Microstructure and corrosion resistance of modified 2024 Al alloy using surface mechanical attrition treatment combined with microarc oxidation process

A top ceramic coating was fabricated on the surface mechanical attrition treatment (SMAT) modified nanocrystalline layer of 2024 Al alloy by microarc oxidation (MAO) process. The corrosion resistance of the SMAT-MAO composite coating was studied by EIS. The results show that SMAT-MAO composite coating with 10 μm top ceramic coating exhibited better corrosion resistance, while the SMAT-MAO coating with the thickness of 15 μm showed worse corrosion resistance compared with those simple MAO coatings with same thickness. The formation of a dense passive film at the damaged region caused by the bottom nanocrystalline interface contributed to the improved corrosion resistance property.     

Passivation and corrosion behaviours of cobalt and cobalt-chromium-molybdenum alloy

Passivation and corrosion behaviour of the cobalt and cobalt-base alloy Co30Cr6Mo was studied in a simulated physiological solution containing chloride and bicarbonate ions and with pH of 6.8. The oxido-reduction processes included solid state transformations occurring at the cobalt/electrolyte interface are interpreted using theories of surface electrochemistry. The dissolution of cobalt is significantly suppressed by alloying it with chromium and molybdenum, since the alloy exhibited “chromium like” passivity. The structural and protective properties of passive oxide films formed spontaneously at the open circuit potential or during the anodic polarization were studied using electrochemical impedance spectroscopy in the wide frequency range.     

Surface characterization of oxides grown on the Ti–13Nb–13Zr alloy and their corrosion protection

Oxide films were formed on the biocompatible alloy Ti–13Nb–13Zr in a phosphate buffer at open-circuit potential (E_oc), potentiodynamically up to 8 V, or by micro-arc oxidation (MAO) at 300 V. Their electrochemical properties were assessed in a phosphate buffer saline solution (PBS). EIS and SEM results showed that the E_oc and potentiodynamically formed oxide films were compact and behave as a monolayer, while the MAO oxide was a bilayered film (compact inner and porous outer layers). Open-circuit potential and EIS resistance values indicated that the MAO oxide provides the best corrosion protection for the alloy in PBS.     

Degradation of the corrosion resistance of anodic oxide films through immersion in the anodising electrolyte

The deterioration of AA2024, AA6061 and AA7475 anodised in an environmentally-compliant tartaric acid/sulphuric acid electrolyte has been examined as a function of the immersion time in the electrolyte after termination of anodising. By transmission electron microscopy and scanning electron microscopy, degradation of the porous oxide film was qualitatively observed on AA2024. Electrochemical impedance spectroscopy revealed that AA2024 and AA7075 were more sensitive to prolonged immersion in the anodising electrolyte compared with AA6061, due to increased barrier layer thinning rates and increased susceptibility to localized corrosion. Salt spray tests confirmed the previous, indicating decay of anticorrosion performance for AA2024 and AA7075.     

Surface characterization and corrosion behavior of a novel gold-imitation copper alloy with high tarnish resistance in salt spray environment

A novel gold-imitation copper alloy (CuZnAlNiSnBRe) was designed and its corrosion behavior in salt spray environment was investigated. The new alloy has better tarnish resistance and corrosion resistance than the current coinage alloy used in China (H7211). A multi-layer film formed on the surface of the new alloy after a period of exposure to salt spray was responsible for the good resistance of the alloy. The corrosion products were a mixture of CuO, Cu₂O, ZnO, Al₂O₃ and Al(OH)₃, with the transition from Cu₂O to CuO occurring during the corrosion process.     

Experimental study of electrochemical corrosion behaviour of bilayer on AZ31B Mg alloy

A bilayer on AZ31B magnesium alloy was prepared by first applying anodization to modify the substrate, and then depositing a self-assembled nanophase particle (SANP) film. Structure and corrosion behaviour are characterized by scanning electron microscopy, energy dispersion spectrometry, X-ray diffraction, X-ray photoelectron spectroscopy, transmission electron microscope and electrochemical impedance spectroscopy. Experimental results indicate that the bilayer consists of a SNAP/loose layer and a dense layer, and provides the corrosion protection of Mg substrate for more than 354 h in 0.005 M NaCl solution. Therefore, the bilayer is effective to protect Mg alloy against corrosion for a long time.     

Degradation behaviour of AZ80E magnesium alloy exposed to phosphate buffer saline medium

Corrosion behaviour of AZ80E alloy in comparison with pure Mg was investigated in phosphate buffer saline (PBS) solution in order to assess its bioactivity. Open circuit potential and EIS results reveal that both samples exhibit self-passivation with time. The higher corrosion resistance of the alloy is discussed from the perspective of its microstructure. Anodic oxidation for the alloy surface in borate buffer solution was also attempted potentiostatically to modify its corrosion behaviour. Anodised specimen at controlled potential of 1.0 V(SCE) can improve the durability of the alloy in PBS medium. The results were further confirmed by SEM and EDX analyses.     

Corrosion resistance of amorphous aluminium-molybdenum alloys in an acidic chloride environment

Pure aluminium corrodes readily in 1 M HCl solution while its supersaturated alloys with Mo, explored in this work, exhibit excellent corrosion properties due to the oxide barrier film formation on the alloy surface. The influence of Mo content in the alloy on the potential and charge distribution across the system alloy |oxide film| solution was studied in situ using dc and ac electrochemical methods. Passivity, a sudden change in electrode impedance, and the onset of secondary passivity and pitting were discussed in terms of the solute segregation, according to the solute-rich mechanism, change in the alumina structure and solid state processes connected with the transport of point defects and spatial distribution of surface charge.     

Electrochemical corrosion behaviour of nanotubular Ti-13Nb-13Zr alloy in Ringer’s solution

Nanotubular oxide layer formation was achieved on biomedical grade Ti-13Nb-13Zr alloy using anodization technique in 1 M H₃PO₄ + 0.5 wt.% NaF. The as-formed and heat treated nanotubes were characterized using SEM, XRD and TEM. Corrosion behaviour of the nanotubular alloy was investigated employing potentiodynamic and potentiostatic polarization. The alloy after nanotubular oxide layer formation exhibited significantly higher corrosion current density than the bare alloy. The lower corrosion resistance of the nanotubular alloy was suggested to be associated with the distinctly separated barrier oxide/concave shaped tube bottom interface. A heat treatment at 150 °C appreciably enhanced the corrosion resistance property.     

Surface characterization and corrosion behavior of 70/30 Cu-Ni alloy in pristine and sulfide-containing simulated seawater

The corrosion behavior of the 70/30 Cu-Ni alloy in stagnant, aerated pristine and sulfide-containing simulated seawater as a function of exposure time was investigated with polarization curve measurement and electrochemical impedance spectroscopy (EIS). It was demonstrated that the compact protective oxide film formed on the 70/30 Cu-Ni alloy resulted in the decrease of corrosion rate in aerated pristine seawater; while the corrosion rate of 70/30 Cu-Ni alloy in aerated sulfide-containing seawater increased dramatically due to the catalysis of the sulfide ions or sulfide scale for both the cathodic and anodic reactions. The impedance spectra and the corresponding equivalent circuits confirmed that a duplex layer of a surface film was formed on the 70/30 Cu-Ni alloy in aerated pristine seawater after a period of time and that the inner layer was responsible for the good resistance of the alloy; while only a porous and non-protective corrosion product layer formed on the 70/30 Cu-Ni alloy in aerated sulfide-containing seawater, which made small values of charge transfer resistance (R_ct) to last for a abnormally long time by interfering with the growth of the protective oxide film. The composition of the surface film on the alloy in pristine and sulfide-containing seawater for different exposure times were investigated thoroughly by XPS. It was found that the duplex corrosion product layer formed on the alloy in pristine seawater was composed of an inner Cu₂O and an outer CuO layer. The porous and non-protective corrosion product layer formed on the alloy in aerated sulfide-containing seawater was a mixture of CuCl, Cu₂S, NiS, Cu₂O and NiO with trace amounts of CuO and Ni(OH)₂ and that the most significant component was Cu₂S. In addition, SEM was used to analyze the topography of the 70/30 Cu-Ni alloy in both solutions after different exposure times.     

Characterisation and corrosion resistance of the electrodeposited hydroxyapatite and bovine serum albumin/hydroxyapatite films on Ti–6Al–4V–1Zr alloy surface

A new titanium base Ti–6Al–4V–1Zr alloy covered with hydroxyapatite or bovine serum albumin/hydroxyapatite was characterized in this paper in order to be used as implant material. Following techniques were used: linear polarization, electrochemical impedance spectroscopy, scanning electronic microscopy, Fourier transform infrared spectroscopy and atomic force microscopy. For HA or BSA/HA covered alloy, the electric equivalent circuit contains two time constants (for the passive film and for coatings). The resistance of the protective films increased in time and BSA/HA coating was slightly rougher than HA coating, this situation being favourably to the cell adhesion.     

Zr-based bulk glassy alloy with improved resistance to stress corrosion cracking in sodium chloride solutions

In order to evaluate stress corrosion cracking (SCC) susceptibility of Zr-based bulk glassy alloys and develop the BGAs with low susceptibility to SCC, the SCC behaviour of Zr₅₀Cu₄₀Al₁₀, Zr₅₀Cu₃₀Al₁₀Ni₁₀ and hypoeutectic Zr₇₀Cu₆Al₈Ni₁₆ BGAs in various environments including sodium chloride solution has been investigated using a slow strain rate technique at an initial strain rate of 5 × 10⁻⁶ s⁻¹. It is found, for the first time, that the Zr₇₀Cu₆Al₈Ni₁₆ BGA has no susceptibility to SCC in a 0.5 M NaCl solution. On the other hand, Zr₅₀Cu₄₀Al₁₀ and Zr₅₀Cu₃₀Al₁₀Ni₁₀ BGAs are highly susceptible to SCC in the NaCl solution, although they are not susceptible to SCC in de-ionized water, phosphate buffer, 0.5 M Na₂SO₄ and 0.5 M NaNO₃ solutions. The possible cause of the high susceptibility to SCC in the NaCl solution for the Zr₅₀Cu₄₀Al₁₀ and Zr₅₀Cu₃₀Al₁₀Ni₁₀ BGAs is discussed.     

Heat treatment effect on the corrosion behaviour of black passivated ZnNi alloys

Electrochemical corrosion behaviour of ZnNi and black passivated ZnNi alloys in aerated and partially deaerated 5% NaCl solution was studied using dc and ac techniques. The heat treatment (24 h, 120 °C) effect on black CCC properties was analyzed. No changes in the R_p values were observed, but differences in the potentiodynamic curves and in EIS diagrams suggested a change in the corrosion mechanism. Comparative studies by AFM and electrochemical techniques showed that these changes in the corrosion behaviour could be explained by taking into account the different effect of heat treatment on the inner and outer layers of the CCC.     

Oxide properties and stress corrosion cracking behaviour for Alloy 600 in leaded caustic solutions at high temperature

The stress corrosion cracking behaviour of Alloy 600 in caustic solutions with and without PbO at 315 °C was investigated by means of slow strain rate tension tests. The characterisation of the oxide that formed on Alloy 600 was derived from transmission electron microscopy, energy dispersive X-ray spectroscopy, X-ray photoelectron spectroscopy and electrochemical impedance spectroscopy. Lead was incorporated into the oxide in a metallic lead state and a lead oxide state, which degraded the passivity and induced PbSCC susceptibility. NiB was used as an inhibitor. It reduced the lead incorporation level in the oxide layer and decreased PbSCC susceptibility.     

Influence of molybdate species on the tartaric acid/sulphuric acid anodic films grown on AA2024 T3 aerospace alloy

AA2024 T3 alloy specimens have been anodised in tartaric acid/sulphuric media and tartaric acid/sulphuric media containing sodium molybdate; molybdate species were added to the anodising bath to enhance further the protection provided by the porous anodic film developed over the macroscopic alloy surface. Morphological characterisation of the anodic films formed in both electrolytes was undertaken using scanning electron and transmission electron microscopies; the chemical compositions of the films were determined by Rutherford backscattering spectroscopy that was complemented by elemental depth profiling using rf-glow discharge optical emission spectrometry. The electrochemical behaviour was evaluated using potentiodynamic polarisations and electrochemical impedance spectroscopy; the corrosion performance was examined after salt spray testing. The porous anodic film morphology was little influenced by the addition of molybdate salt, although thinner films were generated in its presence. Chemical composition of the anodic film was roughly similar; however, addition of sodium molybdate in the anodizing bath resulted in residues of molybdate species in the porous skeleton and improved corrosion resistance measured by electrochemical techniques that was confirmed by salt spray testing.     

Inhibitory effect of some amino acids on corrosion of Pb-Ca-Sn alloy in sulfuric acid solution

The present article describes the inhibition effect of amino acids cysteine (Cys), methionine (Met) and alanine (Ala), towards the corrosion of lead-alloy (Pb-Ca-Sn) in H₂SO₄ solution by potentiodynamic polarization, electrochemical impedance spectroscopy (EIS), weight loss measurement and scanning electron microscopy (SEM) methods. The influence of inhibitor concentration, temperature and time on inhibitory behavior of the amino acids was investigated. The corrosion data including corrosion current density (I_corr), corrosion potential (E_corr) and charge transfer resistance (R_ct) were determined from Tafel plots and EIS. Recording impedance spectra showed that the charge transfer resistance is increased by increasing adsorption time. The SEM micrographs revealed that the corroded surface area is decreased in the presence of amino acids. Meanwhile, the inhibition efficiency (IE) was found to be depending on the type of amino acid and its concentration. The IE for 0.1 M Cys in 0.5 M H₂SO₄ is greater than 96%. Adsorption isotherms were fitted by Langmuir isotherm.     

The effect of oxidation on the corrosion resistance and mechanical properties of a Zr-based metallic glass

The oxidation kinetics of the Zr₆₄Cu₁₆Ni₁₀Al₁₀ bulk metallic glass (BMG) roughly follows a two-stage rate law at both 433 and 593 K in air. An oxide film of 940 nm can be formed by oxidation at 593 K, which is ZrO₂-enriched but Cu-depleted on the outer surface. The oxide film leads to a superior passivity in 0.5 M NaCl and great corrosion resistance improvements in other solutions. The oxidation effect on mechanical properties were characterized by nanoindentation, wedge indentation and compression tests. The Zr-based BMG still keeps the amorphous nature and its good mechanical properties are retained after oxidation.     

Comparative evaluation of corrosion behaviour of type K thin film thermocouple and its bulk counterpart

This paper investigates the corrosion behaviour of type K thermoelements and their thin films, and compares the performance of chromel–alumel thin film thermocouple with its wire counterpart before and after exposure to 5% NaCl medium. Potentiodynamic polarisation tests reveal that chromel and alumel films are more “noble” than their respective wires. Alumel corrodes faster when coupled with chromel in films than as wires. Secondary electron micrographs and electrochemical impedance spectroscopy measurements suggest that chromel shows localised corrosion while alumel undergoes uniform corrosion. Corrosion adversely affects the thermocouple output and introduces an uncertainty in the measurement.     

Plasma anodized ZE41 magnesium alloy sealed with hybrid epoxy-silane coating

Anodic coatings on magnesium ZE41 alloy were formed by DC plasma electrolytic oxidation (PEO) in spark regime in solution composed of NaOH, Na₂SiO₃ and KF. The positive effect of poly(ethylene oxide) addition into the anodizing electrolyte on PEO process, anodic film porosity and its protective performance was described. Anodic films were sealed with hybrid epoxy-silane formulation. The corrosion behavior of the coated ZE41 was studied through electrochemical impedance spectroscopy (EIS) in 0.6 M NaCl solution. Resulting duplex PEO/epoxy-silane coating provides good protective performance without significant signs of corrosion during 1 month of immersion test.     

Novel dispersed magnetite core–shell nanogel polymers as corrosion inhibitors for carbon steel in acidic medium

Novel core–shell preparing poly(2-acrylamido-2-methylpropane sulfonic acid) (PAMPS) and copolymers with acrylic acid (AA) or acrylamide (AM) magnetic nanogels with controllable particle size produced via free aqueous polymerization at room temperature have been developed for the first time. The crosslinking polymerization was carried out in the presence of N,N′-methylenebisacrylamide (MBA) as a crosslinker, N,N,N′,N′-tetramethylethylenediamine (TEMED) and potassium peroxydisulfate (KPS) as redox initiator system. The structure and morphology of the magnetic nanogels were characterized by Fourier transform infrared spectroscopy (FTIR), transmission and scanning electron microscopy (TEM and SEM). The effectiveness of the synthesized compounds as corrosion inhibitors for carbon steel in 1 M HCl was investigated by various electrochemical techniques such as potentiodynamic polarization and electrochemical impedance spectroscopy (EIS). The results showed enhancement in inhibition efficiencies with increasing the inhibitor concentrations and temperatures. The results showed the nanogel particles act as mixed inhibitors. Adsorption of nanogel particles was found to fit the Langmuir isotherm and was chemisorption.