Corrosion and Protection of Metallic Materials, 2nd Edition

Topic Information

Dear Colleagues,

Following a previous Topic (“Corrosion and Protection of Metallic Materials”; https://www.mdpi.com/topics/corrosion_protection_metallic_materials), this new Topic is a collection of research contributions that explore the latest developments in the fields of both surface science and engineering in the areas of corrosion and degradation phenomena, and the most suitable procedures to protect the metallic materials.

Corrosion is the process of degradation or the failure of metallic materials in contact with the surrounding environment. Nowadays, the corrosion of metallic materials remains a technological and major economical challenge because the service lifetime of materials containing metallic components is often limited by the stability or durability of their metallic parts. The environmentally assisted degradation of metals and alloys in civil engineering structures has a detrimental effect on their mechanical and physical properties; this may lead to the collapse of infrastructure, such as the Morandi bridge in Genoa on 14 August 2018, which caused the death of 43 people, the corrosion of stainless steel tanks, such as the Bhopal gas disaster in India in 1984, or lead to environmental consequences, such as the Prestige Oil Spill in Galicia in 2002. The economic impact of metallic corrosion and protection is generally estimated to be about 4.9% of gross domestic product in well-developed countries. One estimate suggests that 40% of this cost could be easily saved with a superior understanding of the basic concepts of protection and material selection. On the other hand, ecological aspects are becoming increasingly crucial, e.g., environmental protocols that seek to reduce fuel consumption and the emission of greenhouse gases. For example, between all the metallic materials utilized for structural applications, magnesium (Mg) alloys have the lowest density; however, their low resistance to corrosion and wear remains one of the main limitations in the use of Mg alloys for transportation applications.

The published papers in this Topic may include (but are not limited to) the following:

• Electrochemical corrosion mechanisms
• High temperature oxidation
• Passivity and localized corrosion
• Anodic oxidation
• Tribocorrosion
• Atmospheric and marine corrosion
• Stress corrosion cracking
• Corrosion of steel in concrete
• Mechanisms and methods of corrosion control
• Surface and coating technology for corrosion protection
• Smart corrosion protection strategies
• Corrosion Inhibitors
• Cathodic protection

Dr. Sebastian Feliú Jr.
Dr. Federico R. García-Galván
Prof. Dr. Lucien Veleva
Topic Editors

Keywords

Participating Journals

Journal Name	Impact Factor	CiteScore	Launched Year	First Decision (median)	APC
Coatings coatings	2.9	5.0	2011	14.5 Days	CHF 2600
Corrosion and Materials Degradation cmd	-	4.5	2020	19.1 Days	CHF 1000
Materials materials	3.1	5.8	2008	13.9 Days	CHF 2600
Metals metals	2.6	4.9	2011	17.8 Days	CHF 2600
Molecules molecules	4.2	7.4	1996	15.1 Days	CHF 2700

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Published Papers (7 papers)

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17 pages, 4502 KiB  

Open AccessArticle

Formation Mechanism and Prevention of Cu Undercut Defects in the Photoresist Stripping Process of MoNb/Cu Stacked Electrodes

by Dan Liu, Liang Fang, Zhonghao Huang, Haibo Ruan, Wenxiang Chen, Jing Xiang, Fang Wu and Gaobin Liu

Materials 2024, 17(20), 5008; https://doi.org/10.3390/ma17205008 - 13 Oct 2024

Cited by 1 | Viewed by 1323

Abstract

The Cu undercut is a recently discovered new defect generated in the wet stripping process of MoNb/Cu gate stacked electrodes for thin-film transistors (TFTs). The formation mechanism and preventive strategy of this defect were identified and investigated in this paper. The impact of [...] Read more.

The Cu undercut is a recently discovered new defect generated in the wet stripping process of MoNb/Cu gate stacked electrodes for thin-film transistors (TFTs). The formation mechanism and preventive strategy of this defect were identified and investigated in this paper. The impact of stripper concentration and stripping times on the morphology and the corrosion potential (E_corr) of Cu and MoNb were studied. It is observed that the undercut is Cu tip-deficient, not the theoretical MoNb indentation, and the undercut becomes severer with the increase in stripping times. The in-depth mechanism analysis revealed that the abnormal Cu undercut was not ascribed to the galvanic corrosion between MoNb and Cu but to the local crevice corrosion caused by the corrosive medium intruding along the MoNb/Cu interface. Based on this newly found knowledge, three possible prevention schemes (MoNiTi (abbreviated as Mo technology development (MTD) layer/Cu), MoNb/Cu/MTD, and MoNb/Cu/MoNb) were proposed. The experimental validation shows that the Cu undercut can only be completely eliminated in the MoNb/Cu/MTD triple-stacked structure with the top MTD layer as a sacrificial anode. This work provides an effective and economical method to avoid the Cu undercut defect. The obtained results can help ensure TFT yield and improve the performance of TFT devices. Full article

(This article belongs to the Topic Corrosion and Protection of Metallic Materials, 2nd Edition)

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14 pages, 4573 KiB  

Open AccessFeature PaperArticle

Catechol/m-Phenylenediamine Modified Sol–Gel Coating with Enhanced Long-Lasting Anticorrosion Performance on 3003 Al Alloy

by Keqi Huang, Xin Huang, Liyan Wang, Sifan Tu, Zi Yang, Honglei Guo, Bing Lei, Zhiyuan Feng and Guozhe Meng

Molecules 2024, 29(19), 4644; https://doi.org/10.3390/molecules29194644 - 30 Sep 2024

Viewed by 1366

Abstract

Aluminum alloys, characterized by their low density and high mechanical strength, are widely applied in the manufacturing sector. However, the application of aluminum alloys in extreme environments presents severe corrosion challenges. Sol–gel organic coating techniques have garnered significant attention due to their excellent [...] Read more.

Aluminum alloys, characterized by their low density and high mechanical strength, are widely applied in the manufacturing sector. However, the application of aluminum alloys in extreme environments presents severe corrosion challenges. Sol–gel organic coating techniques have garnered significant attention due to their excellent stability, barrier properties, and cost-effectiveness, as well as their simpler processing. Nevertheless, conventional sol–gel coatings are unable to withstand the corrosive effects of high-chloride and high-halide ion environments such as marine conditions, owing to their inherent structural defects. Therefore, this study proposes the utilization of a simple method to synthesize catechol (CA) and meta-phenylenediamine (MPD)-derived catecholamine compounds to modify sol–gel coatings. Surface characteristics of the modified coatings were analyzed using Fourier-transform infrared spectroscopy (FT-IR), ultraviolet-visible (UV-Vis) spectroscopy, scanning electron microscopy (SEM), and X-ray photoelectron spectroscopy (XPS). The thickness of the modified coating was approximately 6.8 μm. The CA/MPD-modified substance effectively densifies the sol–gel coating, enhancing its corrosion protection performance. A 3.5 wt% NaCl solution was used to simulate a marine environment, and electrochemical impedance spectroscopy (EIS) was conducted using an electrochemical workstation to evaluate the coating’s protective properties over a long-term period. The results indicate that the modified coating provides protection for 3003 aluminum alloy for a minimum of 30 days under corrosive conditions, outperforming unmodified sol–gel coatings in terms of corrosion resistance. Full article

(This article belongs to the Topic Corrosion and Protection of Metallic Materials, 2nd Edition)

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12 pages, 3140 KiB  

Open AccessArticle

Study of Intergranular Corrosion Behaviors of Mn-Increased 5083 Al Alloy with Controlled Precipitation States of Al₆Mn Formed during Homogenization Annealing

by Peng Zhang, Yue Wang, Pizhi Zhao, Zhengyi Jiang, Yinbao Tian, Yang Yang and Jian Han

Metals 2024, 14(9), 1053; https://doi.org/10.3390/met14091053 - 15 Sep 2024

Cited by 1 | Viewed by 835

Abstract

In this study, as a vital part of the production of Mn-increased 5083 Al alloy, i.e., homogenization annealing before hot rolling, the target states of key Al₆Mn precipitation, including the dispersed, initial coarsening and intensive coarsening states, were designed, and the [...] Read more.

In this study, as a vital part of the production of Mn-increased 5083 Al alloy, i.e., homogenization annealing before hot rolling, the target states of key Al₆Mn precipitation, including the dispersed, initial coarsening and intensive coarsening states, were designed, and the corresponding precipitates formed via the control of the temperature and holding time in the annealing process. By means of metallographic corrosion and nitric acid mass loss tests (NAMLT) for assessing the intergranular corrosion (IGC) resistance, temperatures ranging from 175 °C to 225 °C were determined to induce a transition from sensitization to stabilization for this innovative 5083. At a temperature of 175 °C for a duration of up to 24 h (2 h, 4 h, 8 h, 16 h, 24 h), the results show that when the soak time is 24 h, the sample with initially coarsened Al₆Mn phases has a lower degree of sensitization (DOS) compared to the samples with Al₆Mn phases in both the dispersed and intensive coarsening states, and its NAMLT is reduced by 11% and 15%, respectively. Subsequently, transmission electron microscopy (TEM) analysis has investigated that for the sample with the best IGC resistance, i.e., that with initially coarsened Al₆Mn phases, plate-like Al₆Mn particles (200~500 nm) can act as heterogenous nucleation sites for β phases, driving their preferential precipitation on Al₆Mn particles and resisting their precipitation along grain boundaries, ultimately improving the IGC resistance of 5083 Al alloy after homogenization annealing. Full article

(This article belongs to the Topic Corrosion and Protection of Metallic Materials, 2nd Edition)

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41 pages, 19874 KiB  

Open AccessReview

Green Corrosion Inhibitors for Metal and Alloys Protection in Contact with Aqueous Saline

by Felipe M. Galleguillos Madrid, Alvaro Soliz, Luis Cáceres, Markus Bergendahl, Susana Leiva-Guajardo, Carlos Portillo, Douglas Olivares, Norman Toro, Victor Jimenez-Arevalo and Maritza Páez

Materials 2024, 17(16), 3996; https://doi.org/10.3390/ma17163996 - 11 Aug 2024

Cited by 6 | Viewed by 6308

Abstract

Corrosion is an inevitable and persistent issue that affects various metallic infrastructures, leading to significant economic losses and safety concerns, particularly in areas near or in contact with saline solutions such as seawater. Green corrosion inhibitors are compounds derived from natural sources that [...] Read more.

Corrosion is an inevitable and persistent issue that affects various metallic infrastructures, leading to significant economic losses and safety concerns, particularly in areas near or in contact with saline solutions such as seawater. Green corrosion inhibitors are compounds derived from natural sources that are biodegradable in various environments, offering a promising alternative to their conventional counterparts. Despite their potential, green corrosion inhibitors still face several limitations and challenges when exposed to NaCl environments. This comprehensive review delves into these limitations and associated challenges, shedding light on the progress made in addressing these issues and potential future developments as tools in corrosion management. Explicitly the following aspects are covered: (1) attributes of corrosion inhibitors, (2) general corrosion mechanism, (3) mechanism of corrosion inhibition in NaCl, (4) typical electrochemical and surface characterization techniques, (5) theoretical simulations by Density Functional Theory, and (6) corrosion testing standards and general guidelines for corrosion inhibitor selection. This review is expected to advance the knowledge of green corrosion inhibitors and promote further research and applications. Full article

(This article belongs to the Topic Corrosion and Protection of Metallic Materials, 2nd Edition)

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13 pages, 18105 KiB  

Open AccessArticle

Al₂O₃ Coatings for Protection of Stainless Steel 316L against Corrosion in Zn-Al and Zn-Al-Mg

by Giovanni Paolo Alparone, David Penney, James Sullivan, James Edy and Christopher Mills

Coatings 2024, 14(5), 606; https://doi.org/10.3390/coatings14050606 - 11 May 2024

Cited by 3 | Viewed by 2021

Abstract

The production and quality of automotive-grade galvanised steel are affected by the limited service life of the pot roll bearings used in continuous galvanising lines. The journal bearings are subjected to severe degradation as they react with the molten Zn bath, and coatings [...] Read more.

The production and quality of automotive-grade galvanised steel are affected by the limited service life of the pot roll bearings used in continuous galvanising lines. The journal bearings are subjected to severe degradation as they react with the molten Zn bath, and coatings can provide corrosion protection to the bearing materials. This research investigates the performance of Al₂O₃ coatings applied via the HVOF thermal spray process to stainless steel 316L substrates. Immersion tests were conducted in baths of different compositions, namely GI (Zn-0.3 wt.% Al) and ZMA (Zn-1.5 wt.% Al-1.5 wt.% Mg). Material characterisation after testing showed evidence of coating degradation after 1 week, as the coating tended to crack and detach from the substrate, allowing the molten Zn to attack the underlying steel. The coefficient of thermal expansion of Al₂O₃ and steel was measured, and a difference of 13 × 10⁻⁶ K⁻¹ was found, leading to the development of cracks in the coatings. Zn penetration through cracks was determined to be the main failure mechanism of the Al₂O₃ coatings, which otherwise remained inert to Zn-Al. Conversely, the coatings immersed in Zn-Al-Mg reacted with the Mg in the molten metal bath, showing that changing bath composition affected the performance of the coatings in molten Zn alloy. Full article

(This article belongs to the Topic Corrosion and Protection of Metallic Materials, 2nd Edition)

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18 pages, 3882 KiB  

Open AccessArticle

Effect of a Hybrid Pumice–Portland Cement Extract on Corrosion Activity of Stainless Steel SS304 and Carbon Mild Steel A36

by David Bonfil, Lucien Veleva and Jose Ivan Escalante-Garcia

Materials 2024, 17(10), 2255; https://doi.org/10.3390/ma17102255 - 10 May 2024

Cited by 2 | Viewed by 1281

Abstract

The change in the corrosion activities of SS304 and the carbon steel A36 were studied during their exposure for 30 days to hybrid pumice-Portland cement extract (CE), to simulate the concrete–pore environment. The ionic composition and the initial pH (12.99) of the CE [...] Read more.

The change in the corrosion activities of SS304 and the carbon steel A36 were studied during their exposure for 30 days to hybrid pumice-Portland cement extract (CE), to simulate the concrete–pore environment. The ionic composition and the initial pH (12.99) of the CE were influenced by the reduction of Portland cement (PC) content, volcanic pumice oxides and alkaline activators. Because of the air ${\mathrm{CO}}_{2 }$ dissolution, the pH decreased and maintained a constant value ≈ 9.10 (established dynamic ionic equilibrium). The CE promoted the passivation of both steels and their free corrosion potential (OCP) reached positive values. On the surfaces, Fe and Cr oxides were formed, according to the nature of the steel. Over the time of exposure, the presence of chloride ions in the pumice caused a localized pitting attack, and for carbon steel, this fact may indicate an intermediate risk of corrosion. The chloride effect was retarded by the accumulation of ${{\mathrm{SO}}_4}^{2-}$ ions at the steel surfaces. Based on electrochemical impedance (EIS), the polarization resistance (Rp) and the thickness of the passive layers were calculated. Their values were compared with those previously reported for the steels exposed to CEs of Portland and supersulfated cements, and the hybrid cement was considered as a PC “green” alternative. Full article

(This article belongs to the Topic Corrosion and Protection of Metallic Materials, 2nd Edition)

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12 pages, 8481 KiB  

Open AccessArticle

Influence of Calcareous Deposits on Hydrogen Embrittlement Susceptibility of Q460 Steel

by Xilin Xiong, Haichun Yang, Tongqian Chen, Na Zhang and Tong Niu

Materials 2024, 17(5), 1110; https://doi.org/10.3390/ma17051110 - 28 Feb 2024

Viewed by 1139

Abstract

Cathodic protection is widely used to protect structural steel from corrosion in marine environments. However, an inappropriate cathodic potential may lead to hydrogen embrittlement (HE). Therefore, this study investigates the relationship between cathodic protection potential, structure and composition of calcareous deposits, and hydrogen [...] Read more.

Cathodic protection is widely used to protect structural steel from corrosion in marine environments. However, an inappropriate cathodic potential may lead to hydrogen embrittlement (HE). Therefore, this study investigates the relationship between cathodic protection potential, structure and composition of calcareous deposits, and hydrogen embrittlement susceptibility of Q460 steel. The slow strain rate test results and fracture analysis reveal that Q460 steel had the smallest HE susceptibility when covered with the calcareous deposits formed under −1.1 V_SCE. The deposits have a relatively thin calcium-rich inner layer and a condensed magnesium-rich outer layer, which can significantly inhibit hydrogen entry. A sustained deposition reaction during slow strain rate testing (SSRT) in artificial seawater can also decrease the HE susceptibility of Q460 steel. Full article

(This article belongs to the Topic Corrosion and Protection of Metallic Materials, 2nd Edition)

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