Corrosion and Oxidation of Metals: Mechanisms, Kinetics, and Protection

A special issue of Metals (ISSN 2075-4701). This special issue belongs to the section "Corrosion and Protection".

Deadline for manuscript submissions: closed (30 November 2025) | Viewed by 1276

Special Issue Editor


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Guest Editor
Munir Rachid Corrosion Laboratory, Department of Materials Engineering, Federal University of São Carlos, Rodovia Washington Luís, São Carlos 13565-905, Brazil
Interests: aqueous corrosion; high-temperature oxidation; materials characterization; passive films; welding

Special Issue Information

Dear Colleagues,

Corrosion and oxidation are major challenges in industrial environments, resulting in significant costs for the protection, replacement and maintenance of parts. These phenomena are the primary cause of degradation of the metallic parts used in machinery, infrastructure and critical components of various types, especially those operating at high temperatures or in highly corrosive environments. Under these conditions, metallic materials are very often thermodynamically unstable and tend to react with the environment, leading to their dissolution or the formation of corrosion products such as oxides, nitrides and sulfides. Corrosion and oxidation are complex phenomena that are highly dependent not only on the composition of the metal being corroded, but also on the environment and temperature. Thus, in many cases, corrosion and oxidation cannot be completely prevented, and accurate predictions are difficult. Therefore, research is needed to understand the mechanisms behind these phenomena and to develop highly resistant materials or protective techniques and applications, such as coatings, that increase the longevity and reliability of metal structures.

This Special Issue invites the submission of original research papers, short communications, and reviews dealing with corrosion and oxidation of metals and alloys, with a focus on mechanisms, kinetics, scale characterization, and other related topics. The scope includes metals and alloys exposed to corrosive environments of any kind, including aqueous corrosion phenomena (e.g., marine or biochemical industrial environments) as well as atmospheric corrosion (e.g., high-temperature oxygen, steam, or CO2 environments). Studies of atmospheres that reflect modern industrial applications such as solar salt, marine, or turbine (wet air or steam) environments are strongly encouraged.

Dr. Rodrigo Da Silva
Guest Editor

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Keywords

  • aqueous corrosion
  • high-temperature oxidation
  • protective coatings
  • scale characterization
  • atmospheric corrosion
  • thermodynamic and kinetic mechanisms
  • industrial environments
  • degradation processes

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Published Papers (2 papers)

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Research

23 pages, 4527 KB  
Article
Aluminum Surface Corrosion Behavior and Microstructural Evolution in Dissimilar AA6016-T4 Aluminum to DP600 Steel via Refill Friction Stir Spot Welding
by Willian S. de Carvalho, Guilherme dos Santos Vacchi, Uceu F. H. Suhuddin, Rodrigo da Silva, Danielle C. C. Magalhães and Carlos A. D. Rovere
Metals 2025, 15(12), 1288; https://doi.org/10.3390/met15121288 - 25 Nov 2025
Viewed by 342
Abstract
Refill friction stir spot welding (refill FSSW) is a solid-state joining technique that enables dissimilar welding between aluminum and steel alloys with minimal intermetallic compound (IMC) formation. Previous studies have focused on the interfacial mechanical performance of such joints, limited attention has been [...] Read more.
Refill friction stir spot welding (refill FSSW) is a solid-state joining technique that enables dissimilar welding between aluminum and steel alloys with minimal intermetallic compound (IMC) formation. Previous studies have focused on the interfacial mechanical performance of such joints, limited attention has been given to the localized corrosion behavior of the aluminum surface after welding, particularly in relation to microstructural evolution. This study investigates the effect of refill FSSW on the localized corrosion resistance of the aluminum surface in dissimilar joints with DP600 steel, since the Al side is typically the exposed surface in automotive service conditions. Emphasis is placed on the correlation between microstructural changes induced by the welding thermal cycle, such as grain refinement and precipitate coarsening, and localized corrosion behavior. The welded samples were characterized by optical and scanning electron microscopy, Vickers hardness measurements and potentiodynamic polarization techniques. Corrosion tests revealed a slight reduction in corrosion resistance in the stir zone compared to the base metal, mainly attributed to Mg2Si coarsening. Pit initiation sites were associated with Al(Fe, Mn)Si and Mg2Si precipitates. These findings offer new insights into the corrosion mechanisms acting on the aluminum surface of refill FSSW joints, supporting the development of more corrosion-resistant dissimilar structures. Full article
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16 pages, 4370 KB  
Article
Influence of Pre-Corrosion in NaCl Solution on Cavitation Resistance of Steel Samples (42CrMo4)
by Stanica Nedović, Ana Alil, Sanja Martinović, Stefan Dikić and Tatjana Volkov-Husović
Metals 2025, 15(9), 1041; https://doi.org/10.3390/met15091041 - 19 Sep 2025
Viewed by 671
Abstract
Marine applications often involve metallic materials, including steel, that must endure harsh conditions such as cavitation erosion (CE). This study investigates the CE behavior of 42CrMo4 steel, both in its original state and after pre-corrosion in a 3.5% NaCl solution for 120 days, [...] Read more.
Marine applications often involve metallic materials, including steel, that must endure harsh conditions such as cavitation erosion (CE). This study investigates the CE behavior of 42CrMo4 steel, both in its original state and after pre-corrosion in a 3.5% NaCl solution for 120 days, simulating a simplified marine environment. Cavitation testing was conducted using an ultrasonic vibratory setup with a stationary sample, at intervals of 10 and 30 min, with a total testing time of 150 min. Mass loss (ML), mass loss rate (MLR), mean depth of erosion (MDE), and level of degradation (LoD) were calculated, while surface roughness (Rz) was measured using a TR200 tester. Surface changes were analyzed through field emission scanning electron microscopy (FESEM) and image analysis techniques. Morphological parameters such as the number of pits, average diameter, and total pit area were used to quantify surface damage. Results showed that pre-corroded samples exhibited a significantly higher erosion rate than non-corroded ones. Pre-corrosion introduced microcracks and surface defects that served as initiation sites for cavitation damage. These imperfections increased surface roughness and created favorable conditions for pit formation, leading to faster and deeper material loss. Image and FESEM analyses confirmed the presence of larger and deeper pits in pre-corroded samples compared to the smaller and shallower pits in non-corroded specimens. This study highlights the impact of pre-corrosion on the cavitation resistance of 42CrMo4 steel and demonstrates the effectiveness of combining mass loss data with morphological and surface analyses for evaluating cavitation damage under marine-like conditions. Full article
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