The growth of carbon coating layers on iron particles and the effect of alloying the iron with silicon

Magnetic fine particles of metallic Fe coated with graphitic carbon layers were synthesized by annealing Fe₂O₃ particles with carbon powders at 1673 K in nitrogen atmosphere. For comparison, SiC was added to Fe₂O₃. X-ray diffraction measurement showed that the lattice constants of Fe changed depending on the Si contents. Mössbauer spectroscopy confirmed that Fe-Si alloys were formed by the Si addition and that the iron carbide disappeared. Electron microscope images revealed that the thickness of carbon coating layers increased from 24 nm to 36 nm as a result of the Si addition. Soaking tests showed that the corrosion resistance of the carbon-coated Fe particles was improved by the addition of Si. The results suggest that Si caused C to leave the Fe cores and move to the surface to form a carbon coating.     

The X-ray photo-electron spectra ofseveral oxides of iron and chromium

X-ray photo-electron spectra of Fe₂O₃, Fe₃O₄, α-FeOOH, γ-FeOOH, Cr₂O₃,Cr(OH)₃· 0·4H₂O and CrO₃ were measured. The peak binding energies of 2p, 3s and 3p electrons of Fe and Cr in the above substances were determined. The largest valency dependence was observed in 2p electrons. Binding energies of O 1s electrons were also measured for those oxides and hydroxides. For quantitative analysis the ratios of photo-electron cross-sections of Fe 2p_3/2 and Cr 2p3/2 to O 1s electron levels were estimated as 1.45 and 1.71, respectively, for excitation by A1 Kα_1,2 radiation.     

Taxonomy for protective ability of rust layer using its composition formed on weathering steel bridge

For a quantitative evaluation of the protectiveness of a rust layer formed on a weathering steel bridge, the relationship between the corrosion rate of the bridge and the composition of the rust layers formed on the girders was first investigated. These corrosion rates were clearly classified by the protective ability index (PAI) of α/γ^∗ and (β + s)/γ^∗, where α, γ^∗, β and s are the mass ratio of crystalline α-FeOOH, the total of γ-FeOOH, β-FeOOH and the spinel-type iron oxide (mainly Fe₃O₄), β-FeOOH and spinel-type iron oxide, analyzed by XRD, respectively. The inequality of the former index α/γ^∗ > 1 expressed the protectiveness criterion of the rust layer, while that of the latter index, (β + s)/γ^∗< 0.5 or > 0.5, classified the corrosion rate of the non-protective rust layer. The PAI is useful for a quantitative evaluation of the protectiveness of a rust layer formed on a weathering steel bridge and is an important item for the corrosion assessment of the bridge.     

Photocatalytic performance of nano-photocatalyst from TiO2 and Fe2O3 by mechanochemical synthesis

Nano-particles of homogeneous solid solution between TiO₂ and Fe₂O₃ (up to 10 mol%) have been prepared by mechanochemical milling of TiO₂ and yellow Fe₂O₃/red Fe₂O₃/precipitated Fe (OH)₃ using a planetary ball mill. Such novel solid solution cannot be prepared by conventional co-precipitation technique. A preliminary investigation of photocatalytic activity of mixed oxide (TiO₂/Fe₂O₃) on photo-oxidation of different organic dyes like Rhodamine B (RB), Methyl orange (MO), Thymol blue (TB) and Bromocresol green (BG) under visible light (300-W Xe lamp; λ > 420 nm) showed that TiO₂ having 5 mol% of Fe₂O₃ (YFT1) is 3-5 times higher photoactive than that of P25 TiO₂. The XRD result did not show the peaks assigned to the Fe components (for example Fe₂O₃, Fe₃O₄, FeO₃, and Fe metal) on the external surface of the anatase structure in the Fe₂O₃/TiO₂ attained through mechanochemical treatment. This meant that Fe components were well incorporated into the TiO₂ anatase structure. The average crystallite size and particle size of YFT1 were found to be 12 nm and 30 ± 5 nm respectively measured from XRD and TEM conforming to nanodimensions. Together with the Fe component, they absorbed wavelength of above 387 nm. The band slightly shifted to the right without tail broadness, which was the UV absorption of Fe oxide in the Fe₂O₃/TiO₂ particle attained through mechanochemical method. This meant that Fe components were well inserted into the framework of the TiO₂ anatase structure. EPR and magnetic susceptibility show that Fe³⁺ is in low spin state corresponding to μ_B = 1.8 BM. The temperature variation of μ_B shows that Fe³⁺ is well separated from each other and does not have any antiferromagnetic or ferromagnetic interaction. The evidence of Fe³⁺ in TiO₂/Fe₂O₃ alloy is also proved by a new method that is redox titration which is again support by the XPS spectrum.     

Influence of manganese on iron oxyhydroxides and oxides formed in aqueous solution

Structural analysis techniques such as X-ray diffraction and anomalous X-ray scattering were used for characterizing the influence of manganese on iron oxyhydroxides and oxides formed from green rust (GR) in an aqueous solution. The results showed that the formation of Fe₃O₄ was enhanced by the addition of manganese ions during the conversion of GR2 to α-FeOOH and Fe₃O₄. The results obtained from anomalous X-ray scattering showed that manganese was present both in α-FeOOH and Fe₃O₄ particles. The incorporation of manganese in α-FeOOH appears to induce the distortion of the atomic-scale structure of α-FeOOH particles formed in an aqueous solution.     

Corrosion resistance and mechanical properties of low-alloy steels under atmospheric conditions

The corrosion resistance and mechanical strength of four newly developed low-alloy steels (LAS) were compared with a carbon steel (SS400) and a weathering steel (Acr-Ten A) using a laboratory-accelerated test that involved cyclic wet/dry conditions in a chloride environment (5 wt.% NaCl). The new LAS were designated 1605A, 1605B, 1604A, and 1604B. After 72 cycles of cyclic corrosion tests, the susceptibility of the steels to corrosion could be listed in the following order based on their weight loss (from high to low): SS400 > Acr-Ten A > 1604B ? 1604A > 1605B ? 1605A. The change in mechanical properties by corrosion was the least for SS400, Acr-Ten A was second, and effects of corrosion on the mechanical properties of the other four low-alloy steels were similar. Finally, the characteristics of the rust layers on each LAS sample were observed by SEM, and analyzed by FTIR and EPMA. The results indicated that most of the rust layers on the test steels were composed of a loose outer rust layer and a dense inner rust layer. The outer rust layer of each steel was composed of α-FeOOH, γ-FeOOH, magnetite (Fe₃O₄), H₂O, and amorphous ferric oxyhydroxide (FeO_x(OH)_3−2x, x=0-1), while the inner rust layer was composed mainly of Fe₃O₄ with a little α-FeOOH. In addition, it was apparent that the copper and chromium alloying additions were enriched, respectively, at the rust-layer/substrate interface and in the rust layers. Finally, combining the results of the accelerated tests and the rust layer analysis showed that low-alloy steels, such as 1605A and 1605B, have better weathering steel properties than Acr-Ten A for use in the humid and salty weather.     

Corrosion resistance of the Dhar iron pillar

The corrosion resistance of the 950-year old Dhar iron pillar has been addressed. The microstructure of a Dhar pillar iron sample exhibited characteristics typical of ancient Indian iron. Intergranular cracking indicated P segregation to the grain boundaries. The potentiodynamic polarization behaviour of the Dhar pillar iron and mild steel, evaluated in solutions of pH 1 and 7.6, indicate that the pillar iron is inferior to mild steel under complete immersion conditions. However, the excellent atmospheric corrosion resistance of the phosphoric Dhar pillar iron is due to the formation of a protective passive film on the surface. Rust analysis revealed the presence of crystalline magnetite (Fe_3−xO₄), α-Fe₂O₃ (hematite), goethite (α-FeOOH), lepidocrocite (γ-FeOOH), akaganeite (β-FeOOH) and phosphates, and amorphous δ-FeOOH phases. The rust cross-section revealed a layered structure at some locations.     

Coprecipitation thermodynamics of iron(II-III) hydroxysulphate green rust from Fe(II) and Fe(III) salts

Iron(II-III) hydroxysulphate GR(SO₄²⁻) was prepared by precipitating a mixture of Fe(II) and Fe(III) sulphate solutions with NaOH, accompanied in most cases by iron(II) hydroxide, spinel iron oxide(s) or goethite. Its [Fe(II)]/[Fe(III)] ratio determined by transmission Mössbauer spectroscopy was 2±0.2, whatever the initial [Fe(II)]/[Fe(III)] ratio in solution. Proportion of Fe(OH)₂ increased when the initial [Fe(II)]/[Fe(III)] ratio increased, whereas proportion of α-FeOOH or spinel oxide(s) increased when this ratio decreased. GR(SO₄²⁻) is metastable vs. Fe₃O₄ except in a limited domain around neutral pH. Precipitation from solutions containing both Fe(II) and Fe(III) dissolved species seems to favour GRs formation with respect to stable systems involving iron (oxyhydr)oxides.     

Ex-situ and in-situ X-ray diffractions of corrosion products freshly formed on the surface of an iron-silicon alloy

Ex-situ X-ray diffraction measurements of a small amount of samples extracted from wet corrosion products freshly formed on a pure iron and iron-2 mass% silicon surfaces have been conducted using synchrotron radiation for clarifying the formation process of corrosion products. The results showed that γ-FeOOH was formed on the outer side of wet corrosion products formed on the surface of the pure iron by sodium chloride solution, while γ-FeOOH, α-FeOOH, Fe₃O₄, and green rusts were formed on the inner side. On the other hand, in comparison to the case of the pure iron, a significant formation of β-FeOOH was observed in the iron-silicon alloy. Influences of silicon alloying on corrosion products formed by aqueous solution containing sulfate ions were also observed. Furthermore, in-situ diffraction measurements by a conventional X-ray source were conducted for analyzing corrosion products formed on the pure iron and iron-silicon alloy surfaces by cyclic exposure to wet and dry atmospheres. The results obtained by the in-situ diffraction and ex-situ diffraction measurements on the corrosion products were consistent.     

Synthesis, structure, and high temperature Mössbauer and Raman spectroscopy studies of Ba1.6Sr1.4Fe2WO9 double perovskite

Ba_1.6Sr_1.4Fe₂WO₉ has been prepared in polycrystalline form by solid-state reaction method in air, and has been studied by X-ray powder diffraction method (XRPD), and high temperature Mössbauer and Raman spectroscopies. The crystal structure was resolved at room temperature by the Rietveld refinement method, and revealed that Ba_1.6Sr_1.4Fe₂WO₉ crystallizes in a tetragonal system, space group I4/m, with a = b = 5.6489(10)Å, c = 7.9833(2)Å and adopts a double perovskite-type A₃B′₂B″O₉ (A = Ba, Sr; B′ = Fe/W, and B″ = Fe/W) structure described by the crystallographic formula (Ba_1.07Sr_0.93)_4d(Fe_0.744W_0.256)_2a(Fe_0.585W_0.415)_2bO₆. The structure contains alternating [(Fe/W)_2aO₆] and [(Fe/W)_2bO₆] octahedra. Mössbauer studies reveal the presence of iron in the 3+ oxidation state. The high temperature Mössbauer measurements showed a magnetic to paramagnetic transition around 405 ± 10 K. The transition is gradual over the temperature interval. The decrease in isomer shift is in line with the general temperature dependence. While the isomer shift is rather linear over the whole temperature range, the quadratic dipolar ΔE temperature dependence shows an abrupt change at 405 K. The latter results allow concluding that a temperature-induced phase transition had occurred. The high temperature Raman study confirms the Mössbauer results on the magnetic to paramagnetic transition.     

Effects of DBU, morpholine, and DMA on corrosion of low carbon steel exposed to steam

Effects of morpholine, 1,8-diazabicyclo[5.4.0]undec-7-ene (DBU), and dimethylamine (DMA) on oxidation kinetics and oxide phase formation/transformation of AISI 1018 steel at 120 °C were evaluated. Low carbon steel samples were exposed to steam in an autoclave containing amine added aqueous solution at pH of 9.5 for 1, 2, 4, 6, 8, and 12 h. Control samples exposed to plain steam and amines showed the highest and lowest weight loss respectively. Fourier Transform Infrared Spectrophotometry (FTIR) showed that DBU containing steam favored formation of magnetite (Fe₃O₄) while steam with DMA formed more α and γ-FeOOH. Transformation of magnetite to hematite (α-Fe₂O₃) was fastest for morpholine. Analysis of oxides morphology was done utilizing Scanning Electron Microscopy (SEM). Oxides formed in plain or DMA containing steam exhibited acicular particles of goethite/hematite (α-FeOOH/α-Fe₂O₃) compared to DBU containing steam that showed equiaxed particles of magnetite/maghemite (Fe₃O₄/γ-Fe₂O₃). Morpholine containing steam promoted agglomeration of thin sharp platelets into coarse flakes of hematite.     

The mechanism of formation of iron oxide and oxyhydroxides in aqueous solutions at room temperature

For a better understanding of the atmospheric rusting of iron and steels, the present work is aimed to explore the mechanism of formation of green rusts, Fe₃O₄, α-FeOOH, β-FeOOH, γ-FeOOH, δ-FeOOH and amorphous ferric oxyhydroxide in aqueous solution at room temperature. The formation processes on which end products are determined are strongly affected by the oxidation rate, pH and the structure and composition of initial and intermediate species of iron. The systematic diagram of formation processes of iron oxide and oxyhydroxides has been presented, in which both dissolved and solid species of iron are included.     

The reductive dissolution of γ-FeOOH in corrosion scales formed on cast iron in near-neutral waters

Corrosion scales which form on cast iron in oxygenated, near-neutral waters at 50°C contain green rust, Fe₂O₄ and γ-FeOOH. Upon de-oxygenation of the water, γ-FeOOH → Fe₃O₄ occurs by dissolution-precipitation as a cathodic reaction in the corrosion cell. Mechanisms of corrosion reactions are postulated in which it is proposed that the amount of γ-FeOOH is controlled by a balance between its rate of precipitation and its rate of reductive dissolution. The mechanism explains the eventual predominance of Fe₃O₄ in scales formed in oxygenated waters and the absence of γ-FeOOH from scales formed in waters with [O₂] < ～ 1 ppm.     

Iron oxide hollow spheres: Microwave–hydrothermal ionic liquid preparation,formation mechanism,crystal phase and morphology control and properties

This paper reports on the microwave–hydrothermal ionic liquid method for the synthesis of a variety of iron oxide nanostructures such as α-FeOOH hollow spheres, β-FeOOH architectures and α-Fe₂O₃ nanoparticles. The formation mechanism for α-FeOOH hollow spheres is discussed. The effects of the reaction parameters on the morphology and crystal phase of the final product are studied. The relationship between the morphology and crystal phase of the product is discussed. A general thermal transformation strategy is designed to prepare α-Fe₂O₃ hollow spheres using α-FeOOH hollow spheres as the precursor and template. By thermal treatment of the as-prepared α-FeOOH hollow spheres, α-Fe₂O₃ hollow spheres showing good photocatalytic activity are obtained. And by autocatalysis of the adsorbed available Fe(II) on the α-FeOOH surfaces, Fe₃O₄ hollow spheres are also obtained.     

Formation of ‘ferric green rust’ and/or ferrihydrite by fast oxidation of iron(II-III) hydroxychloride green rust

Fast oxidation processes of iron(II-III) hydroxychloride green rust GR(Cl⁻), Fe^II₃Fe^III(OH)₈Cl · 2H₂O, were simulated by two different methods. The first one consisted in using a strong oxidiser, namely H₂O₂. The main end product, analysed by X-ray diffraction and Mössbauer spectroscopy, is an iron(III) compound, designated as “ferric GR(Cl⁻)”, characterised by a layered structure identical to that of normal GR(Cl⁻). The second method consisted in decreasing the initial concentrations of reactants, thus increasing the proportion of dissolved O₂. Suspensions of GR(Cl⁻), obtained by mixing 4 × 10⁻³ M NaOH with FeCl₂ solutions for various R^′=[Cl⁻]/[OH⁻] values, oxidised rapidly into ferrihydrite-like compounds.     

Characterization of Delhi iron pillar rust by X-ray diffraction, Fourier transform infrared spectroscopy and Mössbauer spectroscopy

Rust samples obtained from the region just below the decorative bell capital of the Delhi iron pillar (DIP) have been analyzed by X-ray diffraction (XRD), Fourier transform infrared spectroscopy (FTIR) and Mössbauer spectroscopy. The identification of iron hydrogen phosphate hydrate in the crystalline form by XRD was unambiguous. Very weak diffraction from the oxyhydroxides/oxides of iron was observed indicating that these phases are most likely to be present in the amorphous form in the rust. The present XRD analysis of rust obtained from an inaccessible area of the DIP has also been compared with earlier analyses of DIP rust obtained from regions accessible to the public. FTIR indicated that the constituents of the scale were γ-, α-, δ-FeOOH, Fe_3−xO₄ and phosphate, and that the scale was hydrated. The unambiguous identification of the iron oxides/oxyhydroxides in the FTIR spectrum implied that they are present in the amorphous state, as XRD did not reveal these phases. The FTIR results have also been compared with earlier FTIR spectroscopic results of atmospheric rust formation. Mössbauer spectroscopy indicated that the rusts contained γ-FeOOH, superparamagnetic α-FeOOH, δ-FeOOH and magnetite, all in the amorphous form. The Mössbauer spectrum also confirmed that iron in the crystalline iron hydrogen phosphate hydrate, whose presence was confirmed by XRD, was in the ferric state indicating that it was a stable end corrosion product.     

Formation of poorly crystalline iron monosulfides: Surface redox reactions on high purity iron, spectroelectrochemical studies

In the use of iron for reductive dehalogenation of chlorinated solvents in ground water, due to presence of sulfate-reducing bacteria the formation of hydrogen sulfide is expected. To simulate those processes the interface between 99.99% pure iron and 0.1 M NaHCO₃ deoxygenated solution with 3.1 × 10⁻⁵-7.8 × 10⁻³ M Na₂S · 9H₂O added was studied. The surface processes were characterised by the in situ normal Raman spectroscopy (NRS) and ex situ techniques; X-ray diffraction (XRD), X-ray photoelectron spectroscopy (XPS), scanning electron microscopy (SEM), energy dispersive X-ray (EDX). The open circuit potential (OCP) was monitored during in situ NRS measurements, and potentiodynamic anodic polarization measurements were carried out to reveal electrochemical behaviour of iron electrode.Open circuit potential-time transients indicated that the native oxide is unstable in deaerated bicarbonate solution and undergoes reductive dissolution (i.e. autoreduction) leaving the metallic Fe covered by Fe(OH)₂, adsorbed OH⁻, and patches of ‘magnetite-like’ oxide. Immediately upon injection of the Na₂S-solution the iron interface undergoes complex redox surface processes and a poorly crystalline FeS film forms. Potentiodynamic anodic polarization measurements indicated a mechanical breakdown of the FeS film. The origin and initiation of this breakdown process is not clear but is probably a result of internal stress developed during film growth. Based on surface studies supported by electrochemical measurements, a conceptual model for the complex redox processes occurring at the iron interface is proposed. This model describes the structural development of a poorly crystalline FeS, which breaks down, allowing further dissolution of the Fe and formation of FeOOH at the interface. Simultaneously and despite the existence of thick layer of FeS the entrance of hydrogen was evident as the typical hydrogen cracks in bulk of the iron material. This work shed the light on the complexity of the iron/sulfide solution interface, this knowledge is important to understand the kinetic of reduction of organic groundwater contaminants.     

Corrosion of X65 steel in CO2-saturated oilfield formation water in the absence and presence of acetic acid

Electrochemical corrosion behavior of X65 steel in CO₂-saturated formation water in the absence and presence of acetic acid was studied by electrochemical measurements, scanning vibrating micro-electrode (SVME), localized electrochemical impedance spectroscope (LEIS) and surface analysis techniques. It is found that, when steel is immersed in formation water, the dissolution of Fe dominates the anodic process and the steel is in active dissolution state. Adsorption of intermediate product on the electrode surface results in generation of an inductive loop in the low frequency range of EIS plot. As corrosion proceeds, the concentration of Fe²⁺ in the solution increases. When the product of [Fe²⁺] × [] exceeds solubility product of FeCO₃, FeCO₃ will deposit on the electrode surface, and protects the steel substrate from further corrosion. The steel is in a “passive” state. When the electrode surface is completely covered with FeCO₃ film, the inductive loop in the low frequency range disappears. In the presence of acetic acid in formation water, the cathodic reaction will be enhanced due to the direct reduction of undissociated acetic acid. Addition of acetic acid degrades the protectiveness of corrosion scale, and thus, enhances corrosion of steel by decreasing the FeCO₃ supersaturation in solution.     

Corrosion behavior of NiCrFe Alloy 600 in high temperature, hydrogenated water

The corrosion behavior of Alloy 600 (UNS N06600) is investigated in hydrogenated water at 260 °C. The corrosion kinetics are observed to be parabolic, the parabolic rate constant being determined by chemical descaling to be 0.055 mg dm⁻² h^−1/2. A combination of scanning and transmission electron microscopy, supplemented by energy dispersive X-ray spectroscopy and grazing incidence X-ray diffraction, are used to identify the oxide phases present (i.e., spinel) and to characterize their morphology and thickness. Two oxide layers are identified: an outer, ferrite-rich layer and an inner, chromite-rich layer. X-ray photoelectron spectroscopy with argon ion milling and target factor analysis is applied to determine spinel stoichiometry; the inner layer is (Ni_0.7Fe_0.3)(Fe_0.3Cr_0.7)₂O₄, while the outer layer is (Ni_0.9Fe_0.1)(Fe_0.85Cr_0.15)₂O₄. The distribution of trivalent iron and chromium cations in the inner and outer oxide layers is essentially the same as that found previously in stainless steel corrosion oxides, thus confirming their invariant nature as solvi in the immiscible spinel binary Fe₃O₄-FeCr₂O₄ (or NiFe₂O₄-NiCr₂O₄). Although oxidation occurred non-selectively, excess quantities of nickel(II) oxide were not found. Instead, the excess nickel was accounted for as recrystallized nickel metal in the inner layer, as additional nickel ferrite in the outer layer, formed by pickup of iron ions from the aqueous phase, and by selective release to the aqueous phase.     

Ultrasonic-assisted in situ synthesis and characterization of superparamagnetic Fe3O4 nanoparticles

Superparamagnetic Fe₃O₄ nanoparticles were synthesized via a modified coprecipitation method, and were characterized with X-ray diffraction (XRD), vibrating sample magnetometer (VSM), Zeta potential and FT-IR, respectively. The influences of different kinds of surfactants (sodium dodecyl benzene sulfonate, polyethyleneglycol, oleic acid and dextran), temperatures and pH values on the grain size and properties were also investigated. In this method, Fe³⁺ was used as the only Fe source and partially reduced to Fe²⁺ by the reducing agent with precise content. The following reaction between Fe³⁺, Fe²⁺ and hydroxide radical brought pure Fe₃O₄ nanoparticles. The tiny fresh nanoparticles were coated in situ with surfactant under the action of sonication. Comparing with uncoated sample, the mean grain size and saturation magnetization of coated Fe₃O₄ nanoparticles decrease from 18.4 nm to 5.9-9.0 nm, and from 63.89 emu g⁻¹ to 52-58 emu g⁻¹ respectively. When oleic was used as the surfactant, the mean grain size of Fe₃O₄ nanoparticles firstly decreases with the increase of reaction temperature, but when the temperature is exceed to 80 °C, the continuous increase of temperature resulted in larger nanoparticles. the grain size decreases gradually with the increasing of pH values, and it remains unchanged when the PH value is up to 11. The saturation magnetization of as-prepared Fe₃O₄ nanoparticles always decreases with the fall of grain size.