Surface Characterization of Mild Steel During Atmospheric Corrosion After Being Treated by Sodium Dihydrogen Orthophosphate

Protection of Metals and Physical Chemistry of Surfaces - The objective of this study was to characterize the surfaces of the steel products produced locally during their exposure to the industrial...     

Hot corrosion behavior of plasma and HVOF sprayed Co- and Ni-based coatings at 900°C

High temperature Co- and Ni-based metallic coatings were applied on samples of 310 stainless steel using plasma spray and high velocity oxy fuel (HVOF) methods. The samples were sprayed with Na₂SO₄, V₂O₅ and NaCl salt solutions and exposed in air at 900°C to cyclic conditions with an aim to simulate an environment typically encountered in oil refinery operation. Extent of hot corrosion damage was assessed using gravimetric measurements while microstructure of the coatings was examined using scanning electron microscopy coupled with energy dispersive X-ray spectroscopy. X-ray diffraction was used to determine phase constitution. The aim of this study was to evaluate and compare the performance of specific coatings in hot corrosive environments. Experimental results indicate that the presence of V₂O₅ and NaCl serves to enhance hot corrosion while Co-based coatings perform better than Ni-based coating.     

Electrochemical Deposition of Ni on an Al-Cu Alloy

Metallic coatings can be used to improve the wear and corrosion resistance of Al alloys. In this study, Ni was used as a candidate material for such a coating which was applied on the surface of Al 2014 alloy using electrodeposition in a standard Watt’s bath. A two-step heat treatment procedure was employed that served to increase the adhesion as well as hardness of Ni. Deposition was undertaken for different durations using both galvanostatic and potentiostatic techniques. The effect of deposition parameters such as surface finish, current, potential, temperature, pH level and duration on the microstructure, adhesion, and surface properties of the Ni deposit was studied. Materials characterization was performed using scanning electron microscopy, atomic force microscopy, and x-ray diffraction. Cross-sectional scanning transmission electron microscope images revealed the fine-grained (10 nm) structure of Ni initially deposited at the Ni-Al alloy substrate. Microhardness, adhesion, and corrosion behavior of the Ni deposit were evaluated. Experimental results indicate that deposition by galvanostatic technique on 1 μm surface finish at 45 °C with a pH level maintained at 3.6 represented the optimum conditions to generate a uniform Ni deposit on Al 2014. It was concluded that Ni deposition can be used to improve the surface properties of Al alloys.     

Corrosion of Bare and Galvanized Mild Steel in Arabian Gulf Environment

Corrosion performance of bare and galvanized mild steel in atmospheric, soil and splash zone exposure conditions was evaluated at a Khaleej Mardumah test station (KMTS) in Jubail Industrial City (JIC) located at Arabian Gulf coast. The samples were exposed for a period of 15 months. During the exposure, the environmental conditions were periodically monitored by analysis of air, soil, groundwater, and seawater samples. The corroded mild steel and galvanized steel samples were examined by SEM, XRD and XRF to identify the corrosion products and study their surface morphology. Weight loss method was employed to determine the corrosion rates. The experimental results showed that intense temperature and humidity variations as well as high chloride and sulfate concentrations in the region result in severe corrosion of bare mild steel especially under the splash zone conditions. A comparison with the corrosion data for other parts of the world shows that atmospheric and soil environments at the selected test site are significantly corrosive to mild steel. The splash zone, on the other hand, is much more corrosive to mild and galvanized steel than the other parts of the world.     

Performance of Cu and Cu‐Zn alloy in the Arabian Gulf environment

Corrosion performance of copper and brass coupons during 15 month exposure in atmosphere, underground and splash zone conditions was undertaken at Khaleej Mardumah test site located in the industrial/coastal city of Jubail along the Arabian Gulf coast, Saudi Arabia. The environmental indicators such as soil, groundwater, seawater, and air particulate samples were assessed. The exposed corrosion coupons were examined by scanning electron microscopy (SEM) coupled with energy dispersive X‐ray spectroscopy (EDS), X‐ray diffraction (XRD) and X‐ray fluorescence (XRF) to identify the corrosion products and study their surface morphology. Corrosion rate was determined by weight loss method. The experimental results indicated that a high degree of variation in temperature and humidity in this region combined with high chloride and sulfate concentrations was primarily responsible for the corrosion of copper and brass at Khaleej Mardumah test site. Underground environment was the most corrosive to both copper and brass coupons studied, followed by splash zone. Corrosion rates were found to range from 4.29 to 10.84 µm/y for copper and from 2.47 to 29.31 µm/y for brass. Corrosion rates of copper and brass obtained in this study are also compared with those reported for other locations worldwide.     

Microstructure and surface mechanical properties of electrodeposited Ni coating on Al 2014 alloy

The surface of Al 2014 was modified by electrochemical deposition of Ni with an aim to improve the surface mechanical properties of the alloy. The deposition was performed at various values of DC current, potential and time using standard Watt's bath. The samples were heat treated to improve the adhesion and hardness of Ni coatings. Material characterization was performed using scanning electron microscopy coupled with energy dispersive X-ray spectroscopy, atomic force microscopy and X-ray diffraction. Microhardness, nanohardness, microscratch and coefficient of friction measurements were undertaken to determine the surface mechanical properties of the electrodeposited Ni coating. Experimental results indicate that electrochemical deposition combined with heat treatment can be used to improve the surface properties of Al alloys.     

Corrosion study of SS304 and SS316 alloys in atmospheric,underground and seawater splash zone in the Arabian Gulf

Bare stainless steel type 304 and 316 alloys were exposed to atmospheric, underground and seawater splash conditions in order to evaluate their corrosion properties. The exposure was undertaken for 15 months at the coastal and industrial city of Jubail located in the Arabian Gulf. The corrosivity of the environment was determined by testing the soil, groundwater, seawater and air quality. Corrosion rate of the exposed coupons was determined by weight loss method. The experimental results indicate that the both types of stainless steels corroded moderately in this environment. Primary factors influencing the corrosion process are thought to be high degree of variation in temperature and humidity combined with high chloride and sulphate concentrations. The corrosion rate of stainless steel is also compared with those reported for other international locations.     

Effect of inhibitor treatment on corrosion of steel in a salt solution

This study examined experimentally different chemicals for inhibition of steel corrosion in a simulated aqueous solution for the industrial marine atmosphere of the Arabian Gulf region. The literature reported various inhibitors that can help in protection against metal corrosion in aqueous environments. Among them, 10 inhibitors (calcium silicate, cyclohexylamine, n-methylcyclohexylamine, dicyclohexylamine nitrite, sodium benzoate, sodium nitrate, sodium nitrite, sodium phosphate, sodium dihydrogen orthophosphate, and magnesium nitrate hexahydrate) were obtained and corrosion resistance of inhibitor applied steel specimens were examined in the simulated solution (2 wt.% NaCl and 1 wt.% Na₂SO₄). Test specimens were prepared from locally produced reinforcing steel products. Treatment of steel with either dicyclohexylamine nitrite or sodium dihydrogen orthophosphate both at 10 mM concentration for 1 day at room temperature resulted in significant inhibition of corrosion. No significant improvement in corrosion inhibition was observed either with an increase in inhibitor concentration at room temperature or with an increase in inhibitor application temperature at 10 mM concentration. A further study is planned to examine the inhibition performances of the two inhibitors under actual atmospheric conditions in the Arabian Gulf region (industrial marine environment).