Materials for Corrosion Protection

Topic Information

Dear Colleagues,

Corrosion has been and remains a challenge in industrial processes. The cost of corrosion, linked to prevention and repair of damage, is estimated at around 3.4% of the global GDP, but around 15% to 35% of this cost could be spared via mitigation methods.

The main avenue for improving corrosion resistance is the protection of materials, either through the selection of intrinsically corrosion-resistant materials or the modification of their surface properties with various treatments and coatings.

We are inviting submissions to a topic related to materials for corrosion protection, to present cutting-edge materials and surface treatments aiming at reducing corrosion in various environments and applications.

Topics of interest for publication are:

• Corrosion-resistant metals and alloys
• Metal substitutes for highly corrosive environments
• Conversion coatings and anodization
• Barrier coatings (metallic or non-metallic)
• Sacrificial coatings
• Self-healing coatings
• Sol–gel coatings, polymer coatings, and paints
• Corrosion-inhibitor-containing coatings
• Complex coating systems
• Atmospheric-corrosion-resistant materials
• High-temperature oxidation-resistant materials

Dr. Nicolas Mary
Dr. Véronique Vitry
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
Materials materials	3.1	5.8	2008	13.9 Days	CHF 2600
Metals metals	2.6	4.9	2011	17.8 Days	CHF 2600
Physchem physchem	-	1.4	2021	24.2 Days	CHF 1000
Polymers polymers	4.7	8.0	2009	14.5 Days	CHF 2700

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Published Papers (9 papers)

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21 pages, 2168 KiB  

Open AccessReview

Corrosion by Polythionic Acid in the Oil and Gas Sector: A Brief Overview

by Mohammadtaghi Vakili, Petr Koutník and Jan Kohout

Materials 2023, 16(21), 7043; https://doi.org/10.3390/ma16217043 - 5 Nov 2023

Cited by 2 | Viewed by 3292

Abstract

Polythionic acid (PTA) corrosion is a significant challenge in the refinery industry, leading to equipment degradation, safety risks, and costly maintenance. This paper comprehensively investigates the origin, progression, mechanism, and impact of PTA corrosion on various components within refinery operations. Special attention is [...] Read more.

Polythionic acid (PTA) corrosion is a significant challenge in the refinery industry, leading to equipment degradation, safety risks, and costly maintenance. This paper comprehensively investigates the origin, progression, mechanism, and impact of PTA corrosion on various components within refinery operations. Special attention is afforded to the susceptibility of austenitic stainless steels and nickel-based alloys to PTA corrosion and the key factors influencing its occurrence. Practical strategies and methods for mitigating and preventing PTA corrosion are also explored. This paper underscores the importance of understanding PTA corrosion and implementing proactive measures to safeguard the integrity and efficiency of refinery infrastructure. Full article

(This article belongs to the Topic Materials for Corrosion Protection)

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16 pages, 9946 KiB  

Open AccessArticle

Modification of Electrochemical Exfoliation of Graphene Oxide with Dopamine and Tannic to Enhance Anticorrosion Performance of Epoxy Coatings

by Suyun Liu, Hu Liu, Ningning Shao and Zhijun Dong

Coatings 2023, 13(10), 1809; https://doi.org/10.3390/coatings13101809 - 22 Oct 2023

Cited by 2 | Viewed by 1741

Abstract

Graphene oxide (EGO) was prepared via an electrochemical exfoliation method and modified with dopamine and tannic acid, and it was then incorporated into epoxy resins to enhance their barrier, self-healing and anticorrosion performances. The morphologies, structures and compositions of the HGO (GO prepared [...] Read more.

Graphene oxide (EGO) was prepared via an electrochemical exfoliation method and modified with dopamine and tannic acid, and it was then incorporated into epoxy resins to enhance their barrier, self-healing and anticorrosion performances. The morphologies, structures and compositions of the HGO (GO prepared via Hummers’ method), EGO and MGO (modified EGO) were characterized via SEM, TEM, AFM, Raman spectroscopy and XPS. The protective performances of the epoxy varnish coatings, EGO/epoxy coatings and MGO/epoxy coatings with different contents of MGO were evaluated via EIS measurements, and the role played by MGO on the coating defects was determined via LEIS and salt spray tests on the scratched coatings in a 3.5% NaCl solution. The results show that the dopamine and tannic were successfully grafted onto the EGO surface via π–π interactions and chemical bonding, and that the dispersibility of the MGO in the epoxy resins was facilitated. The epoxy coatings with a 0.1% addition of MGO possessed the best anticorrosion properties (|Z|_0.01Hz > 10¹⁰ Ω cm² after 70 days immersion in 3.5% NaCl solution) in comparison to the other coatings due to the “labyrinth effect” formed by the uniformly dispersed MGO. Meanwhile, the grafted tannic acid was released at the coating defects and provided inhibition functionalities for the substrate. As a result, the corrosion of the carbon steel was significantly decreased. This work provides a new perspective on the efficient modification of electrochemically exfoliated GO epoxy coatings for metals by combining the advantages of dopamine and corrosion inhibitors. Full article

(This article belongs to the Topic Materials for Corrosion Protection)

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13 pages, 6904 KiB  

Open AccessArticle

The Ablation Performance of Silicon Nitride/Boron Nitride Fibrous Monolithic Ceramics under an Oxyacetylene Combustion Torch

by Qingqing Chen, Yuan Zhang, Yu Zhou, Daxin Li and Guobing Ying

Materials 2023, 16(20), 6703; https://doi.org/10.3390/ma16206703 - 16 Oct 2023

Viewed by 1609

Abstract

In this study, Si₃N₄/BN fibrous monolithic ceramics were successfully prepared by wet spinning extrusion and hot pressing, and the effects on its ablation performance and microstructure were studied. The samples were burned in an oxyacetylene flame for 60 s [...] Read more.

In this study, Si₃N₄/BN fibrous monolithic ceramics were successfully prepared by wet spinning extrusion and hot pressing, and the effects on its ablation performance and microstructure were studied. The samples were burned in an oxyacetylene flame for 60 s $\times$ 30 to evaluate the ablation resistance. With the increase in ablation time, the fibrous monolithic ceramics exhibited specific mass and linear ablation rates, which show a trend of first increasing, then decreasing, and then increasing again. When the ablation time is 60 s $\times$ 10, 60 s $\times$ 20, and 60 s $\times$ 30, the mass ablation rates of the fibrous monolithic ceramics are 1 $\times$ 10⁻⁵ mg/s, −8.3 $\times$ 10⁻⁶ mg/s, −6.7 $\times$ 10⁻⁷ mg/s, respectively; the linear ablation rates are 4.7 $\times$ 10⁻⁵ μg/s, −1.2 $\times$ 10⁻⁵ μg/s and 1.7 $\times$ 10⁻⁶ μg/s. After 60 s $\times$ 30 of ablation, the surface oxides of the species are washed away by the oxyacetylene flame, revealing a porous coral-like structure with many cracks. A glass phase layer, predominantly constituted by sintering aids, envelops the Si₃N₄ ceramic surface on the ablated sample, serving as an effective barrier against additional ablation. Full article

(This article belongs to the Topic Materials for Corrosion Protection)

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15 pages, 13129 KiB  

Open AccessArticle

Microstructure and Corrosion Property of Prepared CoCrW Coatings on the TC4 Surface by Laser Cladding

by Yu-Bin Sun, Hao-Jie Niu, Jia-Ying Wang, Gui-Fu Dong and Cheng-Xin Lin

Coatings 2023, 13(10), 1687; https://doi.org/10.3390/coatings13101687 - 26 Sep 2023

Cited by 10 | Viewed by 1764

Abstract

Ti6Al4V (TC4) is widely used in aerospace, marine equipment, and the petrochemical industry. However, the dense oxide film on the surface of this alloy will be destroyed in reducing acid solution, resulting in surface corrosion in practical application. To enhance the corrosion resistance [...] Read more.

Ti6Al4V (TC4) is widely used in aerospace, marine equipment, and the petrochemical industry. However, the dense oxide film on the surface of this alloy will be destroyed in reducing acid solution, resulting in surface corrosion in practical application. To enhance the corrosion resistance of TC4 in marine environments, this study employed laser cladding technology to deposit a CoCrW cladding layer on the TC4 alloy surface. Experimental results validated the successful preparation of a dense, crack-free CoCrW layer. The microstructure of the CoCrW layer was characterized by predominant bulk grains and minor equiaxed crystal constituents, demonstrating a robust metallurgical bond to the matrix. Notably, the corrosion resistance of the TC4 surface witnessed a marked improvement, evident from the CoCrW coating’s increased open circuit potential, elevated electrochemical impedance spectroscopy (EIS) radius, phase angle, and impedance modulus values. The corrosion rates of both the TC4 and CoCrW cladding layers escalated with extended immersion time and increased immersion corrosion temperature. However, the CoCrW cladding layer reported minimal mass loss and the least corrosion rate. In summary, the CoCrW coating, when prepared via laser cladding on the TC4 surface, markedly bolstered corrosion resistance. Full article

(This article belongs to the Topic Materials for Corrosion Protection)

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19 pages, 11067 KiB  

Open AccessArticle

Influence of UV Illumination on the Corrosion Behavior of New 3Ni Weathering Steel in Marine Atmospheric Environments

by Hongliang Xu, Rui Yuan, Zhihui Zhang, Ying Yang, Yubo Wang, Pengcheng Zhang, Xinping Mao and Huibin Wu

Metals 2023, 13(9), 1543; https://doi.org/10.3390/met13091543 - 1 Sep 2023

Cited by 2 | Viewed by 1305

Abstract

We investigate the effect of pure darkness and UV illumination on the corrosion process of 3Ni weathering steels involved in both marine atmospheric environments. The corrosion behavior of 3Ni steel in both environments was assessed by cyclic acceleration experiments, electrochemical measurements, morphological analysis [...] Read more.

We investigate the effect of pure darkness and UV illumination on the corrosion process of 3Ni weathering steels involved in both marine atmospheric environments. The corrosion behavior of 3Ni steel in both environments was assessed by cyclic acceleration experiments, electrochemical measurements, morphological analysis and physical phase analysis. The results show that UV illumination affects the corrosion process through the photovoltaic effect of the corrosion products, with photoelectrons and photo-vacancies participating in the redox reaction between the substrate and the atmospheric environment, thereby affecting the corrosion rate of 3Ni steel, the physical composition of the corrosion products and the denseness of the rust layer. Full article

(This article belongs to the Topic Materials for Corrosion Protection)

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14 pages, 6159 KiB  

Open AccessArticle

High-Temperature Corrosion Characteristics of Ni-20Cr-xSi Alloy Laser Cladding Layer in NaCl-KCl-Na₂SO₄-K₂SO₄ Mixed Salt Environment

by Shanshan Chen, Zongde Liu and Fulai Liu

Coatings 2023, 13(8), 1320; https://doi.org/10.3390/coatings13081320 - 27 Jul 2023

Cited by 6 | Viewed by 1589

Abstract

Ni-Cr-Si-alloy-cladding layers with Si contents of 0 wt.%, 1 wt.%, 3 wt.% and 5 wt.% were prepared via a laser-cladding technique, and the effect of Si content on the high-temperature corrosion resistance of the Ni-20Cr-Si-alloy-cladding layers in NaCl-KCl-K₂SO₄-Na₂ [...] Read more.

Ni-Cr-Si-alloy-cladding layers with Si contents of 0 wt.%, 1 wt.%, 3 wt.% and 5 wt.% were prepared via a laser-cladding technique, and the effect of Si content on the high-temperature corrosion resistance of the Ni-20Cr-Si-alloy-cladding layers in NaCl-KCl-K₂SO₄-Na₂SO₄ mixed salt was systematically investigated. The results show that at 600 °C, the four cladding layers rely mainly on the generation of dense Cr₂O₃ on the surface to hinder the continuation of corrosion. The addition of Si helps to improve the stability of Cr₂O₃ in the mixed salt, and on the other hand Si is enriched in the corrosion layer, which can effectively hinder the penetration of the corrosive medium. The addition of Si can effectively improve the high-temperature corrosion resistance of the Ni-20Cr-cladding layer, whereas the corrosion product layer is prone to spalling when the Si content is ≥3 wt.%. The best corrosion resistance was demonstrated by Ni-20Cr-1Si in NaCl-KCl-K₂SO₄-Na₂SO₄ mixed salt. Full article

(This article belongs to the Topic Materials for Corrosion Protection)

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21 pages, 11684 KiB  

Open AccessArticle

A Laboratory and Field Assessment of the Performance of Rebar Coatings

by Salah U. Al-Dulaijan

Materials 2023, 16(12), 4270; https://doi.org/10.3390/ma16124270 - 8 Jun 2023

Cited by 2 | Viewed by 1723

Abstract

Deteriorating concrete structures are repaired to restore their load-carrying capacity and enhance their appearance. As part of the repair procedure, the corroded reinforcing steel bars are cleaned by sandblasting, and a protective coating is applied to protect them from further corrosion. Generally, a [...] Read more.

Deteriorating concrete structures are repaired to restore their load-carrying capacity and enhance their appearance. As part of the repair procedure, the corroded reinforcing steel bars are cleaned by sandblasting, and a protective coating is applied to protect them from further corrosion. Generally, a zin-rich epoxy coating is used for this purpose. However, there have been concerns about the performance of this type of coating in protecting the steel due to the formation of galvanic corrosion, thus necessitating the need for developing a durable steel coating. In this study, the performance of two types of steel coatings, namely a zinc-rich epoxy and cement-based epoxy resin coating, was investigated. The performance of the selected coatings was evaluated by conducting both laboratory and field experiments. In the field studies, the concrete specimens were exposed to a marine exposure site for more than five years. The salt spray and accelerated reinforcement corrosion studies indicated that the performance of the cement-based epoxy coating was better than the zinc-rich epoxy coating. However, there was no visible difference between the performance of the investigated coatings in the reinforced concrete slab specimens placed in the field. It is suggested to use cement-based epoxy coatings as steel primers based on the field and laboratory data developed in this study. Full article

(This article belongs to the Topic Materials for Corrosion Protection)

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15 pages, 16366 KiB  

Open AccessArticle

Hydrothermal Synthesis of CaAl-LDH Intercalating with Eugenol and Its Corrosion Protection Performances for Reinforcing Bar

by Ang Liu, Haohua Gu, Yongjuan Geng, Pan Wang, Song Gao and Shaochun Li

Materials 2023, 16(7), 2913; https://doi.org/10.3390/ma16072913 - 6 Apr 2023

Cited by 6 | Viewed by 2573

Abstract

Layered double hydroxides (LDHs) intercalating with a corrosion inhibitor for slowing down the corrosion of a reinforcing bar has attracted considerable attention. However, achieving high-loading capacity of organic inhibitor in LDH with high efficiency and long-term protection characteristics remains an important challenge. In [...] Read more.

Layered double hydroxides (LDHs) intercalating with a corrosion inhibitor for slowing down the corrosion of a reinforcing bar has attracted considerable attention. However, achieving high-loading capacity of organic inhibitor in LDH with high efficiency and long-term protection characteristics remains an important challenge. In this work, the CaAl-LDH intercalating with eugenol (EG) was synthesized via a continuous hydrothermal method. The prepared LDHs were characterized by SEM, XRD, UV-vis absorption spectra and TGA. Additionally, the corrosion protection performances of LDH-EG for steel bar were studied in detail via the electrochemical method. The results show that the loading amount of EG in LDHs was about 30% and about 80% EG could be released from LDH-EG within 4 h in SCPs containing 3.5% NaCl. The electrochemical test results show that the R_ct value (10⁵~10⁶ Ω · cm²) of steel-mortar incorporated with LDH-EG has increased by 3–4 orders of magnitude compared to the specimen without LDHs (10²~10³ Ω · cm²) after 16 dry–wet cycles corrosion test. The significantly improved protection capability is mainly derived from two aspects: one is the filling effect of LDH, which can fill the pores of mortar and improve the impermeability; another reason is that the intercalated EG can slowly diffuse out of the inner structure of LDHs in a controllable way and result in a relatively long-term effect of corrosion inhibition. Full article

(This article belongs to the Topic Materials for Corrosion Protection)

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14 pages, 5439 KiB  

Open AccessArticle

Preparation of Gallic Acid Intercalated Layered Double Hydroxide for Enhanced Corrosion Protection of Epoxy Coatings

by Shuo Fang, Kaifeng Chen, Hongrui Yao, Yanhui Cao, Shuli Guo, Li Wang, Yangsong Wang, Shuai Yu and Na Wang

Coatings 2023, 13(1), 128; https://doi.org/10.3390/coatings13010128 - 10 Jan 2023

Cited by 11 | Viewed by 2653

Abstract

In the field of corrosion protection coatings, layered double hydroxide (LDH) has gained wide attention as a novel controlled-release nanocontainer. In this paper, by using a co-precipitation to store corrosion inhibitors in layered double hydroxide with barrier properties, an environmentally friendly gallic acid [...] Read more.

In the field of corrosion protection coatings, layered double hydroxide (LDH) has gained wide attention as a novel controlled-release nanocontainer. In this paper, by using a co-precipitation to store corrosion inhibitors in layered double hydroxide with barrier properties, an environmentally friendly gallic acid (GA) intercalated layered double hydroxide corrosion protection filler (GA-LDH) was prepared. The epoxy coating was then modified with GA-LDH to improve its corrosion protection performance. The structure, composition, and release behavior of GA-LDH were investigated by a series of characterizations, such as field emission scanning electron microscopy (FE-SEM), X-ray diffraction (XRD), Fourier transform infrared spectroscopy (FT-IR) and ultraviolet-visible spectrophotometry (UV-vis). Electrochemical impedance spectroscopy (EIS) and a neutral salt spray test (NSS) were performed to evaluate the effect of EP coating containing GA-LDH on corrosion protection for Q235 steel. The results show that GA-LDH added to an epoxy coating can achieve excellent corrosion protection performance and is expected to be widely used in marine corrosion protection contexts. Full article

(This article belongs to the Topic Materials for Corrosion Protection)

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