 99.0%, indicating a reliable and long-term ATL extract protection film is formed on the steel surface in harsh acidic solutions. The results of the weight loss, SEM (scanning electron microscope), and LSCM (laser scanning confocal microscopy) are consistent with the above conclusions. Finally, this study anticipates providing theoretical support for developing novel green plant extract inhibitors and aiding in their application in industrial pickling environments. Full article
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22 pages, 32195 KiB  
Article
Hydrothermal Corrosion of Latest Generation of FeCrAl Alloys for Nuclear Fuel Cladding
by Bhavani Sasank Nagothi, Haozheng Qu, Wanming Zhang, Rajnikant V. Umretiya, Evan Dolley and Raul B. Rebak
Materials 2024, 17(7), 1633; https://doi.org/10.3390/ma17071633 - 3 Apr 2024
Cited by 3 | Viewed by 917
Abstract
After the Fukushima nuclear disaster, the nuclear materials community has been vastly investing in accident tolerant fuel (ATF) concepts to modify/replace Zircaloy cladding material. Iron–chromium–aluminum (FeCrAl) alloys are one of the leading contenders in this race. In this study, we investigated FA-SMT (or [...] Read more.
After the Fukushima nuclear disaster, the nuclear materials community has been vastly investing in accident tolerant fuel (ATF) concepts to modify/replace Zircaloy cladding material. Iron–chromium–aluminum (FeCrAl) alloys are one of the leading contenders in this race. In this study, we investigated FA-SMT (or APMT-2), PM-C26M, and Fe17Cr5.5Al over a time period of 6 months in simulated BWR environments and compared their performance with standard Zirc-2 and SS316 materials. Our results implied that water chemistry along with alloy chemistry has a profound effect on the corrosion rate of FeCrAl alloys. Apart from SS316 and Zirc-2 tube specimens, all FeCrAl alloys showed a mass loss in hydrogen water chemistry (HWC). FA-SMT displayed minimal mass loss compared to PM-C26M and Fe17Cr5.5Al because of its higher Cr content. The mass gain of FeCrAl alloys in normal water chemistry (NWC) is significantly less when compared to Zirc-2. Full article
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18 pages, 6410 KiB  
Article
Failure Analyses on a Flexible Anode Cathodic Protection System in a Station
by Wenhui Liu, Runyao Chang, Xian Li, Yanxia Du and Jianhua Liu
Materials 2024, 17(2), 291; https://doi.org/10.3390/ma17020291 - 6 Jan 2024
Viewed by 1038
Abstract
Flexible anodes are a common form of anode ground bed for the cathodic protection of buried pipes in station areas, especially in new stations. In most cases, flexible anode ground beds could obtain uniform potential distribution and good protection. However, in the process [...] Read more.
Flexible anodes are a common form of anode ground bed for the cathodic protection of buried pipes in station areas, especially in new stations. In most cases, flexible anode ground beds could obtain uniform potential distribution and good protection. However, in the process of operation, there are also failure conditions such as anode body or cable breakage, electronic shorting between anode and pipes and other situations, resulting in poor protection. How to troubleshoot failures has become a difficult problem restricting the application of flexible anodes in actual production. In this paper, the failures of a flexible anode cathodic protection system in a station were assessed and analyzed in detail. The main reasons for the failures were the electronic shorting between the flexible anode and buried pipe in local area and the breaking of a partial flexible anode. The troubleshooting methods for two kinds of failures were explored. By measuring the potentials of both the flexible anode and pipes in different areas and the excavation test, the location of electronic shoring was determined. And through measuring the grounding resistance of the flexible anode and excavation test, the breaking location of the flexible anode was found. By repairing the failure sites, the failed system was restored to normal, which could provide guidance for the failure analyses of the flexible anode cathodic protection system. Full article
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15 pages, 8033 KiB  
Article
Effect of Frequency and Ratio of Wet/Dry Stages in Cyclic Corrosion Tests on Localized Corrosion of Complex-Phase High-Strength Steel
by Jin-Seok Yoo, Geon-Il Kim and Jung-Gu Kim
Materials 2023, 16(23), 7329; https://doi.org/10.3390/ma16237329 - 24 Nov 2023
Viewed by 834
Abstract
This study delves into the atmospheric corrosion behavior of chromium-free complex-phase (CP) steel, specifically investigating the influence of wet/dry frequency and ratio in cyclic corrosion tests (CCT). The study employs a modified ISO 14993 standard CCT method, which involves salt spray, dry, and [...] Read more.
This study delves into the atmospheric corrosion behavior of chromium-free complex-phase (CP) steel, specifically investigating the influence of wet/dry frequency and ratio in cyclic corrosion tests (CCT). The study employs a modified ISO 14993 standard CCT method, which involves salt spray, dry, and wet stages. After 15 and 30 CCT cycles, mass loss, maximum corrosion depth, and corrosion products were analyzed to gain insights into corrosion mechanisms. In general, increasing the frequency and wet/dry stage ratio in CCT extends the time for autocatalytic reactions to occur, leading to accelerated localized CP steel corrosion and increased pitting factors. However, as the rust layer thickens, uniform corrosion may also intensify, so careful considerations are necessary. This study underscores the importance of controlling the frequency and ratio of wet/dry stages in CCT for effectively analyzing localized corrosion behavior in specimens. Full article
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