Mild steel is the most common metal used in industry. However, mild steel easily corrodes when exposed to environment. One way to protect mild steel from corrodes is by coating it with more noble metal like copper and its alloys. In this study, copper and Cu-Ni alloys were successfully coated on the mild steel substrate by electrodeposition technique using alkaline citrate solutions containing Cu and Ni ions precursors. The reaction and mechanisms of the electrodeposition of copper and Cu-Ni alloys on the mild steel substrate were investigated by cyclic voltammetry and chronoamperometry methods. Surface morphology of the coatings was examined by FESEM. The elemental compositions of the coatings were confirmed by EDAX analysis. The molar ratios of Cu-Ni solutions have affected the formation of the coatings. Corrosion study shows that copper coated mild steel can improve the corrosion resistance of the mild steel in 0.5 M NaCl. Cu-Ni coating prepared from Cu60-Ni40 showed the highest corrosion resistance. The order of the corrosion resistance of the samples in 0.5 M NaCl at 25 oC is Cu60-Ni40> Cu75- Ni25> Cu90-Ni10> Cu100> mild steel.
Extracts from plant materials have great potential as alternatives to inorganic corrosion inhibitors, which typically have harmful consequences. Experimental and theoretical methodologies studied the effectiveness of agricultural waste, namely, date palm seed extract as a green anti-corrosive agent in 0.5 M hydrochloric acid. Experimental results showed that immersion time and temperature are closely related to the effectivity of date palm seed as a corrosion inhibitor. The inhibition efficiency reduced from 95% to 91% at 1400 ppm when the immersion time was increased from 72 h to 168 h. The experimental results also indicated that the inhibition efficiency decreased as the temperature increased. The presence of a protective layer of organic matter was corroborated by scanning electron microscopy. The adsorption studies indicated that date palm seed obeyed Langmuir adsorption isotherm on the carbon steel surface, and Gibbs free energy values were in the range of -33.45 to -38.41 kJ·mol-1. These results suggested that the date palm seed molecules interacted with the carbon steel surface through mixture adsorption. Theoretical calculations using density functional theory showed that the capability to donate and accept electrons between the alloy surface and the date palm seed inhibitor molecules is critical for adsorption effectiveness. The HOMO and LUMO result indicated that the carboxyl (COOH) group and C=C bond were the most active sites for the electron donation-acceptance type of interaction and most auxiliary to the adsorption process over the Fe surface.
Microbiologically influenced corrosion (MIC) is among the common corrosion types for buried and deep-water pipelines that result in costly repair and pipeline failure. Sulfate-reducing bacteria (SRB) are commonly known as the culprit of MIC. The aim of this work is to investigate the performance of combination of ultrasound (US) irradiation and ultraviolet (UV) radiation (known as Hybrid soliwave technique, HyST) at pilot scale to inactivate SRB. The influence of different reaction times with respect to US irradiation and UV radiation and synergistic effect toward SRB consortium was tested and discussed. In this research, the effect of HyST treatment toward SRB extermination and corrosion studies of carbon steel coupon upon SRB activity before and after the treatment were performed using weight loss method. The carbon steel coupons immersed in SRB sample were exposed to HyST treatment at different time of exposure. Additionally, Field Emission Scanning Electron Microscopy coupled with Energy Dispersive X-ray Spectroscopy were used to investigate the corrosion morphology in verifying the end product of SRB activity and corrosion formation after treatment. Results have shown that the US irradiation treatment gives a synergistic effect when combined with UV radiation in mitigating the SRB consortium.
The performance of pipeline system used in petroleum industry is crucially declined by natural microbial activities and
demanding extra operational cost. Requirement on high capability of functional substances is attracting worldwide
research interest. The aim of this paper was to study the effectiveness of benzyltriethylammonium chloride (BTC) on
reducing the activity of a consortium bacteria consisting of sulfate-reducing bacteria (C-SRB). C-SRB was isolated from
tropical crude oil and enumeration of this consortium was measured by viable cell count technique. The effectiveness of
BTC was calculated from potentiodynamic polarization method and biofilm analysis was performed by scanning electron
microscope. The viable cell count technique indicated that the maximum growth of C-SRB was approximately 160 trillion
CFU/mL at 7 days incubation period. BTC was capable of reducing biocorrosion activity due to adsorption process and
mitigating SRB species. Biofilm analysis has proven that C-SRB activity is minimized due to less presence of bacterial
growth, extracellular polymeric substances and corrosion product. In conclusion, BTC is capable to inhibit C-SRB activity
on biocorrosion of carbon steel pipeline.
Stainless steels are increasingly used in construction today, especially in harsh environments, in which steel corrosion commonly occurs. Cold-formed stainless steel structures are currently increasing in popularity because of its efficiency in load-bearing capacity and its appealing architectural appearance. Cold-rolling and press-braking are the cold-working processes used in the forming of stainless steel sections. Press braking can produce large cross-sections from thin to thick-walled sections compared to cold-rolling. Cold-forming in press-braked sections significantly affect member behaviour and joints; therefore, they have attained great attention from many researchers to initiate investigations on those effects. This paper examines the behaviour of residual stress distribution of stainless steel press-braked sections by implementing three-dimensional finite element (3D-FE) technique. The study proposed a full finite element procedure to predict the residual stresses starting from coiling-uncoiling to press-braking. This work considered material anisotropy to examine its effect on the residual stress distribution. The technique adopted was compared with different finite element techniques in the literature. This study also provided a parametric study for three corner radius-to-thickness ratios looking at the through-thickness residual stress distribution of four stainless steels (i.e., ferritic, austenitic, duplex, lean duplex) in which have their own chemical composition. In conclusion, the comparison showed that the adopted technique provides a detailed prediction of residual stress distribution. The influence of geometrical aspects is more pronounced than the material properties. Neglecting the material anisotropy shows higher shifting in the neutral axis. The parametric study showed that all stainless steel types have the same stress through-thickness distribution. Moreover, R/t ratios' effect is insignificant in all transverse residual stress distributions, but a slight change to R/t ratios can affect the longitudinal residual stress distribution.
This paper reports the corrosivity and leaching behavior of CLSM made using two different industrial wastes i.e. bottom ash from an incineration facility and quarry dust. The leachate samples were derived from fresh and hardened CLSM mixtures, and studied for leaching and electrical resistivity. The release of various contaminants and the consequent environmental impact caused by the contaminants were studied by the measurement of contaminants in the bleed, in the leachate at 28 days, and on the leachate derived from crushed block and whole block leaching done over a period of 126 days. Results indicated that the CLSM mixtures are non corrosive; diffusion was the leaching mechanism; and the contaminants were found to be moderate to low mobility.
This article describes the development of a partially degradable metal bone pin, proposed to minimize the occurrence of bone refracture by avoiding the creation of holes in the bone after pin removal procedure. The pin was made by friction welding and composed of two parts: the degradable part that remains in the bone and the nondegradable part that will be removed as usual. Rods of stainless steel 316L (nondegradable) and pure iron (degradable) were friction welded at the optimum parameters: forging pressure = 33.2 kPa, friction time = 25 s, burn-off length = 15 mm, and heat input = 4.58 J/s. The optimum tensile strength and elongation was registered at 666 MPa and 13%, respectively. A spiral defect formation was identified as the cause for the ductile fracture of the weld joint. A 40-µm wide intermetallic zone was identified along the fusion line having a distinct composition of Cr, Ni, and Mo. The corrosion rate of the pin gradually decreased from the undeformed zone of pure iron to the undeformed zone of stainless steel 316L. All metallurgical zones of the pin showed no toxic effect toward normal human osteoblast cells, confirming the ppb level of released Cr and Ni detected in the cell media were tolerable.
A study has been presented on the effects of intrinsic mechanical parameters, such as surface stress, surface elastic modulus, surface porosity, permeability and grain size on the corrosion failure of nanocomposite coatings. A set of mechano-electrochemical equations was developed by combining the popular Butler-Volmer and Duhem expressions to analyze the direct influence of mechanical parameters on the electrochemical reactions in nanocomposite coatings. Nanocomposite coatings of Ni with Al₂O₃, SiC, ZrO₂ and Graphene nanoparticles were studied as examples. The predictions showed that the corrosion rate of the nanocoatings increased with increasing grain size due to increase in surface stress, surface porosity and permeability of nanocoatings. A detailed experimental study was performed in which the nanocomposite coatings were subjected to an accelerated corrosion testing. The experimental results helped to develop and validate the equations by qualitative comparison between the experimental and predicted results showing good agreement between the two.
In the electrodeposition system, adding saccharin alters the properties of the metal deposits by changing the electrode kinetics of the deposited surface. In this study, nanocrystalline cobalt-iron (CoFe) coating was synthesised using the electrodeposition technique with different saccharin concentrations. The results obtained showed that the coating thickness increased while the grain size decreased from 51 nm to 40 nm when the saccharin concentration increased from 0 to 2 g/L. The nanocrystalline CoFe coating produced with 2 g/L of saccharin concentration resulted in the smallest particle size of 71.22 nm and the highest microhardness of 251.86 HV. From the salt spray test (24 and 48 hours) it was found that the use of saccharin at higher concentration of 2 g/L improves the corrosion resistance of the nanocrystalline CoFe coating significantly due to the change of surface morphology as well as the decrease in grain size.
Anticorrosive properties of nano silicate from paddy husk in salt medium was investigated via weight loss method, Tafel
polarization and impedance techniques. Prior to the corrosion test, the silica powder was obtained from burning the
rice husk and extended with a chemical treatment process. The size of silica powder was characterized via zeta sizer and
showed the amount of micro silica particle appear more than the nano size particle. Nano silica powder was produced
from the refluxing process of micro silica to enhance the good properties of silica particle. The corrosion inhibition
efficiency of nano silicate showed good inhibition with increased in inhibitor concentrations. Weight loss test exhibits
high inhibition as more than 80% even, immersed in the corrosive medium until 14 days. The nano silicate inhibitor
affected the anodic reaction as showed by Tafel plot analysis. Impedance results also correlated with other test as shown
by the large size of Nyquist semicircle which represents as high resistance of charge transfer. The surface morphology
of inhibited specimen showed a smooth surface after nano silicate inhibitor applied in the NaCl medium as observed
through scanning electron microscopy (SEM) and energy-dispersive x-ray spectroscopy (EDX).
Corrosion is a natural deterioration process that destructs metal surface. Metal of highly
protected by passivation layer such as Stainless Steel 316L also undergoes pitting corrosion
when continuously exposed to aggressive environment. To overcome this phenomenon, application
of epoxy based coating with addition of zinc oxide- poly (3,4-ethylenedioxythiophene)
doped with poly (styrene sulphonate) hybrid nanocomposite additive was introduced as
paint/metal surface coating. The compatibility between these two materials as additive
was studied by Fourier Transform Infrared Spectroscopy (FTIR), X-ray Diffraction (XRD),
Field Emission Scanning Electron Microscopy/Energy-Dispersive X-ray spectroscopy (FESEM/EDX)
and Transmission Electron Microscopy (TEM) analysis. The effect of nanocomposite
wt.% in epoxy based coating with immersion duration in real environment on corrosion
protection performance was analyzed through potentiodynamic polarization analysis. The
main finding showed that addition of hybrid nanocomposite had increased corrosion protection
yet enhanced corrosion process when excess additives was loaded into epoxy coating.
Addition of 2 wt.% ZnO-PEDOT:PSS was found significantly provided optimum corrosion
protection to stainless steel 316L as the corrosion rate for 0 day, 15 days and 30 days of
immersion duration is 0.0022 mm/yr, 0.0004 mm/yr and 0.0015 mm/yr; respectively.
Mild steel plays an essential part in many construction industries due to its low cost and excellent mechanical properties. However, the use of strong acid in pickling, construction, and oil refining processes adds to a serious corrosion problem for mild steel. Two Cu(II) dithiocarbamate (DTC) complexes were successfully synthesised, namely Cu(II) ethyl-benzyl DTC (Cu[EtBenzdtc]2) and Cu(II) butyl-methyl DTC (Cu[BuMedtc]2) complexes, by a condensation reaction and subsequently used to scrutinise the corrosion resistance activity towards mild steel in acidic media. The proposed structures of complexes were characterised by using the Fourier transform infrared (FTIR) and ultraviolet-visible (UV-Vis) spectroscopies. The melting point for Cu[EtBenzdtc]2 was found around 362–375°C, and 389–392°C for Cu[BuMedtc]2. The percentages of Cu(II) found in Cu[EtBenzdtc]2 and Cu[BuMedtc]2 were 7.6% and 7.5%, respectively. Both complexes were non-electrolyte based on the molar conductivity analysis. Their corrosion inhibition performances were tested by using a weight loss measurement. Cu[BuMedtc]2 showed a good result as a corrosion inhibitor compared to Cu[EtBenzdtc]2. The complexes showed good effectiveness in sulfuric acid (H2SO4) compared to hydrochloric acid (HCl) solution. Furthermore, Cu[BuMedtc]2 showed a good result as a corrosion inhibitor compared to Cu[EtBenzdtc]2 with the highest percentage of corrosion inhibition recorded at 91.8%. Meanwhile, the highest percentage of corrosion inhibition shown by Cu[EtBenzdtc]2 was only 86.9%. The lowest corrosion rate shown for Cu[BuMedtc]2 was 8.1944×10-4 cm-1 h-1. Meanwhile, the Cu[EtBenzdtc]2 showed the lowest corrosion rate only at 1.3194×10-3 cm-1 h-1. This implies that Cu[BuMedtc]2 showed lower corrosion rate but higher inhibition efficiency compared to Cu[EtBenzdtc]2.
Titanium (Ti) and Ti-based alloys presence the most widely applied as advanced biomaterials
in biomedical implant applications. Moreover, these alloys are known to be the most
valuable metallic materials including spinal cord surgical treatment. It becomes an interest
due to its advantages compared to others, including its bio compatibility and corrosion
resistant. However, an issue arises when it comes for permanent implant application as
the alloy has a possible toxic effect produced from chemical reaction between body fluid
environments with alloys chemical compositions. It also relies on the performance of
neighbouring bone tissue to integrate with the implant surface. Abnormalities usually
happen when surrounding tissue shows poor responses and rejection of implants that would
leads to body inflammation. These cause an increase in foreign body reaction leading to
severe body tissue response and thus, loosening of the implant. Corrosion effects and
biocompatibility behaviour of implantation usage also become one of the reasons of
implant damage. Here, this paper reviews the importance of using Ti and Ti-based alloys
in biomedical implantation, especially in orthopaedic spinal cord injury. It also reviews the
basic aspects of corrosion effects that lead to implant mechanical damage, poor response
of body rejection and biocompatibility behaviour of implantation usage.
Austenitic stainless steels of grade 304 were exposed to dry (Ar-75%CO2) and wet (Ar-75%CO2-12%H2O) environments at 700oC. This experimental setup involved horizontal tube furnace connected to CO2 gas and water vapour facilities. X-ray diffraction (XRD) technique, variable pressure-scanning electron microscope (VP-SEM) and optical microscope techniques were used to characterize the products of corrosion. The results of XRD showed that the phase of oxide layers consists of Cr2O3 and NiCr2O4 in dry CO2, meanwhile Fe2O3, Cr2O3, Fe0.56Ni0.34, Fe3O4 were identified in wet condition after 50 h. Adding 12%H2O in Ar-75%CO2 leads significantly in weight change occurred at 10 h exposure. However, after 20 h, the weight gain was decreased due to spallation of the oxide scale. The addition of water vapour accelerates the oxidation rate on the steel than that in dry condition. Morphologies and growth kinetics of these oxides vary with reaction condition. The oxidation behaviour at different times of exposure and the effect of water vapour were discussed in correlation with the microstructure of the oxides.
In recent years, calcium phosphate-base composites, such as hydroxyapatite (HA) and carbonate apatite (CA) have been considered desirable and biocompatible coating layers in clinical and biomedical applications such as implants because of the high resistance of the composites. This review focuses on the effects of voltage, time and electrolytes on a calcium phosphate-base composite layer in case of pure titanium and other biomedical grade titanium alloys via the plasma electrolytic oxidation (PEO) method. Remarkably, these parameters changed the structure, morphology, pH, thickness and crystallinity of the obtained coating for various engineering and biomedical applications. Hence, the structured layer caused improvement of the biocompatibility, corrosion resistance and assignment of extra benefits for Osseo integration. The fabricated layer with a thickness range of 10 to 20 μm was evaluated for physical, chemical, mechanical and tribological characteristics via XRD, FESEM, EDS, EIS and corrosion analysis respectively, to determine the effects of the applied parameters and various electrolytes on morphology and phase transition. Moreover, it was observed that during PEO, the concentration of calcium, phosphor and titanium shifts upward, which leads to an enhanced bioactivity by altering the thickness. The results confirm that the crystallinity, thickness and contents of composite layer can be changed by applying thermal treatments. The corrosion behavior was investigated via the potentiodynamic polarization test in a body-simulated environment. Here, the optimum corrosion resistance was obtained for the coating process condition at 500 V for 15 min in Ringer solution. This review has been summarized, aiming at the further development of PEO by producing more adequate titanium-base implants along with desired mechanical and biomedical features.
316L stainless steel is a common biomedical material. Currently, biomedical parts are produced through powder injection molding (PIM). Carbon control is the most critical in PIM. Improper debinding can significantly change the properties of the final product. In this work, thermal debinding and sintering were performed in two different furnaces (i.e. laboratory and commercially available furnaces) to study the mechanical properties and corrosion resistance. Debounded samples were sintered in different atmospheres. The samples sintered in inert gas showed enhanced mechanical properties compared with wrought 316L stainless steel and higher corrosion rate than those sintered in the vacuum furnace. The densification and tensile strength of the hydrogen sintered samples increased up to 3% and 51%, respectively, compared with those of the vacuum-sintered samples. However, the samples sintered in inert gas also exhibited reduced ductility and corrosion resistance. This finding is attributed to the presence of residual carbon in debonded samples during debinding.
This article provides an overview of the structural and physicochemical properties of stable carbon-based nanomaterials and their applications as counter electrodes (CEs) in dye-sensitized solar cells (DSSCs). The research community has long sought to harvest highly efficient third-generation DSSCs by developing carbon-based CEs, which are among the most important components of DSSCs. Since the initial introduction of DSSCs, Pt-based electrodes have been commonly used as CEs owing to their high-electrocatalytic activities, thus, accelerating the redox couple at the electrode/electrolyte interface to complete the circuit. However, Pt-based electrodes have several limitations due to their cost, abundance, complicated facility, and low corrosion resistance in a liquid electrolyte, which further restricts the large-area applications of DSSCs. Although carbon-based nanostructures showed the best potential to replace Pt-CE of DSSC, several new properties and characteristics of carbon-CE have been reported for future enhancements in this field. In this review, we discuss the detailed synthesis, properties, and performances of various carbonaceous materials proposed for DSSC-CE. These nano-carbon materials include carbon nanoparticles, activated carbon, carbon nanofibers, carbon nanotube, two-dimensional graphene, and hybrid carbon material composites. Among the CE materials currently available, carbon-carbon hybridized electrodes show the best performance efficiency (up to 10.05%) with a high fill factor (83%). Indeed, up to 8.23% improvements in cell efficiency may be achieved by a carbon-metal hybrid material under sun condition. This review then provides guidance on how to choose appropriate carbon nanomaterials to improve the performance of CEs used in DSSCs.
In the present work, the microstructure, corrosion, and bioactivity of graphene oxide (GO) coating on the laser-modified and -unmodified surfaces of TiNb shape memory alloys (SMAs) were investigated. The surface morphology and chemical composition was examined using field emission scanning electron microscopy (FE-SEM) and X-ray diffraction (XRD). The surface modification was carried out via a femtosecond laser with the aim to increase the surface roughness, and thus increase the adhesion property. FE-SEM analysis of the laser-treated Ti-30at.% Nb revealed the increase in surface roughness and oxygen/nitrogen containing groups on the Ti-30at.% Nb surface after being surface modified via a femtosecond laser. Furthermore, the thickness of GO was increased from 35μm to 45μm after the surface was modified. Potentiodynamic polarisation and electrochemical impedance spectroscopy studies revealed that both the GO and laser/GO-coated samples exhibited higher corrosion resistance than that of the uncoated TiNb SMA sample. However, the laser/GO-coated sample presented the highest corrosion resistance in SBF at 37°C. In addition, during soaking in the simulated body fluid (SBF), both the GO and laser/GO coating improved the formation of apatite layer. Based on the bioactivity results, the GO coating exhibited a remarkable antibacterial activity against gram-negative bacteria compared with the uncoated. In conclusion, the present results indicate that Ti-30at.% Nb SMAs may be promising alternatives to NiTi for certain biomedical applications.
H2S gas when exposed to metal can be responsible for both general and localized corrosion, which depend on several parameters such as H2S concentration and the corrosion product layer formed. Therefore, the formation of passive film on 316L steel when exposed to H2S environment was investigated using several analysis methods such as FESEM and STEM/EDS analyses, which identified a sulfur species underneath the porous structure of the passive film. X-ray photoelectron spectroscopy analysis demonstrated that the first layer of CrO3 and Cr2O3 was dissolved, accelerated by the presence of H2S-Cl-. An FeS2 layer was formed by incorporation of Fe and sulfide; then, passivation by Mo took place by forming a MoO2 layer. NiO, Ni(OH)2, and NiS barriers are formed as final protection for 316L steel. Therefore, Ni and Mo play an important role as a dual barrier to maintain the stability of 316L steel in high pH2S environments. For safety concern, this paper is aimed to point out a few challenges dealing with high partial pressure of H2S and limitation of 316L steel under highly sour condition for the oil and gas production system.
Duplex stainless steels (DSSs) are complex materials and they have been widely used in the marine environment and gas industries, primarily offering a better resistance of pitting corrosion and good mechanical properties. In the present work, the effects of heat treatment on duplex stainless steel (DSS) weld overlay samples that were heat treated at three different temperatures, namely 350 °C, 650 °C, and 1050 °C, and followed by air cooling and water quenching were studied. Stress relief temperature at 650 °C had induced sigma phase precipitation in between delta ferrite and austenite (δ/γ) grain boundaries, resulting in the loss of corrosion resistance in the weld metal. Interestingly, post weld heat treatment (PWHT) test samples that were reheated to solution annealing temperature had shown no weight loss. The ferrite count determination in the region of weld metal overlay increased at hydrogen relief and decreased at stress relief temperatures due to slow cooling, which is more favorable to austenite formation. The amount of ferrite in the weld metals was significantly reduced with the increment of solution anneal temperature to 1050 °C because of sufficient time for the formation of austenite and giving optimum equilibrium fraction in the welds.