Search Results (220)

The aim of this paper is to present the results of an experimental and numerical investigation into the degradation of reinforced concrete (RC) specimens subjected to an accelerated corrosion process using impressed current in the presence of chloride ions. The corrosion of the rebars was carried out using three current densities (50, 100, and 200 µA/cm²) and various exposure times. The experimental results characterised the internal degradation of the RC specimens through measurement of the corrosion product thicknesses at the steel–concrete interface; the widths, lengths and orientations of internal concrete cracks; and the external concrete crack widths. In addition, numerical modelling of the corroded RC specimens was conducted to describe the crack patterns. The comparison between the experimental and numerical results demonstrated a high degree of correlation, providing insights into the degradation process of RC specimens due to corrosion. Full article

The operation of heavy-haul railway trains with large loads results in significant cracking issues in reinforced concrete beams. Atmospheric carbon dioxide, oxygen, and moisture from the atmosphere penetrate into the beam interior through these cracks, accelerating the carbonation of the concrete and the corrosion of the steel bars. The rust-induced expansion of steel bars further exacerbates the cracking of the beam. The interaction between environmental factors and beam cracks leads to a rapid decline in the durability of the beam. To address this issue, a multi-physics field coupling durability assessment method was proposed, considering concrete beam cracking, concrete carbonation, and steel bar corrosion. The interaction among these three factors is achieved through sequential coupling, using crack width, carbonation passivation time, and steel bar corrosion rate as interaction parameters. Using this method, the deterioration morphology and stiffness degradation laws of 8 m reinforced concrete beams under different load conditions, including those of heavy and light trains in heavy-haul railways, are compared and assessed. The analysis reveals that within a 100-year service cycle, the maximum relative stiffness reduction for beams on the heavy train line is 20.0%, whereas for the light train line, it is only 7.4%. The degree of structural stiffness degradation is closely related to operational load levels, and beam cracking plays a critical role in this difference. Full article

This study provides a comprehensive analysis of the fatigue cracking behavior of super martensitic stainless steel in air and water environments, highlighting the critical influence of environmental factors on its mechanical properties. By examining the distribution of fatigue test data, the Weibull three-parameter model was identified as the most accurate descriptor of fatigue life data in both environments. Key findings reveal that, in air, cracks predominantly propagate along the densest crystallographic planes, whereas, in water, corrosive media significantly accelerate crack initiation and propagation, reducing fatigue resistance, creating more tortuous crack paths, and inducing microvoids and secondary cracks at the crack tip. These corrosive effects adversely alter the material’s microstructure, profoundly impacting fatigue life and crack propagation rates. The insights gained from this research are crucial for understanding the performance of super martensitic stainless steel in aqueous environments, offering a reliable basis for its engineering applications and contributing to the development of more effective design and maintenance strategies. Full article

The decommissioning and dismantling of nuclear research reactors can lead to a large amount of low- and intermediate-level radioactive waste. For repositories, the materials must be kept confined and safety must be ensured for extended time spans. Waste is encapsulated in concrete, which leads to alkaline conditions with pH values of 12 and higher. This can be advantageous for some radionuclides due to their precipitation at high pH. For other materials, such as reactive metals, however, it can be disadvantageous because it might foster their corrosion. The Studsvik R2 research reactor contained an AlMg3.5 alloy with a composition close to that of commercial Al5154 for its core internals and the reactor tank. Aluminum corrosion is known to start rapidly due to the formation of an oxidation layer, which later functions as natural protection for the surface. The corrosion can lead to pressure build-up through the accompanied production of hydrogen gas. This can lead to cracks in the concrete, which can be pathways for radioactive nuclides to migrate and must therefore be prevented. In this study, unirradiated rod-shaped samples were cut from the same material as the original reactor tank manufacture. They were embedded in concrete with elevated water–cement ratios of 0.7 compared to regular commercial concrete (ca. 0.45) to ensure water availability throughout all of the experiments. The sample containers were stored in pressure vessels with attached high-definition pressure gauges to read the hydrogen-induced pressure build-up. A second set of samples were exposed in simplified artificial cement–water to study similarities in corrosion characteristics between concrete and cement–water. Additionally, the samples were exposed to concrete and cement–water in free-standing sample containers for deconstructive examinations. In concrete, the corrosion rates started extremely high, with values of more than 10,000 µm/y, and slowed down to less than 500 µm/y after 2000 h, which resulted in visible channels inside the concrete. In the cement–water, the samples showed similar behavior after early fluctuations, most likely caused by the surface coverage of hydrogen bubbles. These trends were further supported by mass loss evaluations. Full article

In order to determine the failure reason for the non-working area of a cracked A-pillar hot-stamping die insert, various instruments were used to detect the properties and microstructures of the cracks and matrix. The results show that the cracks are located in the area where the oxidative corrosion is more serious, and the cracks do not appear in the pitting area, verifying that crack initiation is related to the stress concentration on the upper half of the inner wall of the cooling channel. Meanwhile, pores and cracks exist in the grain boundary and crystal, making the impact energy of the die steel poor. Therefore, crack initiation and propagation easily occur along the brittle oxide layer. In summary, the die insert is damaged by stress-induced corrosion. In engineering applications of hot-stamping dies, we should pay more attention to the cracking of the cooling channel caused by stress and corrosion. Full article

Bond behavior between steel bars and concrete is fundamental to the structural integrity and durability of reinforced concrete. However, corrosion-induced deterioration severely impairs bond performance, highlighting the need for advanced and reliable assessment methods. This paper pioneers an algorithm for an advanced ensemble learning framework to predict bond strength between corroded steel bars and concrete. In this framework, a novel Stacked Boosted Bond Model (SBBM) is developed, in which a Fusion-Based Feature Selection (FBFS) strategy is integrated to optimize input variables, and SHapley Additive exPlanations (SHAP) are employed to enhance interpretability. A merit of the framework is that it can effectively identify critical factors such as crack width, transverse confinement, and corrosion level, which have often been neglected by traditional models. The proposed SBBM achieves superior predictive performance, with a coefficient of determination (R²) of 0.94 and a mean absolute error (MAE) of 1.33 MPa. Compared to traditional machine learning and analytical models, it demonstrates enhanced accuracy, generalization, and interpretability. This paper provides a reliable and transparent tool for structural performance evaluation, service life prediction, and the design of strengthening measures for corroded reinforced concrete structures, contributing to safer and more durable concrete structures. Full article

Chloride-induced corrosion is a major contributor in the degradation of standardised steel-based products (e.g., rebars and fibres) commonly used for reinforcing concrete structures. Since cracked reinforced concrete elements are determined to be more susceptible to corrosion on the one hand, and fibres are effective in arresting crack growth and improving the post-cracking mechanical behaviour on the other hand, the use of fibres emerges as a promising strategy to enhance durability. This review is focused on the degradation of the load-bearing capacity, caused by chloride corrosion, in concrete elements reinforced with fibres and conventional rebar. Based on the recorded values of ultimate loads and the corresponding deflections in the reviewed studies, a lower decrease in the load-bearing capacity and less severe degradation of ductility were observed in elements where fibres (either steel or macro-synthetic) were used in combination with rebar compared with elements where only rebar was used. Furthermore, the recorded values of corrosion potential (E_corr), corrosion current density (i_corr) and gravimetric measurements indicated lower corrosion damage, delayed corrosion initiation and a prolonged propagation phase of corrosion. However, due to many differences in the methodology among the reviewed studies, the optimal fibre type or quantity cannot be identified unless more studies are performed. 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

This study investigates the effects of aluminum (Al) and titanium (Ti) additions on the porosity, microstructure, and corrosion performance of Hastelloy C276-based coatings fabricated via laser cladding on nodular cast iron substrates. Nickel-based alloy powders blended with varying Ti (1–10 wt.%) and Al (0.5–2.5 wt.%) contents were deposited under optimized laser parameters. Microstructural characterization revealed that Ti addition refined the grain structure and promoted the formation of TiC phases, while Al addition dispersed eutectic networks into isolated island-like structures. Both elements effectively suppressed porosity by reducing gas entrapment during solidification. However, excessive Ti (10 wt.%) induced brittle fracture due to TiC agglomeration, and Al addition caused interfacial cracks owing to Al₂O₃ formation. Electrochemical tests in a 3.5 wt.% NaCl solution indicated that Al/Ti additions enhanced initial passivation but reduced corrosion resistance due to weakened oxide film stability. XPS analysis revealed that Al-enriched coatings formed Al₂O₃ and Al(OH)₃, whereas Ti-modified coatings developed TiO₂ and TiC, both influencing the passivation behavior. These findings provide critical insights into tailoring laser-clad coatings for marine applications by balancing porosity suppression and corrosion resistance. Full article

Tunnel lining structures, which are subjected to the combined effects of water and soil pressure as well as a water-rich erosion environment, undergo a corrosion-induced damage and degradation process in the reinforced concrete, gradually leading to structural failure and a significant decline in service performance. By introducing the Cohesive Zone Model (CZM) and the concrete damage plastic model (CDP), a three-dimensional numerical model of the tunnel lining structure in mining method tunnels was established. This model takes into account the multiple effects caused by steel reinforcement corrosion, including the degradation of the reinforcement’s performance, the loss of an effective concrete cross section, and the deterioration of the bond between the steel reinforcement and the concrete. Through this model, the deformation, internal forces, damage evolution, and degradation characteristics of the structure under the effects of the surrounding rock water–soil pressure and steel reinforcement corrosion are identified. The simulation results reveal the following: (1) Corrosion leads to a reduction in the stiffness of the lining structure, exacerbating its deformation. For example, under high water pressure conditions, the displacement at the vault of the lining before and after corrosion is 4.31 mm and 7.14 mm, respectively, with an additional displacement increase of 65.7% due to corrosion. (2) The reinforced concrete lining structure, which is affected by the surrounding rock loads and expansion due to steel reinforcement corrosion, experiences progressive degradation, resulting in a redistribution of internal forces within the structure. The overall axial force in the lining slightly increases, while the bending moment at the vault, spandrel, and invert decreases and the bending moment at the hance and arch foot increases. (3) The damage range of the tunnel lining structure continuously increases as corrosion progresses, with significant differences between the surrounding rock side and the free face side. Among the various parts of the lining, the vault exhibits the greatest damage depth and the widest cracks. (4) Water pressure significantly impacts the internal forces and crack width of the lining structure. As the water level drops, both the bending moment and the axial force diminish, while the damage range and crack width increase, with crack width increasing by 15.1% under low water pressure conditions. Full article

Multi-principal element alloys (MPEAs) exhibit distinct characteristics compared to conventional single-principal element-based metallic materials, primarily due to their unique design, resulting in intricate microstructural features. Currently, a comprehensive understanding of the fabrication processes, compositional design, and microstructural influence on the tribological and corrosion behavior of multi-component alloys remains limited. While the hardness of MPEAs generally correlates positively with wear resistance, with higher hardness typically associated with improved wear resistance and reduced wear rates, quantitative relationships between these properties are not well established. In this study, the Al₁₀Cr₁₇Fe₂₀NiV₄ alloy was selected as a model system. A homogeneous Al₁₀Cr₁₇Fe₂₀NiV₄ alloy was successfully synthesized via mechanical alloying followed by spark plasma sintering (SPS). To further investigate the correlation between hardness and wear rate, varying concentrations of alumina nanoparticles were incorporated into the alloy matrix as a reinforcing phase. The results revealed that the Al₁₀Cr₁₇Fe₂₀NiV₄ alloy exhibited a single-phase face-centered cubic (FCC) structure, which was maintained with the addition of alumina nanoparticles. The hardness of the Al₁₀Cr₁₇Fe₂₀NiV₄ alloy without nano-alumina was 727 HV, with a corresponding wear rate of 2.9 × 10⁻⁴ mm³·N⁻¹·m⁻¹. The incorporation of nano-alumina increased the hardness to 823 HV, and significantly reduced the wear rate to 1.6 × 10⁻⁴ mm³·N⁻¹·m⁻¹, representing a 45% reduction. The Al₂O₃ nanoparticles effectively mitigated alloy wear through crack passivation and matrix strengthening; however, excessive addition reversed this effect due to the agglomeration-induced brittleness and thermal mismatch. The quantitative relationship between hardness (HV) and wear rate (W) was determined as W = 2348 e^(−0.006HV). Such carefully bounded empirical relationships, as demonstrated in studies of cold-formed materials and dental enamel, remain valuable tools in applied research when accompanied by explicit scope limitations. Full article

This study investigates the influence of crack width on the time to chloride-induced corrosion initiation in reinforced concrete (RC) bridge decks, incorporating climate change projections through the year 2100 under IPCC scenarios (RCP2.6 and RCP8.5). A probabilistic modelling approach using Monte Carlo simulations (MCSs) was applied to assess corrosion initiation across a range of environmental and structural conditions, including normal and high-performance concrete (HPC), varying concrete cover depths, and the use of supplementary cementing materials (SCMs). The results indicate that increasing the crack width significantly accelerates chloride ingress, reducing the time to corrosion initiation by up to 41% compared with that under uncracked conditions. HPC demonstrated superior durability, delaying corrosion initiation by nearly twice as long as normal concrete under identical chloride exposure. Elevated temperatures projected under high-emission scenarios further reduce service life by increasing chloride diffusion rates. Polynomial regression models were developed to relate crack width and concrete cover to corrosion initiation time, offering practical tools for durability-based design and service life prediction. These findings highlight the importance of enhanced crack control, climate-adaptive material selection, and updated durability standards to improve the resilience of RC bridge infrastructure in the face of climate change. Full article

Condensate oil, due to its inherent physical and chemical properties, can accelerate the spontaneous combustion of corrosion products in storage tanks during transportation or storage, posing significant risks to the safety and sustainability of energy infrastructure. While prior research has primarily examined crude oil or reactive sulfur effects on tank corrosion, the mechanistic role of condensate oil in promoting corrosion product ignition remains unclear. To address this knowledge gap, this study investigates the impact of condensate oil on simulated tank corrosion product compounds (STCPCs) through a combination of microstructural analysis (XRD and SEM) and thermal behavior characterization (TG-DSC). The results reveal that condensate oil treatment markedly increases STCPC surface roughness, inducing crack formation and pore proliferation. These structural changes may enhance the adsorption of O₂ and condensate oil, thereby amplifying STCPC reactivity. Notably, condensate oil reduces the thermal stability of STCPC, increasing its spontaneous combustion propensity. DSC analysis further demonstrates that condensate oil introduces additional exothermic peaks during oxidative heating, releasing heat that accelerates STCPC ignition. Moreover, condensate oil lowers the apparent activation energy of STCPC by 1.44 kJ/mol and alters the dominant reaction mechanism. These insights advance the understanding of corrosion-induced spontaneous combustion and highlight critical sustainability challenges in petrochemical storage and transportation. By elucidating the hazards associated with condensate oil, this study provides actionable theoretical guidance for improving the safety and environmental sustainability of energy logistics. Future work should explore mitigation strategies, such as corrosion-resistant materials or optimized storage conditions, to align industrial practices with sustainable development goals. Full article

This study investigates the failure of a 750A dual-insulated pipeline, where cracks developed along the weld joints during heat supply resumption at the district heating facility. A comprehensive analysis was conducted through visual inspection, mechanical testing, microstructural characterization, finite element analysis (FEA), and electrochemical corrosion testing. The results indicate that cracks were generated in the heat-affected zone (HAZ), primarily caused by galvanic corrosion and thermal expansion-induced stress accumulation. Open circuit potential (OCP) measurements in a 3 M NaCl solution confirmed that the HAZ was anodic, leading to the most vulnerable position to corrosion. Furthermore, localized electrochemical tests were conducted for respective microstructural regions within the HAZ. The results reveal that coarse-grained HAZ exhibited the lowest corrosion potential, giving rise to preferential corrosion, promoting pit formation, and serving as initiation sites for stress concentration and crack propagation. FEA simulations demonstrate that pre-existing microvoids in the HAZ act as stress concentration sites, undergoing a localized stress exceeding 475 MPa. These findings emphasize the importance of controlling microstructural stability and mechanical integrity in welded pipelines, particularly in corrosive environments subjected to thermal stresses. Full article

Iron and iron-nickel alloy electrodeposits synthesized from sulfate-based electroplating baths were applied to a mild carbon steel substrate. Coated specimens were immersed in an oxygen-saturated, weak ammonium hydroxide solution (pH 9.5–10.0), and their corrosion performance was evaluated using electrochemical techniques. Galvanic and general corrosion behaviors were analyzed to assess the sacrificial protection provided by Fe and Fe-Ni coatings relative to uncoated steel. The influence of anode-to-cathode (A/C) surface area ratios (1:1, 10:1, and 100:1) on the occurrence of plating-induced surface cracks was also examined. Surface morphology and elemental composition of the deposits were characterized. Results of the study indicated that increasing the Ni²⁺/Fe²⁺ molar ratio of the electroplating bath from 0 to 0.167 led to (1) reduced surface porosity and cracking, (2) decreased galvanic corrosion rates between the electrodeposit and substrate, and (3) a progressive increase in the temperature dependence of the general corrosion rate between 20 °C and 60 °C. The development of Fe and Fe-Ni alloy electrodeposits as protective coatings is of particular interest in water-tube power boiler applications, where production of corrosion products must be controlled. Further research is needed to develop coatings that perform predictably under elevated pressures and temperatures typical of operating boiler environments. Full article