Orientation dependence of the electrochemical corrosion properties of electrodeposited Cu foils

In this study, the electrochemical corrosion properties of electrodeposited Cu foils in a CuCl₂-containing acidic etching solution were investigated. The main passive product was CuCl and a trace amount of Cu₂O can also be detected. The (2 2 0)-oriented Cu foils exhibited higher corrosion potential and lower corrosion current density than those with (1 1 1) or (2 0 0) texture, suggesting a superior corrosion resistance against the etching solution. It is proposed that the preferred orientation and thus the differences in atomic stacking density on specific planes dominated the corrosion properties of the electrodeposited Cu foils instead of grain size or surface roughness.     

Effect of small amounts of alloyed tin on the electrochemical behaviour of aluminium in sodium chloride solution

Binary model AlSn alloys containing 30–1000 ppm (by weight) Sn were investigated by electrochemical polarization in 5 wt% chloride solution and subsequent characterization of corrosion morphology. In the homogenized and rolled condition, tin concentration only slightly affected electrochemical behaviour up to 500 ppm, and the pitting potentials were all about −0.8 V_SCE. However, alloy containing 1000 ppm Sn was significantly activated by lowering of the passivity-breakdown potential to −1.38 V_SCE. Annealing at 300 °C caused significant segregation of Sn to the metal surface, and all specimens, independent of bulk Sn concentration, became nearly similarly active with breakdown potentials around −1.2 V_SCE. Corrosion on 300 °C-annealed specimens was uniformly distributed by polarization below the bulk pitting potential of −0.76 V_SCE. Moreover, the activation effect was temporary, and corrosion was significantly reduced as the segregated Sn was etched away from the surface. Thick oxide, formed during water quenching on high Sn concentration samples, containing 500 and 1000 ppm Sn, introduced partial passivation during polarization test. Annealing at 600 °C caused increasing activation with increasing Sn concentration, caused by Sn enrichment at the metal surface by dealloying of aluminium during anodic polarization in chloride solution. Corrosion was localized in the form of grain boundary corrosion for alloyed Sn concentration less than and equal to 500 ppm and pitting following the triple grain boundaries for 1000 ppm.     

Sulphuric acid corrosion of ultrafine-grained mild steel processed by equal-channel angular pressing

A bulk ultrafine-grained (UFG) mild steel with a ferrite grain size of approximately 200 nm and a dispersed distribution of iron carbide particles was fabricated by equal-channel angular pressing (ECAP) at 400 °C. The corrosion behaviour of the ECAP-processed mild steel and pure iron was investigated in a 0.5 mol/L H₂SO₄ solution. They exhibited a higher corrosion rate and better anodic passivity properties due to the presence of more crystalline defects. As a result of the refinement of the iron carbide particles, the forming ability of a continuous dense passive film was improved.     

Formation of self-repairing anodized film on ACM522 magnesium alloy by plasma electrolytic oxidation

Plasma electrolytic oxidation (PEO) on a die-casting ACM522 Mg alloy was conducted in aqueous silicate and phosphate solutions. The corrosion behavior of the anodized ACM522 Mg alloy was investigated in detail. During the investigation, the self-repairing behavior of the anodized films was evaluated by a salt spray test for 168 h, and the mechanism of this self-repairing was discussed in terms of thermodynamic equilibrium constants. Furthermore, the effects of additives to the phosphate solution on the self-repairing behavior were examined, and the addition of Na₂B₄O₇ was found to effectively reduce cracks on a self-repaired film.     

Long-term monitoring of atmospheric corrosion at weathering steel bridges by an electrochemical impedance method

Weathering steel corrosion was monitored for one to two years under natural atmosphere by an electrochemical impedance technique. Two identical comb-shape weathering steel sheets embedded in epoxy resin were used as monitoring probe electrodes at two different bridges in Japan. Impedances at 10 kHz (Z_10kHz) and 10 mHz (Z_10mHz) were automatically measured every hour. Coupons (50 × 50 × 2 mm³) prepared from the same steel sheets were exposed together to measure the corrosion mass loss. The average (Z_10mHz)⁻¹ value for half to one year exposure correlated well with the average corrosion rate determined from the corrosion mass loss.     

Adsorption and inhibition effect of Ascorbyl palmitate on corrosion of carbon steel in ethanol blended gasoline containing water as a contaminant

The adsorption and inhibition effect of Ascorbyl palmitate (AP) on carbon steel in ethanol blended gasoline containing water as a contaminant (GE10 + 1%water) was studied by weight loss and electrochemical impedance spectroscopic (EIS) techniques. The results showed that the addition of ethanol and water to gasoline increase the corrosion rate of carbon steel. AP inhibits the corrosion of carbon steel in (GE10 + 1% water) solution to a remarkable extent. The adsorption of AP on the carbon steel surface was found to obey the Langmuir adsorption isotherm model. The values of activation energy (E_a) and various thermodynamic parameters were calculated and discussed.     

Degradation behaviour of AZ80E magnesium alloy exposed to phosphate buffer saline medium

Corrosion behaviour of AZ80E alloy in comparison with pure Mg was investigated in phosphate buffer saline (PBS) solution in order to assess its bioactivity. Open circuit potential and EIS results reveal that both samples exhibit self-passivation with time. The higher corrosion resistance of the alloy is discussed from the perspective of its microstructure. Anodic oxidation for the alloy surface in borate buffer solution was also attempted potentiostatically to modify its corrosion behaviour. Anodised specimen at controlled potential of 1.0 V(SCE) can improve the durability of the alloy in PBS medium. The results were further confirmed by SEM and EDX analyses.     

Atmospheric corrosion of field-exposed AZ31 magnesium in a tropical marine environment

Corrosion behavior of AZ31 magnesium in tropical marine atmosphere was investigated. Chloride ions deposition rate played an important role in the corrosion process, which resulted in an obvious fluctuation of the corrosion rate. The corrosion was initiated from pitting corrosion and then evolved into general corrosion as the exposure time extended. Mg₅(CO₃)₄(OH)₂·xH₂O was the dominate products during the whole exposure periods. The products on the specimens weathered for 1, 6 and 12 months slightly suppressed the corrosion process, while that generated after 24 months of exposure exhibited good protective ability against further corrosion attacks.     

Corrosion of ultra-high-purity Mg in 3.5% NaCl solution saturated with Mg(OH)2

Corrosion was evaluated for ultra-high-purity magnesium (Mg) immersed in 3.5% NaCl solution saturated with Mg(OH)₂. The intrinsic corrosion rate measured with weight loss, P_W = 0.25 ± 0.07 mm y⁻¹, was slightly smaller than that for high-purity Mg. Some specimens had somewhat higher corrosion rates attributed to localised corrosion. The average corrosion rate measured from hydrogen evolution, P_AH, was lower than that measured with weight loss, P_W, attributed to dissolution of some hydrogen in the Mg specimen. The amount of dissolution under electrochemical control was a small amount of the total dissolution. A new hydride dissolution mechanism is suggested.     

Corrosion behaviour of Al–29at%Co alloy in aqueous NaCl

Microstructure and corrosion behaviour of a binary Al–29 at%Co alloy have been studied. The alloy was prepared by arc-melting of Al and Co in high purity Ar and rapidly solidified on a water-cooled Cu mould. The alloy chemical composition and microstructure were characterized by scanning electron microscopy, energy dispersive X-ray spectroscopy and X-ray diffraction. Furthermore, the corrosion behaviour was studied by potentiodynamic polarization in aqueous NaCl (0.6 mol dm⁻³) at room temperature. The alloy was found to consist of three phases: hexagonal Al₅Co₂, Z-phase and AlCo (β). The corrosion resistance of different intermetallic phases is characterized. The results are compared to previously published results of Al–TM (TM = transition metal) alloys.     

2-Mercaptobenzoxazole as a copper corrosion inhibitor in chloride solution: Electrochemistry, 3D-profilometry,and XPS surface analysis

2-Mercaptobenzoxazole (MBOH) was studied as a corrosion inhibitor for Cu in 3 wt.% NaCl solution using EIS, a potentiodynamic curve, 3D-profilometry, and XPS measurements. It was shown that Cu corrosion in solution containing MBOH follows kinetic-controlled and diffusion-controlled processes and that MBOH is a mixed-type inhibitor. The diffusion coefficient of the Cu ions travelling through the solid surface layers was estimated to be on the order of 10⁻¹⁵–10⁻¹⁴ cm² s⁻¹. It was also demonstrated that the Cu(I)–MBOH complex is formed on the Cu surface and that the thickness of this surface layer is 1.4 ± 0.4 nm.     

Design and synthesis of a novel class of inhibitors for mild steel corrosion in acidic and carbon dioxide-saturated saline media

p-(9-(2-Methylisoxazolidin-5-yl)nonyloxy)benzaldehyde I, prepared using a cycloaddition protocol, was elaborated into its cinnamaldehyde derivative II which upon quarternization with propargyl chloride afforded III bearing an interesting blend of structural traits suitable for imparting inhibition of mild steel corrosion. Novel compounds I–III showed efficient inhibition against mild steel corrosion in CO₂–0.5 M NaCl (40 °C, 1 atm; 120 °C, 10 bar), 1, 4, 7.7 M HCl, and 0.5 M H₂SO₄ at 60 °C as determined by gravimetry and electrochemical methods. The presence of carbonaceous surface and nitrogen, as revealed by XPS study, indicated the formation of a film covering the metal surface, which imparted corrosion inhibition.     

Estimation of residual corrosion rates of steel under cathodic protection in soils via voltammetry

Steel coupons were buried in soil for 2 months under cathodic protection. Their residual corrosion rates were deduced from voltammetry and weight loss measurements. In aerated soils, the current density due to O₂ reduction, j_K,O2, was modelled with a mixed activation–diffusion controlled kinetic. The anodic part j_A of the current density j, computed as j_A = j − j_K,O2, obeyed Tafel law. Its extrapolation to the protection potential gave a corrosion rate (∼7 μm yr⁻¹) consistent with that obtained from weight loss measurements. With a deficient protection, corrosion rates remained at ∼80 μm yr⁻¹, a value given by both methods.     

Corrosion fatigue crack growth behavior of oil-grade nickel-base alloy 718. Part 1: Effect of corrosive environment

The effect of corrosive environment on corrosion fatigue crack growth (CFCG) behavior of oil-grade nickel-base alloy 718 is studied. The results demonstrate that there is no obvious effect of 3.5 wt.% NaCl solution at RT, 50 °C and 80 °C on CGCG rates while 21 wt.% NaCl solution at 80 °C produces a deleterious effect on CFCG rates compared to the ones tested in air. Potentiodynamic polarization results show that alloy 718 exhibits passive behavior in 3.5 wt.% NaCl solution, while pitting corrosion resistance decreases with increasing solution temperature. Nevertheless, alloy 718 shows active corrosion behavior in 21 wt.% NaCl solution at 80 °C.     

Oxidation properties of self-propagating high temperature synthesized niobium disilicide

NbSi₂ monoliths were prepared by self-propagating high temperature synthesis (SHS) and hot pressing (HP) and their oxidation behavior was investigated at various temperatures (823–1123 K) in air. The combustion mode of SHS reaction was steady state combustion, and the combustion product was single-phase NbSi₂. Oxidation studies show that the highest mass gain was 0.95675 kg m⁻² at 1023 K. In cyclic oxidation, the oxidation rate was reduced and the mass gain was only 0.15507 kg m⁻². A dense protective amorphous SiO₂ scale formed at 823 K and 923 K whereas a porous multilayer SiO₂ and α/β-Nb₂O₅ oxide scales formed at and above 1023 K and spalled off. Pest oxidation of NbSi₂ monoliths was not observed in hot pressed NbSi₂ monoliths.     

Electrochemical behavior of a lead-free Sn–Cu solder alloy in NaCl solution

Electrochemical impedance spectroscopy (EIS), potentiodynamic polarization techniques and an equivalent circuit analysis are used to evaluate the electrochemical corrosion behavior of Sn–Cu alloy samples in a naturally aerated 0.5 M NaCl solution at 25 °C. It has been found that a better electrochemical corrosion resistance is provided by a coarser cellular microstructure array. It has also been found that the corrosion current density (i_corr) is of about a quarter when compared with that of the finest microstructure examined. Such behavior is attributed to both localized strains between the Sn-rich phase and intermetallic (IMC) particles and the cathode/anode area ratios. The effect of copper alloying on i_corr is also discussed.     

Improved corrosion resistance in simulated concrete pore solution of surface nanocrystallized rebar fabricated by wire-brushing

Continuous surface nanocrystallization (SNC) of rebar was achieved through wire-brushing process. A uniform NC layer with thickness of 25 μm and average grain size of 50 nm was formed on the rebar surface. Due to the enhanced passivation performance of the NC layer, corrosion resistance of the SNC rebar was significantly improved in Cl⁻-containing saturated Ca(OH)₂ solution. High-energetic crystal defects of the nano-grains leads to the faster passivation and enhanced stability of the passive film of the SNC rebar.     

2-Mercaptobenzimidazole as a copper corrosion inhibitor: Part I. Long-term immersion, 3D-profilometry,and electrochemistry

The high corrosion inhibition effectiveness of 2-mercaptobenzimidazole (MBIH) in 3 wt.% aqueous NaCl solution is reported using long term immersion tests, 3D-profilometry, electrochemical impedance spectroscopy, and potentiodynamic curve measurements. The high corrosion inhibition performance was proven after 180 days of immersion. The impedance spectra were characterized by two time constants relating to charge transfer and finite layer thickness or semi-infinite diffusion of copper ions through the surface layer, therefore Cu corrosion in solution containing MBIH follows kinetic-controlled and diffusion-controlled processes. Moreover, it is shown that MBIH is a mixed-type inhibitor.     

Study of the correlation between pitting corrosion and the component ratio of the dual phase in duplex stainless steel welds

Three duplex stainless steel weldments were produced by changing the chromium element to study the correlation between the pitting corrosion characteristics and the component ratio of the dual phase. The pit morphologies showed that metastable pits were generated at a lower pitting resistance equivalent number (PREN) phase. The secondary austenite phases seemed to serve as a path for the corrosive environment regardless of the ferrite number (FN). There is some discrepancy between the measured values (pitting potential (E_p) through polarization test) and expected values (sequence ranked by PREN of weaker phase) in 1 mol l⁻¹ NaCl solution at 60 °C.     

Preparation,microstructure characterisation and corrosion behaviour of directionally grown TaSi2 fibre arrays with sharp tip fabricated by selective wet etching

Directionally solidified Si–TaSi₂ eutectic composite is selectively etched to fabricate well aligned TaSi₂ tip array for field emission application. The effect of etching parameters on TaSi₂ tip structure, and its corrosion behaviour in HNO₃/HF solution are investigated. At the optimised condition (HNO₃/HF = 5 for 50 min), sharp TaSi₂ tips with curvature radius of 18 nm and homogenous distribution are obtained, which greatly improves the figure of merit associated with field emission current. The TaSi₂ fibre presents smaller dissolution rate in the HNO₃/HF solution than Si matrix. The formation mechanism of etching pit on the Si matrix surface is also discussed.