Search Results (45)

Chloride ion penetration is one of the most aggressive threats to reinforced concrete, as it triggers the electrochemical corrosion of steel reinforcement, compromising structural integrity and durability. Chloride ingress occurs through the porous structure of concrete, making permeability control crucial for enhancing structural longevity. Fiber-reinforced concrete (FRC) is widely used to improve durability; however, the effects of different fiber types on chloride resistance remain unclear. This study examines the influence of glass and polypropylene fibers on concrete’s microstructure and chloride penetration resistance. Cylindrical specimens were prepared, including a reference mix without fibers and mixes with 0.25% and 0.50% fiber content by volume. Both fiber types were tested for chloride resistance. The accelerated non-steady-state migration method was employed to determine the resistance coefficients to chloride ion penetration, while X-ray macrofluorescence (MacroXRF) mapped the chlorine infiltration depth in the samples. Compressive strength decreased in all fiber-reinforced samples, with 0.50% glass fiber leading to a 56% reduction in strength. Nevertheless, the XRF results showed that a 0.25% fiber content significantly reduced chloride penetration, with polypropylene fibers outperforming glass fibers. These findings highlight the critical role of fiber type and volume in improving concrete durability, offering insights for designing long-lasting FRC structures in chloride-rich environments. Full article

Cement-based materials used in China’s coastal and salt lake areas in the northwest are exposed to long-term chloride corrosion, which deteriorates the materials and substantially reduces the durability of the structures. This study investigates the chlorine ion erosion resistance in salt spray environments of cement-based materials made with iron ore tailings (IOTs) as an aggregate (namely, IOTCs). The compressive strength, mass loss, and relative dynamic elastic modulus (RDEM) macroscopic performance of IOTC undergoing different chloride diffusion times (0–180 d) were explored in detail. Chloride ion profiles at 0–180 d were analyzed via chemical titration, while X-ray computed tomography (CT) and scanning electron microscopy (SEM) were employed to characterize microstructural evolution. The results demonstrate that IOTC exhibited superior chloride resistance compared to conventional concrete (GC). While both materials showed early strength gain (<60 d) due to hydration and pore-filling effects, IOTC experienced only a 23.9% strength loss after long-term exposure (180 d) significantly less than the 37.2% reduction in GC. Chloride profiling revealed that IOTC had 43.5% lower free chloride ions (C_f) and 32% lower total chloride ions (C_t) at 1 mm depth after 180 d, alongside reduced chloride diffusion coefficients (D_a). The CT analysis revealed that IOTC exhibited a significantly denser and more uniformly distributed pore structure than GC, with a porosity of only 0.67% under chloride-free conditions. SEM confirmed IOTC’s more intact matrix and fewer microcracks. Full article

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

Chlorine-based plasma is widely used in key etching applications. However, while etching the wafer materials, chlorine plasma can cause damage to the internal components of the etching chamber, which adversely affects the equipment’s lifespan. As a result, selecting appropriate coating materials for the chamber’s internal components is essential for mitigating corrosion. The etch resistance of these coatings directly impacts not only the quality of wafer production but also the operational safety and maintenance cycle of the etching equipment. In this study, three yttrium oxyfluoride coatings with different oxygen contents (3%, 6%, and 9%) were prepared using atmospheric plasma spraying technology. The etch resistance of these YOF coatings, as well as yttrium oxide coating, was systematically investigated under a Cl₂/O₂ plasma environment. Transmission electron microscopy analysis revealed that at the initial stage, Cl⁻ formed a protective layer on the surface of the YOF coatings, effectively slowing down further etching by Cl⁻. Among the samples, the YOF 6% coating exhibited the best etching resistance, which is primarily attributed to its higher capacity for Cl⁻ adsorption. Overall, YOF coatings demonstrated excellent resistance in chlorine-based plasma environments, with YOF 6% in particular showing great potential as an ideal protective material for etching chamber components. Full article

This study investigates the development and performance of a novel GE-EP@OIM solid corrosion inhibitor for enhancing long-term corrosion protection in the oil-and-gas industry’s corrosive environment. The inhibitor was synthesized by incorporating organic imidazole molecules (OIMs) into a Gel-Epoxy (GE-EP) matrix, achieving an OIM-loading capacity of approximately 34.75% (generally reported capacity is up to 20%). The solid inhibitor was designed as a smart material, which exhibits temperature-responsive release behavior in a chlorine-corrosive environment. A combination of electrochemical measurements, weight loss testing, and scanning electron microscopy (SEM) was employed to assess the inhibitor’s performance. The results demonstrate that GE-EP@OIMs significantly improve corrosion resistance, particularly at elevated temperatures (50 °C), with the long-term protection effect serving as a key highlight, maintaining efficacy for up to 60 days, and it shows enhanced stability compared to conventional inhibitors. While the mechanical properties of GE-EP@OIMs are slightly diminished due to the incorporation of OIMs, the inhibitor still meets the necessary fluidity and performance criteria for medium- to long-term applications. This material shows considerable promise for mitigating corrosion in oilfield operations, especially for downhole tubing, and presents a cost-effective solution to the widespread corrosion challenges in the industry. Full article

Marine environment-induced apparatus failures have led to substantial losses in marine engineering. Graphite/copper composites, known for their excellent electrical conductivity and wear resistance, are extensively utilized in various electric contact devices. However, research on the current-carrying friction and wear behavior of graphite/copper composites in marine environments is still limited. This study investigates the effects of mating materials, graphite content (30 wt.% and 45 wt.%), and electric voltage on the friction and wear mechanisms of graphite/copper composites in seawater. The results show that under seawater coupled with electricity, no mass loss was observed in the 30 wt.% graphite composites after friction tests against different counterparts. Electric voltage (3 V) affects the composite’s damage mechanism, inducing delamination wear, arc erosion and accelerating corrosion. Specifically, the electricity factor promotes oxidation recreations while inhibiting chlorine formation. Notably, when the composite is paired with gold-coated copper, it undergoes electrochemical reactions, leading to the formation of needle-like copper oxide. These oxides alter the surface morphology, elevate the mass of worn composites, and raise the friction coefficient of the tribopair to approximately 0.3, an increase from 0.2. Full article

The effects of X-doping (X = Mo, Ti, Ni) on the structure, stability, and electronic properties of B2-FeAl supercells, as well as the migration behavior of Cl atoms between interstitial sites and the corrosion behavior of FeAl coatings in molten chloride, were investigated by combining the first principles based on density functional theory (DFT) experiments. Our results confirmed that Mo and Ti atoms are more likely to replace Al atoms in B2-FeAl supercells, while Ni atoms preferentially replace Fe atoms. A single Cl atom is more inclined to be adsorbed at the tetrahedral (Tet) interstitial site of bulk B2-FeAl, and its formation energy $E_f=$− 2.504 eV, indicating that it can very easily invade FeAl alloys. (Mo, Ti, Ni) doping inhibited the diffusion of Cl atoms in the bulk B2-FeAl configuration and enhanced the corrosion resistance of the material to chlorinated molten salts, and Ti doping (overcoming the energy barrier by 0.326 eV) had the most obvious blocking effect. Based on the theoretical conclusions, this experimental study prepared an FeAl coating on 310S stainless steel with a Ni content of 20.22 wt.% at 800 °C for 15 h, which was then annealed at 900 °C for 25 h, and Ni was uniformly dissolved in the B2-FeAl phase. Subsequently, the annealed FeAl coating was corroded in molten chlorinated salts at 800 °C for 100 h, and an oxide layer with a thickness of 25–35 µm formed on the surface; the main components of this layer were Al₂O₃, NiFe₂O₄, and their solid solutions, which significantly improved the corrosion resistance of 310S stainless steel to chlorinated molten salt. Full article

The low corrosion resistance of aluminum alloy materials in chloride environments limits their application in light metal structural components. In this study, 434 stainless steel (SS) powders with different numbers of scan layers were deposited on T6061 aluminum using high-velocity oxygen fuel (HVOF). Tafel curve, electrochemical impedance spectroscopy (EIS), salt spray, and galvanic corrosion tests were employed to investigate the comprehensive corrosion behavior of the SS coatings in a chlorine environment. The results showed that the porosity of the SS coatings decreased as the scanning layer increased. A lower porosity slowed the penetration of the corrosive solution and led to an enhanced long-term resistance to chloride attacks in immersion and salt spray corrosion. On this basis, the preferred SS4 sample and iron screw composition system was subjected to galvanic corrosion, and its electric current intensity (5.11 × 10⁻⁵ A) was two orders of magnitude lower than that of T6061 aluminum (9.14 × 10⁻³ A), as well as presenting better anti-corrosion behavior. Full article

Ab initio methods based on DFT are utilized to study the formation energy, adsorption energy, and electronic properties of pure and X-doped (X = Mo, Ti, Ni) B2-FeAl (110) surface configurations. The effect of microalloying element doping on the corrosion resistance of B2-FeAl coating to molten chlorinated salts was evaluated by the CI-NEB method. Our results show that the Ni atom preferentially occupies the position of the Fe atom, while the Mo and Ti atoms preferentially replace the Al atom in the supercell. The Cl atom tends to be adsorbed at the SB-FeAl site on a pure B2-FeAl (110) surface. The adsorption energies of a single chlorine atom at stable adsorption sites of Ni-doped B2-FeAl (110) surface are small, which means that Ni doping reduces the possibility of corrosion. The PDOS diagrams confirm that for the chlorine adsorption model of Mo-doped B2-FeAl (110) surface, strong hybridization between Mo-d, Al-p, and Fe-d orbitals occur in the energy region of −4.5~−2 eV and 0.5~2.5 eV, while in the energy range of −7.0~4.8 eV, Cl-p interacts with Mo-d and Al-s, respectively, indicating that Cl bonds with Mo and Al atom, respectively. The addition of Mo and Ni hinders the diffusion of chlorine atoms on the surface, weakens the corrosion rate of B2-FeAl in chlorinated molten salt, and improves the corrosion resistance of B2-FeAl coating. However, Ti doping promotes the migration of chlorine atoms and increases the corrosion rate of B2-FeAl in chlorinated molten salt to a certain extent. The aim of this study is to reveal the corrosion resistance mechanism of FeAl coating from the atomic level and provide a theoretical basis for the application of chloride molten salt as an efficient heat storage medium in the field of photothermal. Full article

Dechlorination is a crucial strategy for archeological bronze stabilization to resist corrosion induced by cuprous chloride (CuCl). Conventional samples, either archeological or simulated ones, have deficiencies in revealing dechlorination mechanisms for their complex rust layers and difficulties in quantifying chlorine content. In this work, samples with fixed chlorine amounts were prepared by compressing method to solve overcomplicated and unquantifiable problems. Then, patina profiles and desalinization solutions were analyzed to revisit the dechlorination mechanism across varying solution concentrations and current densities after dechlorination treatments. Results indicate that the sodium hydroxide (NaOH) desalinization method is achieved by converting CuCl to trihydroxychloride (Cu₂(OH)₃Cl). However, this transformation leads to an expansion of the CuCl layer, nearly doubling the CuCl layer thickness at the current density of 25 μA/cm². Dechlorination solution measurements provide information on quantifying chlorine removal and dechlorination progress. Theoretically, the endpoint (c₀) for the NaOH dechlorination method is supposed to be a chloride ion concentration of 358.2 ppm. As the NaOH solution concentrations vary from 10⁻⁶ to 10⁻², CuCl dechlorination progress (E_t=24h) calculations are at about 3% to 6% at 24 h. Applying the current significantly improves the effectiveness of dechlorination at 2.5 μA/cm². However, the chloride ion concentration in the solution starts to decrease after reaching a current density of 12.5 μA/cm², even dropping to 12.07 ppm at 25 μA/cm². According to a theoretical analysis, chlorine evolution during electrolytic processes would be responsible for this phenomenon. Full article

Drinking water distribution systems (DWDSs) may be contaminated to various degrees when different microorganisms attach to the pipe walls. Understanding the characteristics of biofilms on pipe walls can help prevent and control microbial contamination in DWDSs. The biofilm formation, interspecific interactions, and chlorine resistance of 10 dual-species biofilms in polyethylene (PE) and cast iron (CI) pipes were investigated in this paper. The biofilm biomass (heterotrophic bacterial plate count and crystal violet) of dual species in CI pipes is significantly higher than that in PE pipes, but the biofilm activity in CI pipes is significantly lower than that in PE pipes. The interspecific interaction of Sphingomonas-containing group presented synergistic or neutral relationship in PE pipes, whereas the interspecific interaction of the Acidovorax-containing group showed a competitive relationship in CI pipes. Although interspecific relationships may help bacteria resist chlorine, the chlorine resistance was more reliant on dual-species groups and pipe materials. In CI pipes, the Microbacterium containing biofilm groups showed better chlorine resistance, whereas in PE pipes, most biofilm groups with Bacillus exhibited better chlorine resistance. The biofilm groups with more extracellular polymeric substance (EPS) secretion showed stronger chlorine resistance. The biofilm in the PE pipe is mainly protected by EPS, while both EPS and corrosion products shield the biofilms within CI pipe. These results supported that dual-species biofilms are affected by pipe materials and interspecific interactions and provided some ideas for microbial control in two typical pipe materials. Full article

In this study, chlorine-induced corrosion and blister formation on steel pipes (SPs) coated with modified polyethylene powder (MPP) were evaluated through various tests, including chlorine exposure, wet immersion, and temperature gradient experiments. The results confirmed that the extent of corrosion and iron leaching varied with the coating type as expected. In batch leaching tests, no corrosion was observed on modified polyethylene-coated steel pipes (MPCSPs) within a chlorine concentration range of 0 mg/L to 10 mg/L; similarly, there were no significant changes in specimen weight or iron levels. In contrast, the control group with uncoated SPs exhibited significant iron leaching and corrosion, a trend consistent in sequential leaching experiments. SEM analysis after a month of chlorine exposure revealed no significant corrosion on MPCSPs, and SEM-EDX confirmed no major changes in the carbon bond structure, indicating resistance to high chlorine concentrations. Comparative analysis of wet immersion and temperature gradient tests between MPCSP and conventional epoxy-coated SP (ECSP) specimens revealed that MPCSPs did not develop blisters even after 100 days of immersion, whereas ECSPs began showing blisters as early as 50 days. In temperature gradient tests, MPCSPs showed no blisters after 100 days, while ECSPs exhibited severe internal coating layer blisters. Full article

Direct seawater electrolysis is a promising technology within the carbon-neutral energy framework, leveraging renewable resources such as solar, tidal, and wind energy to generate hydrogen and oxygen without competing with the demand for pure water. High-selectivity, high-efficiency, and corrosion-resistant multifunctional electrocatalysts are essential for practical applications, yet producing stable and efficient catalysts under harsh conditions remains a significant challenge. This review systematically summarizes recent advancements in advanced electrocatalysts for seawater splitting, focusing on their multifunctional designs for selectivity and chlorine corrosion resistance. We analyze the fundamental principles and mechanisms of seawater electrocatalytic reactions, discuss the challenges, and provide a detailed overview of the progress in nanostructures, alloys, multi-metallic systems, atomic dispersion, interface engineering, and functional modifications. Continuous research and innovation aim to develop efficient, eco-friendly seawater electrolysis systems, promoting hydrogen energy application, addressing efficiency and stability challenges, reducing costs, and achieving commercial viability. Full article

Due to the intricate and volatile nature of the service environment surrounding prestressing anchoring materials, stress corrosion poses a significant challenge to the sustained stability of underground reinforcement systems. Consequently, it is imperative to identify effective countermeasures against stress corrosion failure in cable bolts within deep underground environments, thereby ensuring the safety of deep resource extraction processes. In this study, the influence of various coatings on the stress corrosion resistance of cable bolts was meticulously examined and evaluated using specifically designed stress-corrosion-testing systems. The specimens were subjected to loading using four-point bending frames and exposed to simulated underground corrosive environments. A detailed analysis and comparison of the failure patterns and mechanisms of specimens coated with different materials were conducted through the meticulous observation of fractographic features. The results revealed stark differences in the stress corrosion behavior of coated and uncoated bolts. Notably, epoxy coatings and chlorinated rubber coatings exhibited superior anti-corrosion capabilities. Conversely, galvanized layers demonstrated the weakest effect due to their sacrificial anti-corrosion mechanism. Furthermore, the effectiveness of the coatings was found to be closely linked to the curing agent and additives used. The findings provide valuable insights for the design and selection of coatings that can enhance the durability and reliability of cable bolts in deep underground environments. Full article

The assumptions of contemporary energy policies are increasing the share of renewable energy sources. Biomass combustion is developing as an alternative to fossil fuels. However, it faces challenges such as limited corrosion resistance of steel boiler components due to chloride compounds in flue gases and fly ash. This paper provides a comprehensive thermodynamic analysis of chloride-induced corrosion in steel in the Fe-O-Cl-Na environment, focusing on the influence of steam concentration in the gas phase. The study was performed by using the general thermodynamic rules, the thermodynamic properties of the pure components involved in the reaction, and the properties of the solutions formed in the liquid and gas phases. The study also examined the impact of alkali metal chlorides, particularly NaCl, on the formation of NaFeO₂ in the passive oxide scale layer Fe₃O₄/Fe₂O₃. Furthermore, it investigated the condensation of NaCl vapour formation of low-melting eutectic mixtures in deposits and the resulting consequences on the corrosion process. The role of HCl in the chlorination and oxidation process of steel in melted ash deposits was also discussed. The presented thermodynamic analysis was compared with assumptions of an “active oxidation” model. This study can be a valuable resource for experimental research planning and a guide for preventing corrosion in industrial settings. Full article