Search Results (390)

The self-lubricating MoS₂ coating is highly susceptible to degradation in marine environments due to oxidative corrosion. To expand its application in high-humidity and high-salt-fog conditions, this study mixed W with MoS₂ and prepared W-MoS₂ self-lubricating coatings on the surface of CrNi3MoVA steel by electrospark deposition technology. The electrochemical corrosion behaviors of these coatings, with varying W/MoS₂ mass ratios, were examined using an electrochemical workstation in a 3.5 wt.% NaCl solution. The findings indicated that as the MoS₂ content increased, the low-frequency impedance modulus (LIMs) of the W-MoS₂ coating initially rose and then declined. At a MoS₂ content of 20 wt.%, the coating exhibited the highest LIM and the greatest corrosion resistance. In comparison to the CrNi3MoVA steel substrate, the corrosion current density was reduced by 67.4%, a result attributed to the coating’s dense microstructure and improved charge transfer resistance, thereby demonstrating its optimal protective performance. These results provide a laboratory electrochemical basis for designing corrosion-resistant self-lubricating ESD coatings for steel components exposed to chloride-containing environments; however, long-term immersion, cyclic salt-spray, field-exposure, and quantitative adhesion tests are still required before direct long-term marine-service durability can be confirmed. Full article

Organosilane interlayers are widely used to improve the adhesion and corrosion resistance of multilayer protective coating systems. In this work, a nitrile-functional organosilane, 3-[(3-(triethoxysilyl)propyl)amino]propanenitrile (AN), was investigated as a precursor for thin protective coatings on St20 steel and as an adhesion-promoting interlayer for acrylic paint coatings. The coating formation process was optimized, and the structure, morphology, surface properties, adhesion performance, and corrosion resistance of the resulting coatings were comprehensively characterized using spectroscopic, microscopic, and electrochemical techniques. The results demonstrated the formation of a continuous and homogeneous organosiloxane coating with an average thickness of 84 ± 5 nm. Pull-off adhesion tests showed that the AN interlayer provided the highest adhesion strength (0.85 MPa) among the investigated coating systems. Electrochemical impedance spectroscopy and potentiodynamic polarization measurements confirmed a significant improvement in the barrier properties and corrosion resistance of the coated steel in both model and formation water electrolytes. Salt spray testing further demonstrated a more than fivefold reduction in metal mass loss and a substantial decrease in corrosion propagation from an artificial defect compared with the paint-only system. These findings demonstrate that the AN coating is a promising adhesion-promoting organosilane interlayer capable of enhancing both the adhesion and corrosion protection of multilayer coating systems. Full article

The formation of phosphate conversion coatings on St20 low-carbon steel was studied in order to evaluate the effect of organic accelerators on coating formation and protective performance. The influence of pH, temperature, treatment time, and stirring rate on coating formation was studied by gravimetry and SEM-EDS, the influence of accelerators was studied by Raman spectroscopy, salt spray testing, polarization measurements, EIS, and dynamic LPR monitoring. Efficient coating formation was achieved at an initial pH of 3.0, elevated temperature, and intensive stirring; the process showed diffusion-controlled behavior with an apparent activation energy of 28 kJ/mol. Sodium nitrite accelerated coating formation but did not increase the limiting coating mass. Among the organic additives, catechol provided the most pronounced improvement in corrosion resistance, which was attributed to lower effective porosity and possible incorporation of catechol-derived oxidized fragments into the phosphate layer. The catechol-modified coating also improved electrochemical resistance and did not impair the adhesion of subsequent acrylic paint. These results indicate that catechol is a promising organic modifier for zinc phosphate intermediate pretreatment layers. Full article

Chromate-free conversion coatings are increasingly investigated as environmentally acceptable alternatives to conventional chromate conversion coatings for corrosion protection of aluminum alloys. In the present study, the electrochemical behaviour and long-term corrosion stability of several commercial conversion coating systems based on trivalent chromium (TCP), zirconium (ZrCC) and zirconium/titanium (Zr/TiCC) were systematically evaluated on AA3003 aluminum alloy and compared to chromate conversion coating (CCC) CR614. Three TCP coatings (ST650, MC1300 and B30002), two ZrCC (MC1700 and MC160/161), and one Zr/TiCC (B2040) were investigated. Coatings were prepared at pre-selected pH and concentration, but at varying conversion times. The protective performance of the coating was then tested across various exposure conditions using potentiodynamic polarization measurements: (i) after 24 h of exposure to air, (ii) after 24 h of immersion in 3.5 wt.% NaCl solution and (iii) simulated acid rain solution, and (iv) after exposure in a salt spray chamber for 500 h. The protective performance strongly depended on both the conversion conditions and the exposure environment. The optimal conversion times ranged between 40 s and 18 min, depending on the coating type. Differences between the investigated systems remained relatively limited when investigated after exposure to air and immersion in the simulated acid rain solution. However, in chloride-containing environments, substantially greater differentiation between the coatings was observed. Among the investigated systems, TCP coatings exhibited the most favourable overall corrosion performance, particularly after prolonged salt spray exposure, where ST650 and B30002 polarization resistance values were approximately 8800 and 5300 kΩ cm², respectively, together with corrosion current densities as low as 0.0004 and 0.001 μA cm⁻². ZrCC systems MC1700 and MC160/161 also provided significant corrosion protection, achieving polarization resistance values around 2700 and 2400 kΩ cm² after 500 h of salt spray exposure, whereas the Zr/TiCC coating B2040 exhibited poorer long-term performance. The results further demonstrated that prolonged salt spray exposure provides considerably more realistic evaluation of long-term coating protectiveness than short-term electrochemical measurements alone. Overall, optimized TCP and ZrCC systems provided corrosion protection under chloride-containing conditions comparable to or superior to the investigated conventional chromate conversion coating CR614 deposited on AA3003 alloy. Full article

High-temperature corrosion severely impairs the service life of boiler heating tubes and threatens the safe and economical operation of thermal power units. With diversified fuels (coal, biomass and refuse-derived fuels) and continuously elevated operating parameters (steam temperature exceeding 620 °C for ultra-supercritical units), boiler heating surfaces are exposed to increasingly complex corrosive environments. High-temperature oxidation, sulfidation, chlorination, molten salt hot corrosion and deposit-induced multi-factor coupled corrosion coexist and exacerbate each other. This paper adopts a four-dimensional analytical framework of “mechanisms–technologies–materials–evaluation” to systematically summarize relevant research progress. From the perspective of corrosion mechanisms, the evolution of understandings from single high-temperature oxidation to multi-factor coupled corrosion is reviewed. In terms of surface coating technologies, seven mainstream processes including HVOF/HVAF spraying, plasma spraying, cold spraying, laser cladding and weld overlay are compared in terms of preparation characteristics and engineering applicability. For coating materials, twelve material systems such as NiCr alloys, MCrAlY, cermets, Fe-based amorphous/nanocrystalline alloys and high-entropy alloys are evaluated for their corrosion resistance under diverse service conditions. As for monitoring and evaluation, this work introduces full-range corrosion management technologies covering electrochemical monitoring, non-destructive testing, numerical simulation and life assessment. Finally, the paper discusses the application prospects of gradient coating design, AI-assisted material screening and digital twin technology, and points out key research gaps including long-term service reliability verification of coatings and quantitative prediction models for multi-factor coupled corrosion. Full article

Neutral salt spray tests were conducted on assemblies comprising H59 brass and either electrogalvanized or hot-dip galvanized bolts. The polarization curves, electrochemical impedance spectroscopy (EIS), corrosion morphology, elemental distribution, and corrosion product composition of the H59 brass were systematically characterized. The results demonstrated that upon coupling with galvanized bolts, the formation of a protective Cu₂O film on the H59 brass is significantly weakened, leading to accelerated corrosion. After coupling with electrogalvanized bolts, the i_corr reached a maximum value of 0.21 mA/cm². A corrosion layer predominantly composed of ZnO formed on the sample surface with a thickness of approximately 13 μm, and no penetration or enrichment of Cl was observed in the matrix. More seriously, when the brass was assembled with hot-dip galvanized bolts, the i_corr never dropped below 0.2 mA/cm². A porous and complex Zn-Cu-O-Cl mixed corrosion layer developed on its surface. This loose structure allows Cl⁻ to reach a depth of 55 μm into the matrix and continue causing corrosion. The mechanisms underlying the different corrosion behaviors of H59 brass caused by different galvanizing bolt processes require further investigation. Full article

Two-dimensional nanomaterials exhibit excellent physical barrier properties, which can effectively enhance the corrosion resistance of waterborne epoxy coatings. Herein, we report a facile strategy for preparing a multi-component synergistic anti-corrosion coating, where two-dimensional graphitic carbon nitride (g-C₃N₄) and high-entropy layered double hydroxides (HE-LDHs) are integrated into a waterborne epoxy matrix via magnetic-ultrasonic synergistic dispersion. The resulting HE-LDHs/g-C₃N₄-epoxy coating exhibits exceptional corrosion resistance for Q235 steel. Electrochemical impedance spectroscopy (EIS) and polarization curves showed that when the mass ratio of g-C₃N₄ to HE-LDHs was 1:1, the resulting coating (PCN-LDH-1.0) maintained a coating resistance of 5.48 × 10⁵ Ω·m² after 28 days of immersion in 3.5% NaCl solution, which was five orders of magnitude higher than that of pure waterborne epoxy coating. Meanwhile, the corrosion current density was reduced by four orders of magnitude, from 5.83 × 10⁻¹ A·m⁻² to 1.68 × 10⁻⁵ A·m⁻². After 30 days of salt spray testing, no rust, blistering or adhesion loss was observed on the coating surface. These enhanced performances by addition of g-C₃N₄ and HE-LDHs were attributed to the combined effects of the tortuous diffusion pathways. Additionally, the PCN-LDH-1.0 coating retained excellent mechanical properties, including a pencil hardness of 3H and the highest adhesion grade. This study provides a facile method for preparing high-performance waterborne anti-corrosion coatings. Full article

Grounding connectors critically influence the safety and long-term reliability of earthing systems through coupled electro-thermal, mechanical, and corrosion behaviors, yet no standardized quantitative framework exists for jointly evaluating these performance dimensions across diverse deployment scenarios. This study introduces a unified multi-criteria evaluation framework applied to six grounding connector configurations spanning four alloy families and three joining technologies. Electro-thermal response was characterized by coupled finite element simulations (0–100 A), mechanical reliability by quasi-static tensile testing (n = 10 per configuration), and corrosion durability by accelerated salt-spray exposure with image-based corroded area fraction quantification. Performance metrics were normalized and aggregated using equal-weight, Analytic Hierarchy Process, and Shannon entropy weighting schemes, with the Technique for Order of Preference by Similarity to Ideal Solution applied for multi-scenario ranking. One-way analysis of variance confirmed statistically significant effects of connector type on tensile performance (F(5, 54) = 3154.90, p < 0.001). The exothermic welded joint achieved the highest mean ultimate tensile load (61.5 ± 1.5 kN), while copper mechanical connectors exhibited the lowest steady-state temperature rise (~2 K above ambient at 100 A). Compression-crimped connectors ranked first under both equal and Analytic Hierarchy Process weighting (closeness coefficients 0.737 and 0.807, respectively), while stainless steel connectors ranked first under corrosion-critical deployment scenarios. Scenario-weighted analyses demonstrate that the optimal material–process combination shifts with environmental severity, current duty, and mechanical demand, providing a reproducible, evidence-based basis for context-dependent connector specification. Full article

Zn–Al–Mg coatings are widely used because of their excellent corrosion resistance, in which α-Al dendrites play a crucial role. This study investigated the selective corrosion behavior of α-Al dendrites in a hot-dip Zn–14Al–0.5Mg coating, including the as-received state, after 20 months of indoor exposure, and under salt spray corrosion. The coating consisted of α-Al dendrites, η-Zn phase, and a small amount of eutectic Zn–Al–Mg. Minor black spots were observed on the initial surface. After indoor storage, extensive corrosion occurred in α-Al dendritic regions, while the remaining η-Zn became protruding. Corrosion propagated preferentially along the Al-rich dendritic into the coating, reaching the substrate, rather than progressing layer by layer. Electrochemical testing results indicated spatial heterogeneity in the corrosion resistance of the coating surface after long-term indoor storage. Cl⁻ could more readily penetrate into the corroded dendrites, accelerating corrosion and shifting the mode from lateral propagation to vertical penetration. The selective corrosion was attributed to dendrite segregation and surface oxide film breakdown. Controlling dendrite morphology is essential for improving coating performance. Full article

The self-formed rust layer is significant for weathering steels because their corrosion resistance in a marine atmospheric environment mainly relies on the stability, uniformity and compactness of the rust layer. However, the initial stage of rust formation is vulnerable and prone to being disturbed by the external environment, compromising the protectiveness of the rust layer at a later stage. Therefore, weathering steel often requires the application of rust stabilization techniques. This study has developed a waterborne polyurethane (WPU)-based coating incorporated with mesoporous/hollow SiO₂ nanoparticles, acting as the primary components for the construction of pathways for gaseous H₂O and O₂, as well as for Cl⁻ dissolved in moisture, while blocking liquid water. Salt spray was applied to accelerate the rust formation process, and rust can form beneath the coating, which provides shelter for rust formation against the external environment. Hexamethyldisilazane (HMDS) was applied to further hydrophobize the nanoparticles, and a hydrophobic surface with self-cleaning properties was achieved. The hydrophobized and non-hydrophobized coatings with different thicknesses (10–80 µm) were systematically compared: the morphology of the rust layer and coating surface after salt spray was investigated, the ability of the rust layer to inhibit chloride ingress was compared, and the electrochemical behaviors were analyzed. This study presents a new strategy for weathering steel rust stabilization that features maneuverability, environmental friendliness and low cost. Full article

Reported herein is tantalum (Ta)-based film, including TaN, TaO_x, composite TaO_xN_γ, multilayered TaN/TaO_x-(5:5) and TaN/TaO_x-(10:10), prepared by atomic layer deposition (ALD) technology via adjusting the sub-cycle of TaN and TaO_x films. The influence of different growth parameters on microstructure, crystal form, chemical bonding state and corrosion resistance of Ta-based films was systematically investigated. Representative results include the following: (1) The surface of the Ta-based films prepared by ALD is continuous, dense and smooth, and the root mean square roughness (Rq) of those are TaN: 0.74 nm, TaO_x: 0.69 nm, TaO_xN_γ: 0.55 nm, TaN/TaO_x-5:5: 0.56 nm and TaN/TaO_x-10:10: 0.77 nm. (2) The TaN film presents a polycrystalline structure with good crystallinity, while the incorporation of oxygen significantly inhibits the crystallinity of the film. (3) Electrochemical tests in 3.5 wt.% NaCl solution and neutral salt spray experiments show that ALD deposition of Ta-based films can significantly improve the corrosion resistance of carbon steel substrates. The order of corrosion resistance of different films is TaO_xN_γ film > TaN/TaO_x multilayer film > TaN film. Among them, the TaO_xN_γ film exhibited the most excellent corrosion resistance, with a charge transfer resistance (R_ct) as high as 24.75 Ω·cm² and a corrosion current density (I_corr) as low as 1.20 × 10⁻⁶ A/cm², and no obvious rusting phenomenon was observed on the surface of that film after the 2 h neutral salt spray test. Full article

In this study, C/N-containing Fe₃O₄ oxide films over an inner nitride layer were fabricated on 45# steel by oxynitriding to improve corrosion resistance in chloride-containing environments. The films exhibited a dense polyhedral structure, with nanoscale Fe₃O₄ precipitates at grain boundaries. Nitrogen and carbon were uniformly distributed within the oxide grains, inducing lattice expansion and modifying the Fe-O bonding environment. First-principles calculations based on C/N substitution models suggested that C/N incorporation may increase the unit cell volume, strengthen lattice bonding, and enhance the theoretical hardness of Fe₃O₄. The optimally doped films exhibited outstanding corrosion resistance, with a corrosion potential of 0.115 V_SCE, a corrosion current density of 3.16 × 10⁻¹⁰ A/cm² in 3.5 wt.% NaCl solution, and a corrosion-free lifetime of up to 3600 h in neutral salt spray testing. This superior performance is attributed to the synergistic effects of the compact single-phase magnetite layer, grain boundary precipitates, and modified electronic structure, which collectively inhibit chloride ingress and convert localized electrochemical attack into uniform corrosion. The experimental results are consistent with first-principles predictions, which clarified the mechanism of nitrogen doping in material corrosion protection from a mechanistic perspective. Full article

Hot-press forming (HPF) steel is a promising lightweight material for automotive applications but suffers from oxidation and reduced corrosion due to high-temperature processing. Aluminized coatings, particularly Al-10Si, are widely used to mitigate this issue. However, HPF heat treatment can create brittle alloy layers with cracks, compromising retention and increasing corrosion risk. This study investigated the effects of Sr addition on the microstructure and corrosion resistance of Al-Si-coated HPF steel. Al-Si and Al-Si-Sr coatings were applied to steel substrates and subjected to heat treatment to produce heat-treated (HT) Al-Si and HT Al-Si-Sr samples. Sr addition refined and spheroidized eutectic Si particles, improved coating homogeneity, and mitigated vertical crack formation in the Al-Fe-Si intermetallic layer. The resulting dense, crack-free alloy layer effectively shielded the Fe substrate from corrosion. After heat treatment, Sr facilitated the formation of a fine lamellar microstructure and a dense, continuous oxide film, enhancing coating retention and sustaining barrier protection. These improvements significantly delayed corrosion propagation into the Fe substrate. Corrosion resistance was evaluated using salt-spray tests (ASTM B117), potentiodynamic polarization, and electrochemical impedance spectroscopy in 3.5 wt.% NaCl solutions. Microstructural analyses revealed that even minimal Sr content (0.05%) considerably enhanced the performance of Al-Si coatings, demonstrating industrial applicability. This study highlights the potential of Sr-added Al-Si coatings in addressing the demand for lightweight and corrosion-resistant materials in the automotive industry, offering a viable solution for high-performance and environmentally sustainable applications. Full article

This study investigated the degradation behavior of a polyurethane acrylate coating/Q345B steel system under the coastal atmospheric conditions of Wenchang, Hainan, and evaluated the correlation between indoor accelerated tests and outdoor exposure. Outdoor exposure tests, single-factor accelerated tests (UV irradiation and neutral salt spray), and a multi-factor cyclic accelerated test combining UV, salt spray, humidity, and thermal cycling were conducted. Coating degradation was characterized by morphological observation, gloss measurement, adhesion testing, and electrochemical impedance spectroscopy. The results showed that after 8 months of outdoor exposure, localized rust spots, blistering, and under-film corrosion appeared on the coating surface. The gloss loss rate reached 15.72% after 3 months, while adhesion decreased from 5.83 MPa to 2.39 MPa during prolonged exposure. UV irradiation mainly affected gloss degradation, whereas corrosive media penetration played a dominant role in adhesion loss and electrochemical deterioration. Compared with single-factor tests, the multi-factor cyclic accelerated test exhibited the highest correlation with outdoor exposure. The corresponding correlation coefficients for gloss loss, adhesion, and low-frequency impedance modulus were 0.9764, 0.9988, and 0.9929, respectively, while the gray relational coefficients reached 0.8334, 0.8467, and 0.7977. These results demonstrate that the multi-factor cyclic accelerated test more accurately reproduces the degradation behavior and failure characteristics observed in the coastal atmosphere of Hainan. The proposed method provides a practical approach for indoor–outdoor correlation analysis and durability evaluation of protective coatings in marine atmospheric environments. Full article

Ultrasonic impact treatment (UIT) is widely employed as a post-weld treatment to enhance the fatigue performance of welded joints through the introduction of surface plastic deformation and compressive residual stresses. While its beneficial effect on fatigue life when applied at an earlier stage is well established, the influence of UIT on aged structures remains controversial in the literature. This study investigates the effect of UIT on the corrosion performance of S355 steel welded T-joints after accelerated corrosion-induced aging. As-welded (AW) and UIT-treated T-joints were subjected to salt spray exposure, followed by detailed microstructural and surface analyses to assess corrosion morphology and damage evolution. The results show that UIT induces significant surface plastic deformation and microstructural refinement in the weld toe region without promoting preferential corrosion aging or accelerated degradation. The aging behavior of UIT-treated joints, following accelerated environmental exposure, is comparable to that of the AW condition, with corrosion rates decreasing from 3.27 and 3.28 mm/year at 42 days to 1.32 and 1.26 mm/year at 126 days for AW and UIT specimens, respectively. These results indicate that the compressive residual stresses and surface modifications introduced by UIT do not adversely affect material durability. These findings clarify the role of UIT under such exposure conditions and demonstrate that UIT can be applied as a post-weld treatment to improve fatigue properties without compromising the long-term performance of structural steel welded joints. Full article