Search Results (253)

This study explores the use of embedded piezo sensor (EPS) employing the Electro-Mechanical Impedance (EMI) technique for real-time corrosion monitoring in reinforced E-waste concrete exposed to chloride-laden environments. With the growing environmental concerns over electronic waste (E-waste) and the demand for sustainable construction practices, printed circuit board (PCB) materials were incorporated as partial replacements for coarse aggregates in concrete. The experiment utilized M30-grade concrete mixes, substituting 15% of natural coarse aggregates with E-waste, aiming to assess both sustainability and structural performance without compromising durability. EPS configured with Lead Zirconate Titanate (PZT) patches were embedded into both conventional and E-waste concrete specimens. The EPS monitored the changes in the form of conductance and susceptance signatures across a 100–400 kHz frequency range during accelerated corrosion exposure over a 60-day period in a 3.5% NaCl solution. The corrosion progression was evaluated qualitatively through electrical impedance signatures, visually via rust formation and cracking, and quantitatively using the Root Mean Square Deviation (RMSD) of EMI signatures. The results showed that the EMI technique effectively captured the initiation and propagation stages of corrosion. E-waste concrete exhibited earlier and more severe signs of corrosion compared to conventional concrete, indicated by faster increases and subsequent declines in conductance and susceptance and higher RMSD values during the initiation phase. The EMI-based system demonstrated its capability to detect microstructural changes at early stages, making it a promising method for Structural Health Monitoring (SHM) of sustainable concretes. The study concludes that while the use of E-waste in concrete contributes positively to sustainability, it may compromise long-term durability in aggressive environments. However, the integration of EPS and EMI offers a reliable, non-destructive, and sensitive technique for real-time corrosion monitoring, supporting preventive maintenance and improved infrastructure longevity. Full article

In this paper, a series of polyaniline (PANI)/Ti₃C₂ MXene composites (PMCs) with a biomimetic structure were prepared and employed as an anticorrosion coating application. First, the PANI was synthesized by oxidative polymerization with ammonium persulfate as the oxidant. Then, 2D Ti₃C₂ MXene nanosheets were prepared by treating the Ti₃AlC₂ using the optimized minimally intensive layer delamination (MILD) method, followed by characterization via XRD and SEM. Subsequently, the PMC was prepared by the oxidative polymerization of aniline monomers in the presence of Ti₃C₂ MXene nanosheets, followed by characterization via FTIR, XRD, SEM, TEM, CV, and UV–Visible. Eventually, the PMC coatings with the artificial biomimetic surface structure of a macaw feather were prepared by the nano-casting technique. The corrosion resistance of the PMC coatings, evaluated via Tafel polarization and Nyquist impedance measurements, shows that increasing the MXene loading up to 5 wt % shifts the corrosion potential (E_corr) on steel from −588 mV to −356 mV vs. SCE, reduces the corrosion current density (I_corr) from 1.09 µA/cm² to 0.035 µA/cm², and raises the impedance modulus at 0.01 Hz from 67 kΩ to 3794 kΩ. When structured with the hierarchical feather topography, the PMC coating (Bio-PA-MX-5) further advances the E_corr to +103.6 mV, lowers the I_corr to 7.22 × 10⁻⁴ µA/cm², and boosts the impedance to 96,875 kΩ. Compared to neat coatings without biomimetic structuring, those with engineered biomimetic surfaces showed significantly improved corrosion protection performance. These enhancements arise from three synergistic mechanisms: (i) polyaniline’s redox catalysis accelerates the formation of a dense passive oxide layer; (ii) MXene nanosheets create a tortuous gas barrier that cuts the oxygen permeability from 11.3 Barrer to 0.9 Barrer; and (iii) the biomimetic surface traps air pockets, raising the water contact angle from 87° to 135°. This integrated approach delivers one of the highest combined corrosion potentials and impedance values reported for thin-film coatings, pointing to a general strategy for durable steel protection. Full article

Epoxy adhesives derived from bisphenol A diglycidyl ether (BADGE) are widely utilized in segmental construction—particularly in precast concrete structures—and in building structural strengthening, owing to their outstanding adhesion properties and long-term durability. These materials constitute a significant class of polymeric adhesives in structural engineering applications. However, BADGE-based epoxy adhesives are susceptible to aging under service conditions, primarily due to environmental stressors such as thermal cycling, oxygen exposure, moisture ingress, ultraviolet radiation, and interaction with corrosive media. These aging processes lead to irreversible physicochemical changes, manifested as degradation of microstructure, mechanical properties, and dynamic mechanical properties to varying degrees, with performance deterioration becoming increasingly significant over time. Notably, for the mechanical properties of concern, the decline can exceed 40% in accelerated aging tests. A comprehensive understanding of the aging behavior of BADGE-based epoxy resin under realistic environmental conditions is essential for predicting long-term performance and ensuring structural safety. This paper provides a critical review of existing studies on the aging behavior of BADGE-based epoxy resins. This paper summarizes the findings of various aging tests involving different influencing factors, identifies the main degradation mechanisms, and evaluates current methods for predicting long-term durability (such as the Arrhenius method, Eyring model, etc.). Furthermore, this review provides recommendations for future research, including investigating multifactorial aging, conducting natural exposure tests, and establishing correlations between laboratory-based accelerated aging and field-exposed conditions. These recommendations aim to advance the understanding of long-term aging mechanisms and enhance the reliability of BADGE-based epoxy resins in structural applications. Full article

To investigate the corrosion resistance of 60Si2MnA spring steel coated with Zn-Al in a domestic atmospheric environment containing harmful salts, the corrosion environmental factors (temperature, humidity, deposited salts, and pH) were obtained through field research. The deliquescence and weathering behavior of harmful salts were studied using impedance methods to establish their characteristic curves. Additionally, a self-designed salt deposition test apparatus was employed to conduct accelerated atmospheric corrosion tests under constant salt deposition (10 g/m²) and controlled temperature and humidity conditions (20 °C/75% RH and 40 °C/75% RH) over different corrosion periods. The results show that noticeable red rust appeared on the samples after one month of corrosion. As the temperature increased, the consumption of the coating accelerated. XRD and Raman analyses reveal that the main corrosion products of the coating materials were ZnO, Zn(OH)₂, and Zn₅(CO₃)₂(OH)₆, while the red rust primarily consisted of iron oxides and hydroxides. In the early stages of corrosion, the self-corrosion current density was relatively low due to the protective effects of the coating and the corrosion product layer, indicating good corrosion resistance. However, in the later stages, the integrity of the coating and the corrosion product layer deteriorated, leading to a significant increase in the self-corrosion current density and a decline in corrosion resistance. This study provides a data foundation for understanding the corrosion behavior of Zn-Al-coated spring steel in atmospheric environments and offers theoretical insights for developing more corrosion-resistant coatings and optimizing anti-corrosion measures. Full article

The traditional detection method of transformer oil acid value has limitations, such as long detection period and toxicity of reagents; while, with the traditional spectral analysis, it is difficult to realize the efficient extraction of key features related to the acid value content. Early detection of rising acid levels is critical to prevent transformer insulation degradation, corrosion, and failure. Conversely, delayed detection accelerates aging and can cause costly repairs or unplanned outages. To address this need, this paper proposes a new method for predicting the acid value content of the transformer oil based on the infrared spectra in the transformer oil and a deep neural network (DNN). The infrared spectral data of the transformer oil is acquired by ALPHA II FT-IR spectrometer, the high frequency noise effect of the spectrum is reduced by wavelet packet decomposition (WPD), and the bootstrapping soft shrinkage (BOSS) algorithm is used to extract the spectra with the highest correlation with the acid value content. The BOSS algorithm is used to extract the feature parameters with the highest correlation with the acid value content in the spectrum, and the DNN prediction model is established to realize the fast prediction of the acid value content of the transformer oil. In comparison with the traditional infrared spectral preprocessing method and regression model, the proposed prediction model has a coefficient of determination (R²) of 97.12% and 95.99% for the prediction set and validation set, respectively, which is 4.96% higher than that of the traditional model. In addition, the accuracy is 5.45% higher than the traditional model, and the R² of the proposed prediction model is 95.04% after complete external data validation, indicating that it has good accuracy. The results show that the infrared spectral analysis method combining WPD noise reduction, BOSS feature extraction, and DNN modeling can realize the rapid prediction of the acid value content of the transformer oil based on infrared spectroscopy technology, and the prediction model can be used to realize the analytical study of transformer oils. The model can be further applied to the monitoring field of the transformer oil characteristic parameter to realize the rapid monitoring of the transformer oil parameters based on a portable infrared spectrometer. Full article

Half-cell potential (HCP) is widely acknowledged as a nondestructive method for assessing the durability of concrete, although the variability in environmental and material conditions compromises its accuracy. The reliability of traditional prediction models, which are often derived from limited data, is questionable under various conditions. This study employed a Bayesian-enhanced probabilistic model to predict corrosion reinforcement using HCP, addressing both known and unknown uncertainties. Constructed as a piecewise function, the model integrates insights from the literature with the results of an accelerated corrosion experiment conducted by the research team, thereby validating the effectiveness of the probabilistic approach. This study also examines the influence of prior knowledge on the accuracy of predictions. The findings revealed a biphasic relationship between HCP and the corroded mass reduction ratio. HCP decreased exponentially with a corroded mass reduction ratio below 15%, whereas beyond this threshold, the decline became more pronounced, modeled by a combination of exponential and cubic polynomial functions. These results underscore the critical role of employing a piecewise function to accurately define the relationship between HCP and corrosion in reinforced concrete, thereby providing a solid foundation for future durability assessments. Full article

The application of rebar reinforced ultra-high-performance concrete (R-UHPC) has been increasingly adopted in engineering structures due to its exceptional mechanical performance and durability characteristics. Nevertheless, when subjected to combined saline and stray current conditions, R-UHPC remains vulnerable to severe corrosion degradation. This investigation examined the corrosion performance and tensile behavior evolution of R-UHPC containing 2.0 vol% copper-coated steel fiber content and HRB400 steel rebar with a reinforcement ratio of 3.1%. The accelerated corrosion process was induced through an impressed current method, followed by direct tensile tests at varying exposure periods. The findings revealed that the embedding of rebar in UHPC led to the formation of fiber-to-rebar (F-R) conductive pathways, generating radial cracks besides laminar cracks. The bonding between rebar and UHPC degraded as corrosion progressed, leading to the loss of characteristic multiple-cracking behavior of R-UHPC in tension. Meanwhile, R-UHPC load-bearing capacity, transitioning from gradual to accelerated deterioration phases with prolonged corrosion, aligns with steel fibers temporally. During the initial 4 days of corrosion, the specimens displayed surface-level corrosion features with negligible steel fiber loss, showing less than 4.0% reduction in ultimate bearing capacity. At 8 days of corrosion, the steel fiber decreased by 22.6%, accompanied by an 18.3% reduction in bearing capacity. By 16 days of corrosion, the steel fiber loss reached 41.5%, with a corresponding bearing capacity reduction of 29.1%. During the corrosion process, corrosion cracks and load-bearing degradation in R-UHPC could be indicated by the ultrasonic damage factor. Full article

Using direct seawater electrolysis (DSE) for hydrogen production has garnered increasing scientific attention as a promising pathway toward sustainable energy solutions. Given the complex ionic environment of seawater, researchers have proposed a diverse range of strategies aimed at addressing the issue of enhancing the corrosion resistance of anodes, yet no optimal solution has been found so far. Among the emerging approaches, a design using multilayer electrode architecture offers notable advantages by introducing abundant active sites, diverse chemical environments, and robust physical structures. Crucially, these configurations enable the synergistic integration of distinct material properties across different layers, thereby enhancing both electrochemical activity and structural stability in harsh seawater environments. Despite these benefits, a limited understanding of the role played by solid–solid interfaces has hindered the rational design and practical application of such electrodes. This review focuses on the design principles and functional roles of solid–solid interfaces in multilayer anodes for the oxygen evolution reaction (OER) under DSE conditions. In addition, we systematically summarize and discuss the representative fabrication methods for constructing solid–solid interfaces in hierarchically structured electrodes. By screening recent advances in these techniques, we further highlight how engineered interfaces influence interfacial bonding, electron transfer, and mass transport during DSE processes, enhancing the intrinsic catalytic activity, as well as protecting the metallic electrode from corrosion. Finally, current challenges and future research directions to deepen the mechanistic understanding of interface phenomena are discussed, with the aim of accelerating the development of robust and scalable electrodes for direct seawater electrolysis. Full article

Marine steel structures face severe corrosion risks due to harsh environmental conditions, posing significant logistical, economic, and safety challenges for inspection and maintenance. Traditional corrosion assessment methods are costly, labor-intensive, and potentially hazardous. This study evaluated the capabilities of visible-to-near-infrared hyperspectral imaging (HSI) for automating corrosion detection and severity classification in steel samples subjected to accelerated corrosion conditions simulating marine exposure. Marine steel coupons were partially coated to simulate protective paint and immersed in natural brackish water from the Panama Canal, creating varying corrosion levels. Hyperspectral images were acquired in controlled illumination conditions, calibrated radiometrically, and reduced in dimensionality via principal component analysis (PCA). Four machine learning models, including k-nearest neighbors, support vector machine, random forest, and multilayer perceptron, were tested for classifying corrosion severity. The multilayer perceptron achieved the highest accuracy at 96.18%, clearly distinguishing among five defined corrosion stages. These findings demonstrate that hyperspectral imaging, coupled with machine learning techniques, provides a viable, accurate, non-destructive methodology for assessing marine steel corrosion, potentially reducing costs, improving safety, and streamlining maintenance procedures. Full article

This work aims to characterize flow-accelerated corrosion of carbon steel A36 coupons exposed to simulated treated reverse-osmosis seawater under ambient conditions and a Reynolds number range of 6000 to 25,000 using a standard corrosion testing method. The flow behavior in the corrosion compartment and the turbulent parameters were determined by computational fluid dynamics simulation. Using selected flow parameters, complemented with experimental corrosion rate measurements, the oxygen mass transfer coefficients (m_c) and the rate constant for the cathodic reaction (k_c) at the coupon surface were determined. As expected, m_c depends only on the fluid conditions, while k_c is highly influenced by interface resistance, leading to significantly different runs with and without a corrosion inhibitor. The dissimilar fluid flow distribution on intrados and extrados generates irregular corrosion patterns, depending on the angular position of the coupon inside the corrosion compartment. Morphological studies using scanning electron microscopy and atomic force microscopy support simulation results. Full article

This study investigates the long-term corrosion behavior of reinforced concrete (RC) under accelerated chloride exposure for about 1600 days, using electrochemical methods like galvanostatic pulse (GP) testing. Two concrete mixes (T1 and T2), incorporating distinct supplementary cementitious materials (SCMs), were evaluated to determine their performance in aggressive environments. Specimens with varying reservoir lengths were exposed to a 10% NaCl solution (by weight), with electromigration applied to accelerate chloride transport. Electrochemical assessments, including measurements of rebar potential, concrete solution resistance, concrete polarization resistance, corrosion current, and mass loss, were conducted to monitor the degradation of embedded steel. The findings revealed that smaller reservoirs (2.5 cm) significantly restricted chloride and moisture penetration, reducing corrosion, while larger reservoirs (10 cm) resulted in greater exposure and higher corrosion activity. Additionally, T1 mixes (partial cement replacement with 20% fly ash and 50% slag) showed higher corrosion currents and mass loss, whereas T2 mixes (partial cement replacement with 20% fly ash and 8% silica fume) demonstrated enhanced matrix densification, reduced permeability, and superior durability. These results underscore the importance of mix design and exposure conditions in mitigating corrosion, providing critical insights for improving the longevity of RC structures in aggressive environments. Full article

Chloride ions in zinc refining accelerate equipment corrosion and anode and cathode losses, increase lead content, and reduce zinc quality. Therefore, the removal of chloride ions has become a research priority. The existing copper slag dechlorination process has problems such as the solid film barrier leading to impeded mass transfer, product wrapping triggering active site coverage, and incomplete reactions due to insufficient reaction-driving force, leading to low utilization of copper slag, poor dechlorination efficiency, and long reaction times. To address these issues, a new method of deep dechlorination based on the reduction of Cu²⁺ by liquid-phase mass transfer is proposed in this paper. The process utilizes ascorbic acid as a reducing agent, establishes a homogeneous aqueous phase reaction system, breaks through the solid membrane barrier, and avoids the encapsulation of the product layer, achieving efficient dechlorination. The enol structure of ascorbic acid promotes rapid dechlorination through proton-coupled electron transfer (PCET). Thermodynamic calculations show that compared to the current copper slag dechlorination process, this method increases the reaction-driving force by 18.6%, reduces the Gibbs free energy (ΔG^θ) by 59.3%, and increases the equilibrium constant by 6.7 × 10⁹ times, making the reaction more complete and achieving a higher degree of purification. The experimental results show that under optimized conditions, the chloride ion concentration in the solution decreases from 1 g/L to 0.0917 g/L within 20 min, with a removal rate of 90.8%. The main precipitate is CuCl. This process provides a more efficient solution to the chloride ion contamination problem in the hydrometallurgical zinc refining process. Full article

The present article describes an example of the use of ground-penetrating radar (GPR) to detect early stages of reinforcement corrosion. Two series of concrete samples with reinforcing bars were tested. The first series was reference samples (without corrosion). Samples of the second series were subjected to accelerated corrosion by immersing them in NaCl solution, while undergoing 120 freeze–thaw cycles. Unlike the commonly used electrochemical method of corrosion acceleration, in the studies discussed here, the corrosion processes were more similar to natural ones, taking into account the influence of changes in the structure of the cover under the influence of frost. GPR scanning of samples of both series indicated that all physical and chemical processes accompanying corrosion together caused a decrease in the amplitude of the reflected wave and an increase in its propagation time. The wave amplitude, due to the significant dispersion of results, was, however, a rather unreliable parameter. The wave propagation time was characterized by significantly better repeatability, which makes it a better measure of the progress of corrosion. In general, the GPR with a 2 GHz antenna proved to be an effective tool for diagnosing early stages of corrosion in reinforced concrete. Full article

In the extraction of shale gas, Cl⁻ and S₂O₃²⁻ are one of the important factors causing severe corrosion and failure of equipment and pipelines. Addressing the Cl⁻/S₂O₃²⁻ corrosion challenge in shale gas exploitation pipeline steels, this study evaluates the corrosion rates of L245 steels under diverse conditions, including S₂O₃²⁻ concentration and exposure time, utilizing the weight loss method. The microstructural, elemental, and phase compositions of the corrosion products were examined, and the electrochemical behavior of L245 steel was scrutinized under various conditions. Findings indicate that S₂O₃²⁻ addition intensifies localized corrosion on L245 steel, with the corrosion nature being contingent upon S₂O₃²⁻ concentration in the Cl⁻-containing solution. Concurrently, an escalation in S₂O₃²⁻ concentration correlates with a reduction in capacitive arc diameter and a significant decrease in film resistance, culminating in an accelerated corrosion rate. Full article

This study examines the waste sulfuric acid pipeline within the waste acid system from a certain petrochemical company, specifically, related to its sulfuric acid alkylation process. The current study sought to investigate the corrosion perforation mechanism of pipelines and revealed the synergistic effects of sulfuric acid temperature and concentration on the corrosion behavior of 20# carbon steel. The corrosion features of the failed part were analyzed by scanning electron microscopy, X-ray energy-dispersive spectroscopy, and X-ray diffraction. The corrosion rates of 20# carbon steel in sulfuric acid at different concentrations (80%, 90%, 98%) and working temperatures (20 °C, 40 °C) were measured using the immersion corrosion method, potentiodynamic polarization curves, and electrochemical impedance spectroscopy. The results indicate that the failed pipeline exhibited multi-form corrosion characteristics, with both uniform and localized corrosion occurring simultaneously in concentrated sulfuric acid. The lowest corrosion rate was 0.0795 mm/a in 98% H₂SO₄ at 40 °C. The sulfuric acid concentration and working temperature exhibited synergistic effects on the corrosion behavior of 20# carbon steel. The corrosion rates increased with concentration in the range of 80–90% H₂SO₄ but reached a minimum of 98% due to passive film formation. In a nutshell, we established that elevated temperatures accelerated corrosion in low-concentration systems, but triggered localized active dissolution in high-concentration systems by disrupting the passive film on the surface of the steel. Full article