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Corrosion Prediction and Corrosion Protection
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Corrosion Prediction and Corrosion Protection

A special issue of Materials (ISSN 1996-1944). This special issue belongs to the section "Corrosion".

Deadline for manuscript submissions: closed (20 March 2023) | Viewed by 21182

Special Issue Editor

Prof. Dr. Sergey E. Barykin

E-Mail Website
Guest Editor
Graduate School of Service and Trade, Peter the Great St. Petersburg Polytechnic University, St. Petersburg, Russia
Interests: manufacturing processes; digital platforms; industry 4.0; digital economy
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

 Dear Colleagues,

We are pleased to announce that you can submit a publication for this Special Issue on the latest research in the field of corrosion resistance of metals and the degree of influence of various factors on it, methods of studying the corrosion resistance of materials and non-destructive testing, assessing the reliability and durability of structures, as well as modeling corrosion processes.

Topics of the Special Issue include but are not limited to:

  • Approaches to modeling corrosion processes;
  • Reliability of structures;
  • The effectiveness of methods of protection against corrosion;
  • Corrosion resistance of pipelines;
  • Assessment of the reliability of pipelines;
  • Approaches to modeling corrosion processes.

Prof. Dr. Sergey E. Barykin
Guest Editor

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 100 words) can be sent to the Editorial Office for announcement on this website.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Materials is an international peer-reviewed open access semimonthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2600 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

  • corrosion resistance
  • modeling of corrosion processes
  • methods of corrosion resistance research
  • corrosion prediction
  • oil pipeline
  • gas pipeline

Published Papers (12 papers)

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Research

11 pages, 6248 KiB  
Article
Derivation of Corrosion Depth Formula According to Corrosion Factors in District Heating Water through Regression Analysis
by Yoon-Sik So, Jeong-Min Lim, Sin-Jae Kang, Woo-Cheol Kim and Jung-Gu Kim
Materials 2023, 16(8), 3254; https://0-doi-org.brum.beds.ac.uk/10.3390/ma16083254 - 20 Apr 2023
Cited by 1 | Viewed by 951
Abstract
In order to predict the corrosion depth of a district heating pipeline, it is necessary to analyze various corrosion factors. In this study, the relationship between corrosion factors such as pH, dissolved oxygen, and operating time and corrosion depth was investigated using the [...] Read more.
In order to predict the corrosion depth of a district heating pipeline, it is necessary to analyze various corrosion factors. In this study, the relationship between corrosion factors such as pH, dissolved oxygen, and operating time and corrosion depth was investigated using the Box–Behnken method within the response surface methodology. To accelerate the corrosion process, galvanostatic tests were conducted in synthetic district heating water. Subsequently, a multiple regression analysis was performed using the measured corrosion depth to derive a formula for predicting the corrosion depth as a function of the corrosion factors. As a result, the following regression formula was derived for predicting the corrosion depth: “corrosion depth (μm) = −133 + 17.1 pH + 0.00072 DO + 125.2 Time − 7.95 pH × Time + 0.002921 DO × Time”. Full article
(This article belongs to the Special Issue Corrosion Prediction and Corrosion Protection)
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17 pages, 4887 KiB  
Article
The Effect of the Operation of Downhole Equipment on the Processes of Corrosive Wear (by the Example Inflow Control Devices of Nozzle Type)
by Pavel Kruk, Ivan Golubev, Nikita Shaposhnikov, Julia Shinder and Dmitry Kotov
Materials 2022, 15(19), 6731; https://0-doi-org.brum.beds.ac.uk/10.3390/ma15196731 - 28 Sep 2022
Viewed by 1246
Abstract
Existing approaches to assessing the reliability and safe operation of downhole equipment provide for assessing only the direct impact of erosion and corrosion processes on the degradation of the material. At the same time, the influence of downhole equipment operating modes on the [...] Read more.
Existing approaches to assessing the reliability and safe operation of downhole equipment provide for assessing only the direct impact of erosion and corrosion processes on the degradation of the material. At the same time, the influence of downhole equipment operating modes on the intensity of corrosion and erosion processes is not evaluated. The necessity of using inflow control devices is shown. The necessity of selecting inflow control devices for specific operating modes of the well is highlighted in order to avoid increased erosion wear due to increased sand production. In this article, a series of studies was conducted to assess the influence of the hydrodynamic characteristics of the fluid flow, which vary depending on the operating modes of the nozzle-type inflow control device, on corrosion processes in the well. It was shown that the level of wall shear stress (WSS) of the base pipe, immediately after the flow control device in the direction of fluid flow, affects the intensification of corrosion processes in downhole equipment. Studies of WSS on the pipe wall were carried out using a dynamic autoclave and elements of mathematical modeling. The design factors (the angle of inclination of the main hydraulic channel of the inflow control device relative to the base pipe) affecting the change in tangential stresses on the wall of the base pipe were investigated. The mechanism of corrosion wear of the base pipe was revealed. Full article
(This article belongs to the Special Issue Corrosion Prediction and Corrosion Protection)
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16 pages, 6771 KiB  
Article
Development of a Methodology for the Quality Management of Duplex Stainless Steels
by Aleksandr Fedorov, Andrey Zhitenev, Vladimir Karasev, Aleksey Alkhimenko and Pavel Kovalev
Materials 2022, 15(17), 6008; https://0-doi-org.brum.beds.ac.uk/10.3390/ma15176008 - 31 Aug 2022
Cited by 6 | Viewed by 1648
Abstract
The use of traditional materials leads to failures and breakdowns of expensive equipment, so advanced materials are needed that can provide reliable and durable solutions. The ability to control the quality of duplex stainless steels (DSSs) can greatly help with the development of [...] Read more.
The use of traditional materials leads to failures and breakdowns of expensive equipment, so advanced materials are needed that can provide reliable and durable solutions. The ability to control the quality of duplex stainless steels (DSSs) can greatly help with the development of new compositions or choosing existing DSSs. In this case, it is necessary to consider the final consumer properties—corrosion resistance and mechanical properties, which depend on the phase composition, contamination with non-metallic inclusions (NMIs), and the presence of undesirable secondary phases. In this research, specimens of cast DSSs of different grades, produced at laboratory and industrial scales, were studied. A technique for quantifying the microstructure of DSSs was developed. A thermodynamic database was chosen that adequately describes the processes of phase formation in DSSs. The effects of heat treatment on the microstructure and corrosion properties of cast DSSs were studied. The effects of the structural state on the changes in consumer properties of the final product are shown. It is shown that using various deoxidation technologies, it is possible to obtain both NMIs that are dangerous in terms of corrosive activity and ones that are relatively safe. Full article
(This article belongs to the Special Issue Corrosion Prediction and Corrosion Protection)
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21 pages, 4521 KiB  
Article
Superhydrophobic Anticorrosive Phosphonate–Siloxane Films Formed on Zinc with Different Surface Morphology
by Galina V. Redkina, Alexandra S. Sergienko, Yurii I. Kuznetsov and Oleg Yu. Grafov
Materials 2022, 15(15), 5360; https://0-doi-org.brum.beds.ac.uk/10.3390/ma15155360 - 04 Aug 2022
Cited by 3 | Viewed by 1237
Abstract
The composition, structure, and protective and hydrophobic properties of nanoscale films formed layer-by-layer in solutions of sodium dodecylphosphonate (SDDP) and vinyltrimethoxysilane or n-octyltriethoxysilane (OTES) on the zinc surface with different morphologies were studied by SEM, XPS, water contact angle measurements, and electrochemical [...] Read more.
The composition, structure, and protective and hydrophobic properties of nanoscale films formed layer-by-layer in solutions of sodium dodecylphosphonate (SDDP) and vinyltrimethoxysilane or n-octyltriethoxysilane (OTES) on the zinc surface with different morphologies were studied by SEM, XPS, water contact angle measurements, and electrochemical and corrosion tests. The protective, hydrophobic properties of phosphonate–siloxane films on zinc and their stability in a corrosive media are determined both by the initial surface morphology and composition of the surface oxide layer, and by the nature of inhibitors. It was shown that preliminary laser texturing of the zinc surface is preferable than chemical etching to enhance the anticorrosive properties of the resulting thin films. The most stable films with excellent superhydrophobic and protective properties in atmospheres of high humidity and salt spray are formed on the zinc surface with fractal morphology during layer-by-layer passivation with SDDP and OTES. Full article
(This article belongs to the Special Issue Corrosion Prediction and Corrosion Protection)
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25 pages, 8928 KiB  
Article
New Chemically Resistant Coating Systems with Progressive Incorporation of Hazardous Waste in Polyurethane and Epoxy Matrices
by Jakub Hodul, Lenka Mészárosová and Rostislav Drochytka
Materials 2022, 15(9), 3235; https://0-doi-org.brum.beds.ac.uk/10.3390/ma15093235 - 29 Apr 2022
Cited by 1 | Viewed by 1699
Abstract
New types of highly chemically resistant coating systems, primarily intended for concrete and metal substrates, were designed and experimentally verified in the paper. Secondary raw materials in optimal amounts, including solidified hazardous waste (e.g., end product and cement bypass dust), were used as [...] Read more.
New types of highly chemically resistant coating systems, primarily intended for concrete and metal substrates, were designed and experimentally verified in the paper. Secondary raw materials in optimal amounts, including solidified hazardous waste (e.g., end product and cement bypass dust), were used as microfillers. The polymer coating systems, containing pre-treated hazardous waste (HW), showed high abrasion resistance and excellent adhesion to metal and concrete surfaces. Based on polyurethane and epoxy resins, the coatings can be used in environments where aggressive chemical media act, such as sewers and the chemical industry. The developed polymeric coating systems showed even better properties than the compared reference coating systems. The chemical resistance of the three-layer coating systems was evaluated both visually and based on changes in mechanical properties, such as hardness and adhesion. The microstructure of the coating systems was also monitored using a digital optical microscope and a scanning electron microscope with energy dispersive X-ray analysis (SEM-EDX) after chemical stress. It was observed that the particles of HW were fully incorporated into the polymer matrix of the coating systems. Full article
(This article belongs to the Special Issue Corrosion Prediction and Corrosion Protection)
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15 pages, 7699 KiB  
Article
A Critical Analysis on the Current Design Criteria for Cathodic Protection of Ships and Superyachts
by Davide Clematis, Alessandro Marroccu, Marco Panizza and Antonio Barbucci
Materials 2022, 15(7), 2645; https://0-doi-org.brum.beds.ac.uk/10.3390/ma15072645 - 04 Apr 2022
Cited by 2 | Viewed by 2029
Abstract
Classification Society and ISO standard regulate the design of cathodic protection (CP) plans of ships and superyachts. However, due to shipyards’ long experience, the hull vessel protection plans often rely on an adaptation of previous CP designs for similar ships. This simple practice [...] Read more.
Classification Society and ISO standard regulate the design of cathodic protection (CP) plans of ships and superyachts. However, due to shipyards’ long experience, the hull vessel protection plans often rely on an adaptation of previous CP designs for similar ships. This simple practice could expose ships to low protection or overprotection. Here, the protection plan of an existing 42 m superyacht is considered to highlight critical CP design issues. The numerical analysis gives evidence of discrepancies between the CP design proposed in accordance with ISO standard and the protection plan that was actually implemented. Indeed, for a proper protection plan, the anode weight according to the ISO standard is 2.7 kg, whereas the real protection plan uses a 7 kg anode. The numerical optimization highlights an optimal anode mass of 5 kg (−28.5% in weight). It provides sufficient protection for the expected lifetime, and will preserve the system in cases of damage to the hull and a consequent increase in the breakdown factor. This new solution underlines the importance and necessity of improving cathodic protection plan design. Full article
(This article belongs to the Special Issue Corrosion Prediction and Corrosion Protection)
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25 pages, 3815 KiB  
Article
The Useful Life of Reinforced Concrete Structures with Reinforcement Corrosion Due to Carbonation in Non-Aggressive and Normal Exposures in the Spanish Mediterranean
by Pascual Saura-Gómez, Carlos Rizo-Maestre and Víctor Echarri-Iribarren
Materials 2022, 15(3), 745; https://0-doi-org.brum.beds.ac.uk/10.3390/ma15030745 - 19 Jan 2022
Cited by 5 | Viewed by 1653
Abstract
Some reinforced concrete structures must be repaired at an early stage in their life due to the oxidation processes suffered by their reinforcements; such processes involve serious pathologies that affect the stability and safety of buildings. Spanish legislation distinguishes several classes of environments, [...] Read more.
Some reinforced concrete structures must be repaired at an early stage in their life due to the oxidation processes suffered by their reinforcements; such processes involve serious pathologies that affect the stability and safety of buildings. Spanish legislation distinguishes several classes of environments, with non-aggressive and normal exposure providing a longer useful life of the structure. The present study shows that some structural elements in reinforced concrete, mainly the pillars in the area of contact with the ground, are exposed to significant corrosion by carbonation. This position of the structural elements dramatically and abruptly shortens the useful life of the models provided for the current regulations. A total of 17 pillars in 10 buildings of different ages and locations in the Spanish Mediterranean area, not subject to the presence of chlorides, have been analyzed. These buildings are situated in environments considered by the standard as normal and non-aggressive. The actual carbonation that these elements present have been compared with that which can be derived from the model established by Spanish regulations. Of these pillars, 14 present a carbonation higher than that derived from the model, and the last three pillars largely conform to the figures of the model. This significant deviation shows the need for a revision of the Spanish EHE 08 regulation, which should include aspects such as the action of dampness by capillarity and the differences in electrochemical potential between the different materials. Full article
(This article belongs to the Special Issue Corrosion Prediction and Corrosion Protection)
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21 pages, 5785 KiB  
Article
Experimental Study on the Corrosion of Carbon Steel and Aluminum Alloy in Firefighting Protein Foam Concentrates
by Marina Teodora Patrascu, Andrei Dan Busuioc, Cristina Busuioc, Adina Cotarta, Anca Cojocaru, Teodor Visan and Danut Ionel Vaireanu
Materials 2021, 14(23), 7259; https://0-doi-org.brum.beds.ac.uk/10.3390/ma14237259 - 27 Nov 2021
Cited by 1 | Viewed by 1811
Abstract
The corrosion of mild steel and Al alloy in Fomtec P 6% and 6% P Profoam 806 protein-based foam concentrates was investigated. Weight-loss data for steel showed corrosion penetration of 0.745 mipy in Fomtec and 2.269 mipy in Profoam, whereas for Al alloy [...] Read more.
The corrosion of mild steel and Al alloy in Fomtec P 6% and 6% P Profoam 806 protein-based foam concentrates was investigated. Weight-loss data for steel showed corrosion penetration of 0.745 mipy in Fomtec and 2.269 mipy in Profoam, whereas for Al alloy the penetration levels were 0.474 and 1.093 mipy, respectively. Scanning electron microscopy and energy dispersive X-ray spectroscopy allowed characterization of the metallic surface covered or free from corrosion products. Values of corrosion potential, corrosion current density and corrosion penetration were calculated by using potentiodynamic polarization curves. Electrochemical impedance spectra illustrated the change in polarization resistance during anodic polarization. Data obtained by accelerated electrochemical methods confirm the greater aggressiveness of the Profoam concentrate compared to Fomtec concentrate. Full article
(This article belongs to the Special Issue Corrosion Prediction and Corrosion Protection)
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23 pages, 6206 KiB  
Article
Quantum Chemical Analysis of the Corrosion Inhibition Potential by Aliphatic Amines
by Szymon Malinowski, Michał Wróbel and Agnieszka Woszuk
Materials 2021, 14(20), 6197; https://0-doi-org.brum.beds.ac.uk/10.3390/ma14206197 - 19 Oct 2021
Cited by 18 | Viewed by 1741
Abstract
Destructive corrosion processes lead to the loss of primary mechanical properties of metal construction materials, which generates additional costs during their maintenance connected with repairs and protection. The effectiveness of corrosion inhibitors can be determined by using many methods, in particular quantum chemical [...] Read more.
Destructive corrosion processes lead to the loss of primary mechanical properties of metal construction materials, which generates additional costs during their maintenance connected with repairs and protection. The effectiveness of corrosion inhibitors can be determined by using many methods, in particular quantum chemical modeling. The subject of the theoretical analyses presented in this work involves the anticorrosion properties of amines with various chemical structures. Evaluation of the corrosion inhibition properties of selected amines was performed on the basis of the HOMO–LUMO energy gap, dipole moment (µ), electronegativity (χ) determined as a result of the energy of the highest occupied molecular orbital (HOMO) and the energy of the lowest unoccupied molecular orbital (LUMO). Moreover, the HSAB (Hard and Soft Acids and Bases) theory was used to explain the reactivity of the analyzed amines, while the Mulliken population analysis was used to determine their electrostatic interactions with the surface of protected metal. The obtained results indicate that the protonation reaction of aliphatic amines leads to a change in the nature of the formation of a coordination bond with the surface of the protected metal. In turn, the quantum chemical calculations showed that the protonation reaction of aliphatic amines leads to a decrease in their corrosion inhibition efficiency. Most of the analyzed parameters indicated that tertiary amines are characterized by the highest corrosion inhibition efficiency. Full article
(This article belongs to the Special Issue Corrosion Prediction and Corrosion Protection)
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14 pages, 7473 KiB  
Article
Adsorption of Organosilanes on the Surface of Aluminium and the Formation of Organosilane Films to Protect It from Corrosion
by Natalia Gladkikh, Maxim Petrunin, Ludmila Maksaeva and Tatyana Yurasova
Materials 2021, 14(19), 5757; https://0-doi-org.brum.beds.ac.uk/10.3390/ma14195757 - 02 Oct 2021
Cited by 9 | Viewed by 1417
Abstract
Adsorption of diaminesilane (DAS), vinyltrimethoxysilane (VS) on the surface of thermally precipitated aluminium was examined. The use of different adsorption isotherms made it possible to calculate the adsorption heats for DAS and VS. It was determined that chemisorption of these organosilanes occurred on [...] Read more.
Adsorption of diaminesilane (DAS), vinyltrimethoxysilane (VS) on the surface of thermally precipitated aluminium was examined. The use of different adsorption isotherms made it possible to calculate the adsorption heats for DAS and VS. It was determined that chemisorption of these organosilanes occurred on the surface of aluminium. Exposure of aluminium for 60 min to aqueous solutions of organosilanes led to the formation of organosilane films on the surface of the metal. The use of infrared spectroscopy and scanning electron microscopy in the work made it possible to assess the interactions of organosilanes with the metal surface, as well as to determine the structural features of the films and their thickness. Electrochemical and corrosion research methods made it possible to study the protective properties of organosilane films on aluminium. Full article
(This article belongs to the Special Issue Corrosion Prediction and Corrosion Protection)
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13 pages, 9785 KiB  
Article
The Localized Corrosion and Stress Corrosion Cracking of a 6005A-T6 Extrusion Profile
by Jijun Ma, Jing Sun, Quanmei Guan, Qingwei Yang, Jian Tang, Chengxiong Zou, Jun Wang, Bin Tang, Hongchao Kou, Haisheng Wang, Jun Gao, Jinshan Li and William Yi Wang
Materials 2021, 14(17), 4924; https://0-doi-org.brum.beds.ac.uk/10.3390/ma14174924 - 30 Aug 2021
Cited by 1 | Viewed by 1760
Abstract
In the present work, the localized corrosion and stress corrosion cracking (SCC) behaviors of a commercial 6005A-T6 aluminum extrusion profile was studied comprehensively. The velocity of crack growth in self-stressed double-cantilever beam (DCB) specimens under constant displacement was estimated, which also provides insight [...] Read more.
In the present work, the localized corrosion and stress corrosion cracking (SCC) behaviors of a commercial 6005A-T6 aluminum extrusion profile was studied comprehensively. The velocity of crack growth in self-stressed double-cantilever beam (DCB) specimens under constant displacement was estimated, which also provides insight into the local microstructure evolutions at the crack tips caused by the localized pitting corrosion, intergranular corrosion (IGC), and intergranular SCC. Characterizations of local corrosion along the cracking path for a period of exposure to 3.5% NaCl were revealed via optical microscope (OM), scanning electron microscope (SEM), and electron backscatter diffraction (EBSD). The typical features of the pits dominated by the distribution of precipitates included the peripheral dissolution of the Al matrix, channeling corrosion, intergranular attack, and large pits in the grains. The discontinuous cracking at the crack tips indicated the hydrogen-embrittlement-mediated mechanism. Moreover, the local regions enriched with Mg2Si and Mg5Si6 phases and with low-angle grain boundaries presented better SCC resistance than those of the matrix with high-angle grain boundaries, supporting a strategy to develop advanced Al–Mg–Si alloys via interfacial engineering. Full article
(This article belongs to the Special Issue Corrosion Prediction and Corrosion Protection)
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14 pages, 9178 KiB  
Article
Corrosion Assessment of a Weathering Steel Bridge Structure after 30 Years of Service
by Agnieszka Królikowska, Leszek Komorowski, Izabela Kunce, Damian Wojda, Katarzyna Zacharuk, Urszula Paszek, Tomasz Wierzbicki and Katarzyna Bilewska
Materials 2021, 14(14), 3788; https://0-doi-org.brum.beds.ac.uk/10.3390/ma14143788 - 06 Jul 2021
Cited by 9 | Viewed by 2399
Abstract
The first steel with improved resistance towards atmospheric corrosion, the so-called weathering steel, was patented in the USA in 1933 and was initially used for coal railway cars, and after that, in building and bridge engineering. Weathering steels show higher corrosion resistance than [...] Read more.
The first steel with improved resistance towards atmospheric corrosion, the so-called weathering steel, was patented in the USA in 1933 and was initially used for coal railway cars, and after that, in building and bridge engineering. Weathering steels show higher corrosion resistance than carbon steels in many types of atmosphere due to their ability to form a compact, stable, adherent and protective patina during the time of exposure. Morphological evaluation of the appearance of the corrosion product layer, together with phase analysis of its components, can enable determination of the type of patina and the degree of protection of the steel. To support the visual assessment of a patina, a check based on the qualitative and quantitative phase analysis of its components may be carried out, and the PAI (Protective Ability Index) can be calculated. The estimation of the corrosion processes on original Polish-made weathering steel (12HNNbA) was carried out on a 30-year-old bridge in Poland. There are some structural problems within the deck derived not only from corrosion but also steel cracking, both inside and outside the boxes, at different heights. Fourteen representative samples of patina were analysed and their phase structures were determined by the X-ray powder diffraction method. The PAIs were determined and analysed. Full article
(This article belongs to the Special Issue Corrosion Prediction and Corrosion Protection)
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