Long-term corrosion monitoring of carbon steels and environmental correlation analysis via the random forest method

In this work, the atmospheric corrosion of carbon steels was monitored at six different sites (and hence, atmospheric conditions) using Fe/Cu-type atmospheric corrosion monitoring technology over a period of 12 months. After analyzing over 3 million data points, the sensor data were interpretable as the instantaneous corrosion rate, and the atmospheric “corrosivity” for each exposure environment showed highly dynamic changes from the C1 to CX level (according to the ISO 9223 standard). A random forest model was developed to predict the corrosion rate and investigate the impacts of ten “corrosive factors” in dynamic atmospheres. The results reveal rust layer, wind speed, rainfall rate, RH, and chloride concentration, played a significant role in the corrosion process.

An integrated metagenomic and metabolite profiling study of hydrocarbon biodegradation and corrosion in navy ships

Naval vessels regularly mix fuel and seawater as ballast, a practice that might exacerbate fuel biodegradation and metal biocorrosion. To investigate, a metagenomic characterization and metabolite profiling of ballast from U.S. Navy vessels with residence times of 1-, ~20-, and 31 weeks was conducted and compared with the seawater used to fill the tanks. Aerobic Gammaproteobacteria differentially proliferated in the youngest ballast tank and aerobic-specific hydrocarbon degradation genes were quantitatively more important compared to seawater or the other ballast tanks. In contrast, the anaerobic Deltaproteobacteria dominated in the eldest ballast fluid with anaerobic-specific hydrocarbon activation genes being far more prominent. Gene activity was corroborated by detection of diagnostic metabolites and corrosion was evident by elevated levels of Fe, Mn, Ni and Cu in all ballast samples relative to seawater. The findings argue that marine microbial communities rapidly shift from aerobic to anaerobic hydrocarbonoclastic-dominated assemblages that accelerate fuel and infrastructure deterioration.

Forty years of durability assessment of nuclear waste glass by standard methods

Standard methods to assess the durability of vitrified radioactive waste were first developed in the 1980’s and, over the last 40 years, have evolved to yield a range of responses depending on experimental conditions and glass composition. Mechanistic understanding of glass dissolution has progressed in parallel, enhancing our interpretation of the data acquired. With the implementation of subsurface disposal for vitrified radioactive waste drawing closer, it is timely to review the available standard methodologies and reflect upon their relative advantages, limitations, and how the data obtained can be interpreted to support the post-closure safety case for radioactive waste disposal.

Microbiologically influenced corrosion inhibition of carbon steel via biomineralization induced by Shewanella putrefaciens

Microbiologically influenced corrosion inhibition (MICI) of Q235 carbon steel by biomineralization was investigated via a combination of surface analysis, electrochemistry, and scanning electrochemical microscopy (SECM). The results showed that Shewanella putrefaciens used the cell walls as the nucleation sites to induce the formation of a protective biomineralized layers which contained calcite and extracellular polymeric substances on the steel surface. The potentiodynamic polarization results demonstrated that the corrosion current density (icorr value) of the biomineralized steel surface was 0.38 μA cm−2, which was less than one-tenth that of the blank steel in a sterile medium (4.86 μA cm−2) after 14 days. The biomineralized layers presented wear resistance and could self-repair after undergoing mechanical damage under microbial conditions as verified by morphological and SECM observations. This work reveals that microbial-induced carbonate biomineralization, as a MICI approach, may be considered as a reliable, low-cost, environmentally friendly corrosion inhibition strategy.

Electrochemical tomography as a nondestructive technique to study localized corrosion of metals

We present an approach, termed electrochemical tomography (ECT), for the in-situ study of corrosion phenomena in general, and for the quantification of the instantaneous rate of localized corrosion in particular. Traditional electrochemical techniques have limited accuracy in determining the corrosion rate when applied to localized corrosion, especially for metals embedded in opaque, porous media. One major limitation is the generally unknown anodic surface area. ECT overcomes these limitations by combining a numerical forward model, describing the electrical potential field in the porous medium, with electrochemical measurements taken at the surface, and using a stochastic inverse method to determine the corrosion rate, and the location and size of the anodic site. Additionally, ECT yields insight into parameters such as the exchange current densities, and it enables the quantification of the uncertainty of the obtained solution. We illustrate the application of ECT for the example of localized corrosion of steel in concrete.

Applying laboratory methods for durability assessment of vitrified material to archaeological samples

Laboratory testing used to assess the long-term chemical durability of nuclear waste forms may not be applicable to disposal because the accelerated conditions may not represent disposal conditions. To address this, we examine the corrosion of vitrified archeological materials excavated from the near surface of a ~1500-year old Iron Age Swedish hillfort, Broborg, as an analog for the disposal of vitrified nuclear waste. We compare characterized site samples with corrosion characteristics generated by standard laboratory durability test methods including the product consistency test (PCT), the vapor hydration test (VHT), and the EPA Method 1313 test. Results show that the surficial layer of the Broborg samples resulting from VHT displays some similarities to the morphology of the surficial layer formed over longer timescales in the environment. This work provides improved understanding of long-term glass corrosion behavior in terms of the thickness, morphology, and chemistry of the surficial features that are formed.

Flow accelerated corrosion and erosion−corrosion behavior of marine carbon steel in natural seawater

In this work, flow accelerated corrosion (FAC) and erosion−corrosion of marine carbon steel in natural seawater were electrochemically studied using a submerged impingement jet system. Results show that the formation of a relatively compact rust layer in flowing natural seawater would lead to the FAC pattern change from ‘flow marks’ to pits. The increase of the flow velocity was found to have a negligible influence on the FAC rate at velocities of 5−8 m s−1. The synergy of mechanical erosion and electrochemical corrosion is the main contributor to the total steel loss under erosion−corrosion. The increase of the sand impact energy could induce the pitting damage and accelerate the steel degradation. The accumulation of the rust inside the pits could facilitate the longitudinal growth of the pits, however, the accumulated rusts retard the erosion of the pit bottom. The erosion and corrosion could work together to cause the steel peeling at the pit boundary. The steel degradation would gradually change from corrosion-dominated to erosion-dominated along with the impact energy increasing.

Examining oxidation in β-NiAl and β-NiAl+Hf alloys by stochastic cellular automata simulations

We present results from a stochastic cellular automata (CA) model developed and employed for examining the oxidation kinetics of NiAl and NiAl+Hf alloys. The rules of the CA model are grounded in diffusion probabilities and basic principles of alloy oxidation. Using this approach, we can model the oxide scale thickness and morphology, specific mass change and oxidation kinetics as well as an approximate estimate of the stress and strains in the oxide scale. Furthermore, we also incorporate Hf in the grain boundaries and observe the “reactive element effect”, where doping with Hf results in a drastic reduction in the oxidation kinetics concomitant with the formation of thin, planar oxide scales. Interestingly, although we find that grain boundaries result in rapid oxidation of the undoped NiAl, they result in a slower-growing oxide and a planar oxide/metal interface when doped with Hf.

Smart coating with dual-pH sensitive, inhibitor-loaded nanofibers for corrosion protection

Smart coatings that provide corrosion protection on demand have received a lot of recent attention. In the present study, nanofibers containing a corrosion inhibitor were prepared by a coaxial electrospinning technique, which addresses the limitations of inhibitor-loaded microcapsules or nanocontainers. The as-prepared nanofibers have a core-shell structure with Ce(NO3)3 and the chitosan/polyacrylic acid polyelectrolyte coacervate as the core and shell materials, respectively. UV-vis spectroscopic analysis confirms that the nanofibers are pH-sensitive and able to release the enclosed Ce(NO3)3 at both low and high pH conditions, which are spontaneously generated during corrosion at local anodes and cathodes, respectively. A coating system consisting of such nanofibers within a polyvinyl butyral coating matrix exhibits improved corrosion protection of an AA2024-T3 substrate. Moreover, the embedded Ce(NO3)3-loaded nanofibers can persistently release Ce(NO3)3 to impede corrosion of AA2024-T3 when the artificially damaged coating sample is exposed to NaCl solution.