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Advances in Corrosion and Protection of Metallic Materials

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

Deadline for manuscript submissions: 20 September 2026 | Viewed by 16112

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Special Issue Editors

Dr. Xiaowei Lei

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Guest Editor

School of Physical Science and Technology, Northwestern Polytechnical University, Xi’an 710072, China
Interests: corrosion; passivity and passivity breakdown; laser welding/surface treatment
Special Issues, Collections and Topics in MDPI journals

Dr. Peng Han

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Guest Editor

School of Chemical and Environmental Engineering, China University of Mining and Technology (Beijing), Beijing 100083, China
Interests: corrosion inhibition; theoretical calculation; inhibitor-coating system
Special Issues, Collections and Topics in MDPI journals

Dr. Wenlan Wei

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Guest Editor Assistant

School of Mechanical Engineering, Xi’an Shiyou University, Xi’an 710065, China
Interests: corrosion; cracking and fracture mechanism; ultrafine grain strengthening

Special Issue Information

Dear Colleagues,

The corrosion of metallic materials refers to the gradual destruction of metals and alloys due to their chemical or electrochemical reactions with the corrosive environment. These processes can lead to significant losses in structural integrity, performance degradation, and, ultimately, material failure.

To combat corrosion, it is key to understand the corrosion mechanism through experimental analyses and simulations. Meanwhile, various protective measures can be employed. For instance, coatings such as paints, galvanized zinc, or polymeric materials can act as barriers between the metal and corrosive agents. Alloys with corrosion-resistant elements such as chromium or nickel also have enhanced durability. Additionally, devising high-efficiency corrosion inhibitors is also a practical method especially in engineering application scenarios. By implementing these protective strategies, we can mitigate the adverse effects of corrosion and ensure the reliability and safety of metallic components in engineering applications.

In summary, this Special Issue will present studies on the corrosion mechanisms of metallic materials and advanced anti-corrosion methodologies for corrosion protection. Original research articles, reviews, and communications are welcome. We invite you to submit manuscripts to this Special Issue, the scope of which includes, but is not limited to, the following aspects:

(1) Uniform corrosion and localized corrosion including pitting corrosion, intergranular corrosion, stress corrosion cracking, crevice corrosion, galvanic corrosion, erosion corrosion, wear corrosion, etc.;

(2) Corrosion studies using electrochemical measurements such as polarization, EIS, Mott–Schottky measurements, etc., to unravel the thermodynamics and kinetics behaviors;

(3) Surface characterizations, including SEM, EDS, TEM, XPS, AFM, etc., and surface modification through physical and chemical approaches;

(4) Organic/inorganic coatings and inhibitors designed for surface corrosion protections;

(5) Multi-scale modeling to simulate corrosion processes and corrosion protection mechanisms.

Dr. Xiaowei Lei
Dr. Peng Han
Guest Editors

Dr. Wenlan Wei
Guest Editor Assistant

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 250 words) can be sent to the Editorial Office for assessment.

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. Materials is an international peer-reviewed open access semimonthly 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 2600 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

uniform and localized corrosion
electrochemical corrosion
surface analysis and modification
coatings
inhibitors
modeling and simulation

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Published Papers (12 papers)

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Research

20 pages, 22823 KB

Open AccessArticle

Corrosion Behavior of Typical Engineering Structural Steels in a Plateau Valley Atmospheric Environment

by Xiayan Wang, Xuexu Xu, Lili Zhang, Junjie Cai, Bingkun Yang, Hongchi Ma, Cuiwei Du, Zhiyong Liu and Xiaogang Li

Materials 2026, 19(6), 1142; https://doi.org/10.3390/ma19061142 - 15 Mar 2026

Viewed by 538

Abstract

This study systematically investigated the corrosion behavior of three typical engineering structural steels (Q235, Q420, and Q420qENH) in the plateau valley atmospheric environment of the Sichuan–Tibet region using field exposure tests (including uniform corrosion and stress corrosion coupon tests), electrochemical measurements, and microscopic characterization. The results reveal that the three steels underwent predominantly uniform corrosion, accompanied by pitting corrosion, regardless of the presence of stress. Compared with Q235 and Q420 steels, Q420qENH exhibits superior corrosion resistance, which is ascribed to the denser rust layer formed as a result of its corrosion-resistant composition. Under tensile stress, both the uniform corrosion rate and pit dimensions increased significantly relative to stress-free conditions, demonstrating a pronounced accelerating effect of stress on uniform and localized corrosion. Furthermore, the enrichment of sulfur within the rust layer at the pit bottoms suggests the involvement of atmospheric SO₂ in the localized corrosion process, which aggravates the breakdown of the rust layer and the acidification of the local environment at the pit bottom, thereby promoting pit growth. Full article

(This article belongs to the Special Issue Advances in Corrosion and Protection of Metallic Materials)

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17 pages, 3630 KB

Open AccessArticle

Chloride Ion-Induced Modification of Passive Film on the Surface of 18%Ni High-Strength Steel

by Shule Yu, Boheng Yan, Botao Jiang, Hao Guo, Eshov Bakhtiyor and Liang Wang

Materials 2026, 19(2), 444; https://doi.org/10.3390/ma19020444 - 22 Jan 2026

Viewed by 513

Abstract

This work investigates the corrosion behavior of 18%Ni high-strength steel (00Ni18Co-8Mo5TiAl, solution-treated at 820 °C for 3 h and aged at 480 °C for 3 h) in NaCl solutions with 1%, 3.5%, and 6% chloride ions, as well as chloride ions’ effect on passive film properties. The corrosion process was systematically studied via chemical immersion tests (GB/T 17897-1999, 144 h, solution-to-sample contact area ratio 20:1) and electrochemical methods, including EIS (frequency range: 100 kHz–0.01 Hz) and Tafel polarization curves (scan rate: 10 mV/min). Passive film evolution was analyzed via Mott–Schottky curves (fixed frequency: 1000 Hz, scanning potential: −1 V to 1 V vs. SCE). Microstructural observations show the steel exhibits pitting corrosion in chloride environments, with corrosion products transforming from loose outer α-FeOOH/γ-FeOOH to dense inner Fe₃O₄/β-FeOOH. These dense products inhibit anodic reactions. Electrochemical results reveal polarization resistance decreases and corrosion current density rises with increasing chloride concentration. Mott–Schottky curves indicate that flat band potential increases from −0.2177 V to −0.1258 V with rising chloride concentration, increasing point defects in the passive film and weakening its self-healing ability. Full article

(This article belongs to the Special Issue Advances in Corrosion and Protection of Metallic Materials)

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16 pages, 4917 KB

Open AccessArticle

Study on the Corrosion Resistance of Copper Slag/Cr₃C₂-NiCr Composite Coating

by Jiaran Du, Dongliang Jin, Nan Guo, Zhengxian Di and Xiqiang Ma

Materials 2026, 19(2), 395; https://doi.org/10.3390/ma19020395 - 19 Jan 2026

Viewed by 444

Abstract

Copper slag was introduced as a second phase into Cr₃C₂–NiCr coating to improve corrosion resistance and reduce material cost. Composite coatings with different copper slag/Cr₃C₂–NiCr ratios were prepared by high-velocity oxygen fuel (HVOF) spraying. The corrosion behavior was evaluated through electrochemical tests and immersion experiments, and the effect of coating composition on corrosion resistance was elucidated by microstructural and compositional analysis. To increase the addition of copper slag, the open-circuit potential of the coatings shifted positively, the corrosion current density decreased significantly, and both the polarization resistance and charge-transfer resistance increased markedly, leading to a notable reduction in corrosion rate. The coating with a copper slag-to-Cr₃C₂–NiCr mass ratio of 3:7 exhibited the best corrosion resistance. The improvement can be attributed to the reduced porosity and more compact structure resulting from the copper slag addition, as well as the homogeneous distribution of copper slag, which enhances the stability of the surface passivation layer. Full article

(This article belongs to the Special Issue Advances in Corrosion and Protection of Metallic Materials)

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26 pages, 4979 KB

Open AccessArticle

Chloride-Induced Corrosion Performance of ASR-Contaminated Concrete: Coupled Analysis Using Resistance Variation and NT Build 492 Method

by Tianxing Shi, Shami Nejadi and Harry Far

Materials 2026, 19(2), 247; https://doi.org/10.3390/ma19020247 - 8 Jan 2026

Cited by 1 | Viewed by 638

Abstract

This study examines how the Alkali–Silica Reaction (ASR) modifies chloride transport and chloride-induced corrosion (CIC) in reinforced concrete beams. Non-reactive and reactive concrete beams were cast with blue metal and dacite aggregates and subjected to a two-stage exposure: (i) alkali-rich immersion at 38 °C to induce ASR, and (ii) impressed-current CIC and NT BUILD 492 chloride migration testing. Microstructural changes were characterized using SEM–EDS and TGA. The reactive specimens developed extensive surface cracking, but after one year of ASR exposure, exhibited 47–53% lower non-steady-state migration coefficients (Dnssm: 7.03–8.02 × 10⁻¹² m²/s) than the non-reactive beam (15.09 × 10⁻¹² m²/s). After two years, Dnssm was reduced by approximately 37–56% (4.78–6.93 vs. 10.92 × 10⁻¹² m²/s). Crack mapping confirmed higher crack density and width in reactive beams, while SEM–EDS and TGA evidenced Ca depletion and the formation of C–(N,K)–S–H gels, which fill cracks and refine the pore structure. Electrical resistance monitoring showed earlier corrosion initiation in ASR-damaged beams but less pronounced resistance loss during the propagation phase. Overall, the results indicate that ASR can initially accelerate corrosion initiation through microcracking and reduced resistivity, but long-term gel deposition can partially seal transport paths and lower chloride migration under the specific conditions of this study. Full article

(This article belongs to the Special Issue Advances in Corrosion and Protection of Metallic Materials)

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20 pages, 6202 KB

Open AccessArticle

Highly Efficient Corrosion Inhibitor for Pure Iron and Aluminum Metals in Aggressive Acidic Medium: Experimental and Computational Study

by Aeshah H. Alamri

Materials 2026, 19(1), 114; https://doi.org/10.3390/ma19010114 - 29 Dec 2025

Viewed by 989

Abstract

The influence of 5-Methyl-1H-benzotriazole (MHBTZ) on the corrosion of pure iron (Fe) and aluminum (Al) in 1 M HCl was investigated in this study. The experimental and theoretical aspects of MHBTZ adsorption onto pure iron (Fe) and aluminum metal (Al) surfaces, as well as the stability of adsorbed layers based on the metal type, were also studied. Different electrochemical measurements were performed to explore the corrosion rates and inhibition efficiencies on the Fe and Al surfaces at 298 K. Optical profilometry was used to obtain the 3D surface topography of Fe and Al metals after immersion with and without the MHBTZ molecule. The results showed that MHBTZ exhibited excellent inhibition properties for both metals. Electrochemical impedance spectroscopy (EIS) achieved inhibition efficiencies of 98.1% and 98.5% for Fe and Al, respectively, at a concentration of 2500 ppm. Potentiodynamic polarization (PDP) indicated that MHBTZ acted as a mixed-type inhibitor. Density functional theory (DFT) analysis and molecular dynamics (MD) simulations were used to explore the relationship between the molecular structure of MHBTZ and its inhibition efficiency at the atomic level. Full article

(This article belongs to the Special Issue Advances in Corrosion and Protection of Metallic Materials)

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18 pages, 4007 KB

Open AccessArticle

Synergistic Corrosion Inhibition of Mild Steel in Acidic Media by a Benzimidazole–Thiophene Ligand and Its Metal Complexes: A Multi-Technique Electrochemical Approach

by Mariya Kadiri, Majid Driouch, Ibissam Elaaraj, Ayoub Tanji, Afafe Elabbadi, Mohammed Fahim, Mouhcine Sfaira and Hendra Hermawan

Materials 2025, 18(19), 4545; https://doi.org/10.3390/ma18194545 - 30 Sep 2025

Cited by 2 | Viewed by 1280

Abstract

This study investigates the corrosion inhibition efficiency of [2-(thiophen-2-yl)-1-(thiophen-2-ylmethyl)-1H-benzo[d]imidazole] and its Zn and Cu complexes for mild steel in 1.0 M HCl. The ligand was selected for its non-toxic profile and high electron density, favoring strong adsorption onto the metal surface. Electrochemical methods, including EIS, PDP, LPR, and CASP, were employed to evaluate the inhibitors’ performance. The results showed a significant decrease in corrosion current density and increased polarization resistance, with the Zn complex achieving the highest inhibition efficiency (93.8%). EIS fitting confirmed the formation of a protective film with high charge transfer and film resistance. Surface analyses by SEM and EDS revealed smoother steel morphology and inhibitor adsorption. XPS confirmed the presence of Fe³⁺, Zn²⁺and Cu²⁺ oxides, as well as all active inhibitor elements on the surface, supporting a mixed inhibition mechanism. The enhanced performance of the metal complexes is attributed to synergistic effects between the metal ions and the heterocyclic ligand, offering a promising strategy for the design of effective and environmentally friendly corrosion inhibitors. Full article

(This article belongs to the Special Issue Advances in Corrosion and Protection of Metallic Materials)

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20 pages, 7113 KB

Open AccessArticle

Effect of Cu Content on Corrosion Resistance of 3.5%Ni Weathering Steel in Marine Atmosphere of South China Sea

by Yuanzheng Li, Ziyu Guo, Tianle Fu, Sha Sha, Bing Wang, Xiaoping Chen, Shujun Jia and Qingyou Liu

Materials 2025, 18(15), 3496; https://doi.org/10.3390/ma18153496 - 25 Jul 2025

Cited by 2 | Viewed by 1329

Abstract

The influence of the copper (Cu) content on the corrosion resistance of 3.5%Ni low-carbon weathering steel was investigated using periodic dry–wet cycle accelerated corrosion tests. The mechanical properties of the steels were assessed via tensile and low-temperature impact tests, while corrosion resistance was evaluated based on weight loss measurements. Surface oxide layers were characterized using three-dimensional laser confocal microscopy, X-ray diffraction (XRD), X-ray photoelectron spectroscopy (XPS), and electrochemical methods. Electron probe microanalysis (EPMA) was employed to examine the cross-sectional morphology of the oxide layer after 72 h of accelerated corrosion tests. The results indicate that the solution state of Cu increased the strength of 3.5%Ni steels but significantly damaged the low-temperature toughness. As the Cu content increased from 0.75% to 1.25%, the corrosion rate decreased from 4.65 to 3.74 g/m² h. However, when there was a further increase in the Cu content to 2.15%, there was little decrease in the corrosion rate. With the increase in the Cu content from 0.75% to 2.15%, the surface roughness of 3.5%Ni weathering steel after corrosion decreased from 5.543 to 5.019 μm, and the corrosion behavior was more uniform. Additionally, the α/γ protective factor of the oxide layer of the surface layer increased from 2.58 to 2.84 with an increase in the Cu content from 0.75% to 1.25%, resulting in the oxide layer of the surface layer being more protective. For 1.25%Cu steel, the corrosion current density of rusted samples is lower (ranging from 1.2609 × 10⁻⁴ A/cm² to 3.7376 × 10⁻⁴ A/cm²), and the corrosion potential is higher (ranging from −0.85544 V to −0.40243 V). Therefore, the rusted samples are more corrosion resistant. The Cu in the oxide layer of the surface layer forms CuO and CuFeO₂, which are helpful for increasing corrosion resistance, which inhibits the penetration of Cl⁻. Full article

(This article belongs to the Special Issue Advances in Corrosion and Protection of Metallic Materials)

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11 pages, 1722 KB

Open AccessCommunication

Comparative Study of Corrosion Inhibition Properties of Q345 Steel by Chitosan MOF and Chitosan Schiff Base

by Lizhen Huang, Jingwen Liu, Li Wan, Bojie Li, Xianwei Wang, Silin Kang and Lei Zhu

Materials 2025, 18(13), 3031; https://doi.org/10.3390/ma18133031 - 26 Jun 2025

Cited by 1 | Viewed by 1359

Abstract

This study synthesized two eco-friendly inhibitors—a chitosan–copper metal–organic framework (CS@Cu MOF) and chitosan–Schiff base–Cu complex (Schiff–CS@Cu)—for Q345 steel protection in 3.5% NaCl/1M HCl. Electrochemical and weight loss analyses demonstrated exceptional corrosion inhibition: untreated specimens showed a 25.889 g/(m²·h) corrosion rate, while 100 mg/L of CS@Cu MOF and Schiff–CS@Cu reduced rates to 2.50 g/(m²·h) (90.34% efficiency) and 1.67 g/(m²·h) (93.56%), respectively. Schiff–CS@Cu’s superiority stemmed from its pyridine–Cu²⁺ chelation forming a dense coordination barrier that impeded Cl⁻/H⁺ penetration, whereas CS@Cu MOF relied on physical adsorption and micro-galvanic interactions. Surface characterization revealed that Schiff–CS@Cu suppressed pitting nucleation through chemical coordination, contrasting with CS@Cu MOF’s porous film delaying uniform corrosion. Both inhibitors achieved optimal performance at 100 mg/L concentration. This work establishes a molecular design strategy for green inhibitors, combining metal–organic coordination chemistry with biopolymer modification, offering practical solutions for marine infrastructure and acid-processing equipment protection. Full article

(This article belongs to the Special Issue Advances in Corrosion and Protection of Metallic Materials)

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17 pages, 10861 KB

Open AccessEditor’s ChoiceArticle

Corrosion Behaviors of Ni80A Alloy Valve in Marine Engine Within Ammonia-Rich Environment

by Ying-ying Liu, Guo-zheng Quan, Yan-ze Yu, Wen-jing Ran and Wei Xiong

Materials 2025, 18(13), 3006; https://doi.org/10.3390/ma18133006 - 25 Jun 2025

Cited by 3 | Viewed by 1695

Abstract

Ammonia fuel is regarded as a promising zero-carbon alternative to diesel in next-generation marine engines. However, the high-temperature ammonia-rich environment poses significant corrosion challenges to hot-end components such as valves. This study investigates the corrosion behavior of Ni80A alloy marine valves under the coupled effects of a high temperature and ammonia atmosphere. Using computational fluid dynamics (CFD), the service temperature of the valve and the ammonia concentration distribution inside the engine cylinder were identified. High-temperature corrosion experiments were conducted with a custom-designed setup. Results show that corrosion kinetics accelerated markedly with temperature: the initial corrosion rate at 800 °C was four times that at 500 °C, and the maximum corrosion layer thickness reached 37 μm—double that at lower temperatures. Microstructural analysis revealed a transition from a dense, defect-free corrosion layer at 500 °C to a non-uniform layer with coarse CrN particles and aggregated nitrides at 800 °C. Notably, surface hardness increased at both temperatures, peaking at 590 HV at 500 °C, while matrix hardness at 800 °C declined due to γ′ phase coarsening and grain growth. This work provides detailed insight into the temperature-dependent ammonia corrosion mechanisms of marine Ni-based alloy valves, offering essential data for material design and durability assessment in ammonia-fueled marine engines. Full article

(This article belongs to the Special Issue Advances in Corrosion and Protection of Metallic Materials)

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28 pages, 6157 KB

Open AccessArticle

Towards a Sustainable Material Protection: Olanzapine Drugs and Their Derivatives as Corrosion Inhibitors for C1018 Steel in 1 M Hydrochloric Acid

by Habibah M. A. Omar, Nestor Ankah, Mohamed S. Gomaa, Malak Y. Alkhaldi, Nadir M. A. Osman, Abdullah R. Al-Subaie, Ibrahim Aldossary, Irshad Baig, Ashraf A. Bahraq, Marwah Aljohani, Ihsan Ulhaq Toor and Aeshah H. Alamri

Materials 2025, 18(12), 2902; https://doi.org/10.3390/ma18122902 - 19 Jun 2025

Cited by 2 | Viewed by 1419

Abstract

This study investigates the synthesis process and characterization methods and evaluates the inhibition behavior of olanzapine (2-methyl-4-(4-methyl-1-piperazinyl)-10H-thieno-[2,3-b] 1,5]benzodiazepine (OLZ)) and its derivatives, such as 3-(2-methyl-4-(4-methylpiperazin-1-yl)-10H-benzo[b]thieno[2,3-e] [1,4]diazepin-10-yl) propenamide (OLZ1) and Ethyl 2-(2-methyl-4-(4-methylpiperazin-1-yl)-10H-benzo[b]thieno[2,3-e][1,4]diazepin-10 yl) acetate (OLZ2) for carbon steel (C1018) in a 1 M HCl acidic solution. Fourier Transform Infrared Spectroscopy (FTIR) and Nuclear Magnetic Resonance (NMR) were employed to verify their molecular structures and functional groups, which characterized the derivatives after synthesis. Their corrosion inhibition potential for C1018 steel in acidic media was estimated by weight loss (WL) and electrochemical techniques, such as electrochemical impedance spectroscopy (EIS), linear polarization resistance (LPR), and potentiodynamic polarization (PDP), accompanied by surface analysis methods. The findings revealed that all three derivatives demonstrated exceptional inhibition performance, achieving maximum efficiencies of 88.83%, 91.20%, and 91.82% for OLZ, OLZ1, and OLZ2 at 300 ppm, respectively. Weight loss experiments across different temperatures further explored their inhibitory behavior. Although inhibition efficiency decreased with a temperature increase to 318 K, the derivatives still displayed notable performance, with maximum efficiencies of 74.75% for OLZ, 81.63% for OLZ1, and 79.44% for OLZ2. Polarization studies identified the corrosion inhibition mechanisms as an anodic type. Surface characterization of the C1018 steel coupons, both with and without the inhibitors, was performed using FTIR and scanning electron microscopy (SEM) combined with energy-dispersive X-ray spectroscopy (EDX). These analyses indicated the creation of a protective inhibitor layer on the carbon steel surface, reducing corrosion in the acidic environment. Overall, this study underscores the potential of these drug derivatives as corrosion inhibitors, combining structural insights and performance assessments to support their industrial application. Full article

(This article belongs to the Special Issue Advances in Corrosion and Protection of Metallic Materials)

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16 pages, 8657 KB

Open AccessArticle

Impact of NaHCO₃/Na₂CO₃ Buffer Reagent on Mitigating the Corrosion of C110 Steel in Water-Based Annulus Protection Fluid at Ultrahigh Temperature

by Zhi Zhang, Mifeng Zhao, Yan Li, Junfeng Xie, Wenwen Song, Juantao Zhang, Mengkai Wang, Jie Zhou, Yuan Wang, Xiaowei Lei and Danping Li

Materials 2025, 18(7), 1668; https://doi.org/10.3390/ma18071668 - 5 Apr 2025

Cited by 1 | Viewed by 1618

Abstract

The drilling of ultradeep oil wells brings many challenges to the downhole tubular materials, where corrosion induced by halide annulus protection fluid is one major problem. In this work, the Na₂CO₃/NaHCO₃ buffer system is employed to mitigate the corrosion of C110 steel in NaBr annulus protection fluid at 220 °C. Weight loss tests, corrosion morphologies characterizations, and electrochemical measurements were used to investigate the inhibition effect. X-ray diffraction and X-ray photo-electron spectroscopy were employed to analyze the surface phase compositions. It is found that the Na₂CO₃/NaHCO₃ buffer reagents effectively inhibit the corrosion of C110 steel, and the inhibition efficiency can reach 96.1%. The higher pH leads to the better inhibition performance, and, particularly, the buffer system is more effective in the corrosion environment of greater aggressivity. Without buffer reagents, the steel substrate is subjected to higher degree of uniform etching and pitting corrosion due to the formation of loose and porous corrosion products. In contrast, the addition of buffer reagents facilitates the formation of thinner but denser and more protective Fe₃O₄ passive film, contributing the high corrosion inhibition efficiency. Our work paves the way for the safe service of NaBr annulus protection fluid at 220 °C in ultradeep oil wells. Full article

(This article belongs to the Special Issue Advances in Corrosion and Protection of Metallic Materials)

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21 pages, 17144 KB

Open AccessArticle

Failure and Degradation Mechanisms of Steel Pipelines: Analysis and Development of Effective Preventive Strategies

by Marcin Kowalczyk, Jakub Andruszko, Paweł Stefanek and Robert Mazur

Materials 2025, 18(1), 134; https://doi.org/10.3390/ma18010134 - 31 Dec 2024

Cited by 7 | Viewed by 3274

Abstract

The increasing challenges related to the reliability and durability of steel pipeline infrastructure necessitate a detailed understanding of degradation and failure mechanisms. This study focuses on selective corrosion and erosion as critical factors, analyzing their impact on pipeline integrity using advanced methods, including macroscopic analysis, corrosion testing, microscopic examination, tensile strength testing, and finite element method (FEM) modeling. Selective corrosion in the heat-affected zones (HAZs) of longitudinal welds was identified as the dominant degradation mechanism, with pit depths reaching up to 6 mm, leading to tensile strength reductions of 30%. FEM analysis showed that material loss exceeding 8 mm in weld areas under standard operating pressure (16 bar) induces critical stress levels, risking pipeline failure. Erosion was found to exacerbate selective corrosion, accelerating degradation in high-stress zones. Practical recommendations include the use of corrosion-resistant materials, such as duplex steels, and implementing integrated monitoring strategies combining non-destructive testing with FEM-based predictive modeling. These insights contribute to developing robust preventive measures to ensure the safety and longevity of pipeline infrastructure. Full article

(This article belongs to the Special Issue Advances in Corrosion and Protection of Metallic Materials)

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