Distribution of millscale on corroded steel bars and penetration of steel corrosion products in concrete

This study investigated a reinforced concrete specimen that had deteriorated in an artificial environment for 2 years. The steel/concrete interface and corrosion-induced cracks were observed by SEM to investigate the millscale on the rebar surface and the distribution of rust. The millscale was not further oxidised before the surface cracking of the concrete cover. The penetration of corrosion products into concrete and the formation of a corrosion layer proceeded simultaneously. The rust did not fill the corrosion-induced cracks in concrete. Instead of the three-stage model, a two-stage model is proposed to describe the concrete cracking process induced by steel corrosion.     

Atmospheric corrosion of Ni-advanced weathering steels in marine atmospheres of moderate salinity

One conventional and three Ni-advanced weathering steels have been exposed for one year in two marine atmospheres of moderate aggressivity (30 and 75 mg Cl⁻/m² d). The rusts generated have been analysed by polarised light optical microscopy, SEM, XRD, Raman spectroscopy and Mössbauer spectroscopy.The presence of high nickel (1–3% weight) contents in the steel composition leads to higher corrosion resistance in moderate marine atmospheres. The presence of nickel in the weathering steel also raises the proportion of nanophasic (superparamagnetic) goethite in the inner rust layer.     

Mechanical and barrier properties of MOCVD processed alumina coatings on Ti6Al4V titanium alloy

This study focuses on the implementation of different aluminum oxide coatings processed by metal-organic chemical vapor deposition from aluminum tri-isopropoxide on commercial Ti6Al4V titanium alloy to improve its high temperature corrosion resistance. Films grown at 350 °C and at 480 °C are amorphous and correspond to formulas AlOOH, and Al₂O₃, respectively. Those deposited at 700 °C are composed of γ-Al₂O₃ nanocrystals dispersed in a matrix of amorphous alumina. Their mechanical properties and adhesion to the substrates were investigated by indentation, scratch and micro tensile tests. Hardness and rigidity of the films increase with increasing deposition temperature. The hardness of the coatings prepared at 350 °C and 480 °C is 5.8 ± 0.7 GPa and 10.8 ± 0.8 GPa respectively. Their Young's modulus is 92 ± 8 GPa (350 °C) and 155 ± 6 GPa (480 °C). Scratch tests cause adhesive failures of the films grown at 350 °C and 480 °C whereas cohesive failure is observed for the nanocrystalline one, grown at 700 °C. Micro tensile tests show a more progressive cracking of the latter films than on the amorphous ones. The films allow maintaining good mechanical properties after corrosion with NaCl deposit during 100 h at 450 °C. After corrosion test only the film deposited at 700 °C yields an elongation at break comparable to that of the as processed samples without corrosion. The as established processing–structure–properties relation paves the way to engineer MOCVD aluminum oxide complex coatings which meet the specifications of the high temperature corrosion protection of titanium alloys with regard to the targeted applications.     

Crack shape and rust distribution in corrosion-induced cracking concrete

This study investigated a reinforced concrete specimen that had deteriorated in an artificial environment for 2 years. The crack width and the rust distribution were observed by digital microscopy. The variation of the total circumferential crack width along the radial direction is presented using a linear function. Observation reveals that rust does not penetrate into the corrosion-induced cracks before concrete surface cracking. After concrete surface cracking, rust fills the cracks, lining the edges of the cracks due to the circulation of the outer solution. A schematic diagram is proposed to describe crack propagation and rust development.     

A study on the initial corrosion behavior of carbon steel exposed to outdoor wet-dry cyclic condition

The initial corrosion behavior of carbon steel subjected to outdoor wet-dry cyclic exposure and exposure under natural environments have been investigated. The weight loss results indicate a transition from corrosion acceleration to deceleration during the early stage of corrosion of carbon steel under both conditions. The corrosion kinetics under both conditions follow empirical equation D = Atⁿ. Outdoor wet-dry cyclic exposure significantly promoted the initiation but the rate of corrosion was about three times as fast. The morphology of corrosion surfaces and cross-section of rust layer have been examined using SEM and the compositions have been analyzed using XRD and EPMA.     

Influence of cooling rate on microstructure evolution and pitting corrosion resistance in the simulated heat-affected zone of 2304 duplex stainless steels

Pitting corrosion resistance of 2304 duplex stainless steel heat-affected zone with different cooling rates has been studied by potentiostatic critical pitting temperature (CPT) in 1.0 M NaCl. The results showed that, as cooling rate decreased from 100 to 10 °C/s in the temperature range of 1350–800 °C, the austenite fraction increased from 27.8% to 35.7%, and the CPT value increased from 14 to 19 °C. The morphologies after the CPT tests showed pitting occurred preferentially in the ferrite phase for all specimens. Moreover, relationship between pitting corrosion resistance and microstructure evolution was further discussed.     

The inhibition effect of tannic acid on mild steel corrosion in seawater wet/dry cyclic conditions

The inhibition effect of tannic acid on mild steel corrosion in seawater wet/dry cyclic conditions was studied by weight loss and electrochemical methods. Result of the polarisation curves shows that corrosion current density decreases from 47.85 μA cm⁻² to 6.67 μA cm⁻² after tannic acid is added; charge transfer resistance remains stable in the electrochemical impedance spectra. Scanning electron microscopy, X-ray diffraction, and Fourier transform infrared reflection are performed to study the corrosion inhibition. The inhibition effect of the compound is attributed to ferric tannate film formation on the steel surface, which is relatively stable during wet/dry cycles.     

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.     

Elastic properties of hard cobalt boride composite nanoparticles

This paper reports on the determination of elastic and hardness properties of Co–B composite nanoparticles (CNP). Co boride materials is usually known for their functional properties (hydrogen catalysis, magnetism, corrosion, biomedics), but nanoscale dimensions also bring significant mechanical properties. In situ compression tests of 70–150 nm core–shell silica-coated Co₂B CNP (Composite nanoparticles) were performed for the first time with a nanoindenter in the load range 30–300 μN. The CNP modulus is comparable with the bulk material (E_CNP = 159–166 GPa), but the hardness is as much as 5 times higher (～4.5 ± 1.0 GPA). Both modulus and hardness (to a lesser extent) are found to increase with the applied pressure. The paper first addresses the limitations of ordinary contact analysis intended for single-phase NP, and then presents a hybrid Oliver–Pharr strategy suitable for CNP, where numerical modeling overcomes issues related to anisotropy and heterogenety of the composite nanostructure that hinder the direct application of basic contact models. An alternative regression-based approach for estimating modulus and hardness is also considered for comparison. The importance of the model selection for the contact area A for accurate modulus and hardness results is emphasized. Besides typical Hertzian, geometrical and cylindrical area models, a new one is formulated from a “rigid-sphere” approximation, which turned out to perform best and consistently in this study, on a par with the cylindrical model. Finally, evidence of the magnetic nature of CNP and, unexpectedly, reverse plasticity is provided.     

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.     

Evaluation of environment-assisted cracking susceptibility of a grade X100 pipeline steel

Susceptibility of as-received grade X100 steel was compared to that of simulated and seam-weld heat-affected zone microstructures by slow strain rate testing in a sodium hydrogen carbonate–sodium carbonate solution at 75 °C over a potential range of ?500 to ?1100 mV vs. standard calomel electrode (sce).Heat treatment has an effect on the resistance of the steel to environment-assisted cracking. Stress corrosion cracking at anodic potentials was intergranular (IG) and became transgranular (TG) as the free corrosion potential of ?890 mV (sce) was approached. At cathodic potentials, transgranular hydrogen embrittlement occurred with faster growth rates up to 1.4 × 10^?5 mm/s and less secondary cracking.     

Electrochemical corrosion performance of Cr and Al alloy steels using a J55 carbon steel as base alloy

Cr- and Al-modified alloy steels using J55 carbon steel as base alloy were produced by remelting in a vacuum. Their corrosion resistance was estimated by open circuit potential, electrochemical polarisation measurements and immersion tests in a 3.5 wt.% NaCl solution. The modified alloy steels exhibit higher corrosion resistance with a more positive open circuit potential, lower corrosion current density and higher impedance than J55 steel. The immersion tests showed that the new alloy steels have lower corrosion rates and smaller pitting depth than J55 steel and a low-Cr steel.     

Fatigue crack growth of two pipeline steels in a pressurized hydrogen environment

Fatigue crack growth tests were conducted on two pipeline steel alloys, API 5L X52 and X100. Baseline tests were conducted in air, and those results were compared with tests conducted in pressurized hydrogen gas. All tests were run at (load ratio) R = 0.5 and a frequency of 1 Hz, except for one test on X100, run at 0.1 Hz. Tests were conducted at hydrogen pressures of 1.7 MPa, 7 MPa, 21 MPa, and 48 MPa. Fatigue crack growth rates for both X100 and X52 were significantly higher in a pressurized hydrogen environment than in air. This enhanced growth rate appears to correlate to pressure for X100 but may not for X52.     

Mechanism of (Mg, Al, Ca)-oxide inclusion-induced pitting corrosion in 316L stainless steel exposed to sulphur environments containing chloride ion

The mechanism of oxide inclusion-induced pitting corrosion in 316L stainless steel exposed to sulphur environments containing chloride ions was investigated by scanning electron microscope analysis, electrochemical measurements and scanning Kelvin probe force microscopy (SKPFM). Two inclusion types were observed. The (Mg, Al, Ca)-oxide inclusions play an important role in pitting formation. SKPFM measurement results show that the inclusion sites exhibited a lower surface potential than the matrix. Finally, the schematic representation of the initiation and propagation process of the (Mg, Al, Ca)-oxide inclusion-induced pitting corrosion in 316L stainless steel exposed to sulphur environments containing chloride ions was established.     

Preparation of Fe2B boride coating on low-carbon steel surfaces and its evaluation of hardness and corrosion resistance

Fe₂B coating was prepared on low-carbon steel by surface alloying. A series of experiments were carried out to examine some surface properties of boride coating. The surface heat treatment of coated low-carbon steel was performed at 700 °C, 800 °C and 900 °C for 2 h, 4 h, 6 h and 8 h under hydrogen atmosphere. The boride coating was revealed by XRD analysis and the microstructure of the boride coating was analyzed by scanning electron microscopy (SEM). Depending on the temperature and time of the process, the hardness of the borided low-carbon steel ranged from 99 to 1100 HV. The hardness showed a maximum (about 1100 HV) at 900 °C for 8 h. The corrosion resistance of the borided samples was evaluated by the Tafel polarization and electrochemical impedance spectroscopy (EIS). Shift in the corrosion potential (E_corr) towards the noble direction was observed, together with decrease in the corrosion current density (I_corr), increase in the charge transfer resistance (R_ct) and decrease in the capacitance (C_c), which indicated an improvement in corrosion resistance with increasing temperature and time of the treatment.     

Influence of anions on the formation of artificial steel rust particles prepared from acidic aqueous Fe(III) solution

For simulation of atmospheric corrosion of steels, artificial steel rust particles were prepared in acidic aqueous solutions containing FeCl₃, Fe(NO₃)₃ and Fe₂(SO₄)₃. A single phase α-FeOOH was formed in only Fe(NO₃)₃ system. The β-FeOOH was formed by added Cl⁻ in FeCl₃–Fe(NO₃)₃ system. Adding SO₄²⁻ in Fe(NO₃)₃, FeCl₃ and a mixture of FeCl₃–Fe(NO₃)₃ solutions turned the products following as α- or β-FeOOH → Schwertmannite (Fe₈O₈(OH)₆(SO₄)·nH₂O). Further, increasing the added SO₄²⁻ suppressed the formation of steel rust particles. Accordingly, the influence of anions on the formation of steel rust particles was to be suggested in order of SO₄²⁻ ≫ Cl⁻ > NO₃⁻.     

Corrosion of a stainless steel and nickel-based alloys in high temperature supercritical carbon dioxide environment

Corrosion of four alloys has been studied in supercritical carbon dioxide at 650 °C and 20 MPa, specifically AL-6XN stainless steel and three nickel-based alloys, PE-16, Haynes 230, and Alloy 625. The tests were performed for exposure durations of up to 3000 h with samples being removed for analyses at 500 h intervals. The corrosion performance of the alloys was evaluated by weight change measurements, and the surface oxide layers were characterized by scanning electron microscopy, X-ray diffraction and X-ray photoelectron spectroscopy. Weight gain measurements showed that the Al-6XN stainless steel exhibited the least corrosion resistance while the weight gains were nearly similar for the other alloys. The oxide layer in AL-6XN stainless steel was composed of large equiaxed grained outer layer of Fe₃O₄ (magnetite) and an inner layer of FeCr₂O₄. Oxide spallation was observed in this stainless steel even after 500 h exposure. In all alloys, Cr-rich oxides phases of Cr₂O₃ and Cr_1.4Fe_0.7O₃ were identified as the protective layers. In alloy PE-16 a thin layer of aluminum oxide formed that promoted the corrosion resistance of the alloy. Cr₂O₃ was identified as the main protective oxide layer in nickel base alloys Haynes 230 and 625.     

Influence of the grain orientation spread on the pitting corrosion resistance of duplex stainless steels using electron backscatter diffraction and critical pitting temperature test at the microscale

The corrosion behavior of UNS S32202 duplex stainless steel was studied by combining electron backscatter diffraction (EBSD) measurements and critical pitting temperature tests at the microscale. The grain orientation spread (GOS) value was determined in grains of both phases from EBSD data. It was shown that austenitic sites containing extremely small ferrite grains having a GOS value greater than 1.3° were precursor sites for pitting in 4 M NaCl. The critical pitting temperature range was 45–90 °C. All the other sites of both phases remained passive up to 100 °C.     

Corrosion behaviour of copper containing low alloy steels in sulphuric acid

The influence of the addition of Cu on the corrosion resistance of low alloy steel in sulphuric acid was investigated using AC and DC electrochemical methods and a weight loss test, which took place in 10 wt% H₂SO₄ solution at room temperature. The electrochemical measurements indicated that the corrosion rate is suppressed by the addition of Cu due to a higher hydrogen overpotential and prevention of the active dissolution. Surface analyses (XPS, EPMA and SEM) of the corroded surfaces conducted after the immersion test indicated that the rust layer formed on the Cu containing steels was enriched with Cu compounds.     

Pulse current plasma assisted electrolytic cleaning of AISI 4340 steel

An electrolytic plasma process (EPP) for cleaning AISI 4340 steel was performed in a 10% solution of sodium bicarbonate operated at 70 °C. The effects of the pulse frequency (f) and duty cycle (δ) on the surface morphology, microstructure, mechanical and corrosion properties were investigated. Compared to the conventional DC process, the pulsed EPP cleaning resulted in reduced surface roughness and compressive residual stress at the surface. Minimal reduction in hardness and no reduction in toughness due to hydrogen embrittlement (ASTM F519) were found. At the same time, rotating bending beam fatigue tests indicated a noticeable reduction in fatigue life, which could be offset by a shot peening treatment prior to EPP cleaning at 10 kHz and δ = 0.8. Glow discharge optical emission spectroscopy indicated minimal changes in the surface composition and potentiodynamic corrosion studies revealed a slight ennoblement of the surface attributable to an increased rate of cathodic processes. Optimal process parameters were identified for δ = 0.8 and f = 100–10,000 Hz.