Structural health monitoring: a practical approach to achieving in-situ and site-specific warning of pipeline corrosion and coating failure

An approach to achieving the ambitious goal of cost effectively extending the safe operation life of energy pipelines to, for instance, 100 years is the application of structural health monitoring and life prediction tools that are able to provide long-term remnant pipeline life prediction and in-situ pipeline condition monitoring. A critical step in pipeline structural health monitoring is the enhancement of technological capabilities that are required for quantifying the effects of key factors influencing buried pipeline corrosion and environmentally assisted materials degradation, and the development of condition monitoring technologies that are able to provide in-situ monitoring and site-specific warning of pipeline damage. This paper provides an overview of our current research aimed at developing new sensors for monitoring, categorising and quantifying the level and nature of external pipeline and coating damages under the combined effects of various inter-related variables and processes such as localised corrosion, coating damage and disbondment, cathodic shielding. The concept of in-situ monitoring and site-specific warning of pipeline corrosion is illustrated by a case of monitoring localised corrosion under disbonded coatings using a new corrosion monitoring probe. A basic principle that underpins the use of sensors to monitor localised corrosion has been presented: Localised corrosion and coating failure are not an accidental occurrence, it occurs as the result of fundamental thermodynamic instability of a metal exposed to a specific environment. Therefore corrosion and coating disbondment occurring on a pipeline will also occur on a sensor made of the same material and exposed to the same pipeline condition. Although the exact location of localised corrosion or coating disbondment could be difficult to pinpoint along the length of a buried pipeline, the ‘worst-case scenario’ and high risk pipeline sections and sites are predictable. Sensors can be embedded at these strategic sites to collect data that contain ‘predictor features’ signifying the occurrence of localised corrosion, CP failure, coating disbondment and degradation. Information from these sensors will enable pipeline owners to prioritise site survey and inspection operations, and to develop maintenance strategy to manage aged pipelines, rather than replace them.

Effects of Nd on the microstructures, mechanical properties and in vitro corrosion behavior of cast Mg-1Mn-2Zn-xNd alloys

Effects of neodymium (Nd) on the microstructures, mechanical properties, in vitro corrosion behavior, and cytotoxicity of as-cast Mg- 1Mn-2Zn-xNd alloys (x = 0.5, 1.0, 1.5, mass%) have been investigated to assess whether Nd is an effective element to increase the strength and corrosion resistance of Mg alloys, and to evaluate whether those alloys are suitable for biomedical applications. The microstructures were examined by X-ray diffraction analysis and optical microscopy. The mechanical properties were determined from uniaxial tensile and compressive tests. The corrosion behavior was studied using electrochemical measurement and cytotoxicity was evaluated using osteoblast-like SaOS2 cell. The results indicate that all the cast Mg-1Mn-2Zn-xNd alloys are composed of both alpha phase of magnesium (Mg) and a compound of Mg7Zn3, and their grain sizes decrease with Nd content. Nd is not an effective element to improve the strength and corrosion resistance of cast Mg-Mn-Zn alloys. Increase of Nd content from 0.5 to 1.5 does not significantly change biocompatibility of alloys. The cast alloys exhibit much better corrosion resistance than pure Mg and good biocompatibility.

Synergistic corrosion inhibition of mild steel in aqueous chloride solutions by an imidazolinium carboxylate salt

Mild steel infrastructure is constantly under corrosive attack in most environmental and industrial conditions. There is an ongoing search for environmentally friendly, highly effective inhibitor compounds that can provide a protective action in situations ranging from the marine environment to oil and gas pipelines. In this work an organic salt comprising a protic imidazolinium cation and a 4-hydroxycinnamate anion has been shown to produce a synergistic corrosion inhibition effect for mild steel in 0.01 M NaCl aqueous solutions under acidic, neutral, and basic conditions; an important and unusual phenomenon for one compound to support inhibition across a range of pH conditions. Significantly, the individual components of this compound do not inhibit as effectively at equivalent concentrations, particularly at pH 2. Immersion studies show the efficacy of these inhibitors in stifling corrosion as observed from optical, SEM, and profilometry experiments. The mechanism of inhibition appears to be dominated by anodic behavior where dissolution of the steel, and in particular the pitting process, is stifled. FTIR spectroscopy provides confirmation of a protective interfacial layer, with the observation of interactions between the steel surface and 4-hydroxycinnamate.

Experimental and theoretical investigation on corrosion inhibition of AA5052 aluminium alloy by l-cysteine in alkaline solution

The corrosion inhibition of l-cysteine on AA5052 aluminium alloy in 4 mol/L NaOH solution was investigated by hydrogen gas evolution experiment, polarisation curve, galvanostatic discharge, electrochemical impedance spectroscopy measurements and quantum chemical calculations. The adsorption of l-cysteine on aluminium alloy surface obeyed the amended Langmuir's adsorption isotherm. The polarisation curves indicated that l-cysteine acted as a cathodic inhibitor to inhibit cathodic reaction. The inhibition mechanism was dominated by the geometric covering effect. The galvanostatic discharge shows that the additives restrain the hydrogen evolution and increase the anodic utilization rate. Quantum chemical calculations indicated that l-cysteine molecules mainly interacted with on the carboxyl groups on the aluminium alloy surface. A strong hybridization occurred between the s-orbital and p-orbital of reactive sites in the l-cysteine molecule and the sp-orbital of Aluminium.

Multifunctional rare earth organic corrosion inhibitors

All rights reserved.Chromium (VI) compounds are commonly used in paint systems to provide corrosion protection, particularly for aerospace alloys. These compounds are toxic, carcinogenic and environmentally detrimental, therefore alternatives that are safe, environmentally benign and meet or exceed current levels of corrosion protection are vital. Multifunctional rare earth organic compounds incorporate known inhibitor species, achieving synergistic inhibition in corrosive environments. The mechanism, efficiency and surface interactions of these complexes are explored. The complexes were effective inhibitors for steel and aluminium alloys, through mixed inhibition. Advantages and limitations of these inhibitor complexes, along with applications and future research direction, are discussed.

Rare earth-based corrosion inhibitors

Corrosion inhibitors are an important method for minimizing corrosion; however traditional inhibitors such as chromates pose environmental problems. Rare earth metals provide an important, environmentally-friendly alternative. This book provides a comprehensive review of current research and examines how rare earth metals can be used to prevent corrosion and applied to protect metals in such industries as aerospace and construction. Chapter 1 begins by examining the important need to replace chromate, and then goes on to discuss the chemistry of the rare earth metals and their related compounds. Chapter 2 considers the techniques that can be used to identify corrosion inhibition mechanisms and to test the levels of protection offered to different metals by rare earth compounds. Subsequent chapters consider in more detail how rare earth elements can be used as corrosion inhibitors in different forms and for different metals. This includes discussion on the potential of rare earth elements for self-healing, tunable and multifunctional coatings. Finally, chapter 10 considers the cost and availability of the rare earths and the potential health and environmental risks associated with extracting them. Provides a review of current research and examines how rare earth metals can be used to prevent corrosion and applied to protect metals in such industries as aerospace and construction. Includes discussion on the potential of rare earth elements for self-healing, tunable and multifunctional coatings. Considers the cost and availability of the rare earths and the potential health and environmental risks associated with extracting them.

Visualising dynamic passivation and localised corrosion processes occurring on buried steel surfaces under the effect of anodic transients

A new method of visualising dynamically changing electrode processes has been demonstrated by mapping localised corrosion processes occurring on buried steel surfaces under the effect of anodic transients. Dynamically shifting external electrical interferences such as anodic transients are known to affect the efficiency of cathodic protection (CP) of underground pipelines; however unfortunately conventional techniques including electrochemical methods have difficulties in measuring such effects. In this paper we report that the wire beam electrode has necessary temporal and spatial resolutions required for measuring and visualising the dynamic effects of anodic transients on CP, passivation and localised corrosion processes occurring on buried steel surfaces. For the first time a critical anodic transient duration has been observed and explained as the incubation period for the breakdown of passivity and the initiation of localised corrosion.

P F Thompson - Australia's pioneer in corrosion research and education

Percival Faraday Thompson (P F Thompson, PFT), (1885-1951),(Figure1), a metallurgistand chemical analyst, is widely considered as Australia’s pioneer in corrosion science and education. Each year at the annual ACA Conference, the P F Thompson Memorial Lectureis presented by a person who has made a most significant contribution to corrosion science and engineering in Australia. While each presenter usually gives a few detailsof the work of PFT for the benefit of Conference attendees, the entire body of his work and details about his life are not provided due to the limitations on the lecture duration. A review of Thompson’s life and some of his work is available in the ‘Australasian Corrosion Engineering’ publication which was the ACA publication in the early 70s, and is one of theprecursors to the current ACA publication Corrosion & Materials (Potter, 1972). However this publication is not widely available to the ACA membership, and certainly not inelectronic format. The purpose of this paper is to provide readers with some of the history of the PFT Lecture, and to acquaint readers of ‘Corrosion & Materials’ and the broader corrosion prevention community with the breadth of the scientific work of PFT and his enthusiasm for describing corrosion science through practical public demonstrations ofexperiments of the basic principles of corrosion.

Electrochemical methods for monitoring localized corrosion under cathodic protection

This research proposes two new electrochemical methods for measuring corrosion rates and their distribution under cathodic protection (CP). These methods were incorporated into a corrosion monitoring sensor that grow a great interest in the Australian energy pipeline industry.

In situ measurement of pipeline coating integrity and corrosion resistance losses under simulated mechanical strains and cathodic protection

A novel experimental assembly consisting of a specially designed tensile testing rig and a standard electrochemical flat cell has been designed for simulating buried high pressure pipeline environmental conditions in which a coating gets damaged and degrades under mechanical strain, and for studying the influence of mechanically induced damages such as the cracking of a coating on its anti-corrosion property. The experimental assembly is also capable of applying a cathodic protection (CP) potential simultaneously with the mechanical strain and environmental exposure. The influence of applied mechanical strain as well as extended exposure to the corrosive environment, coupled with the application of CP, has been investigated based on changes in electrochemical impedance spectroscopy (EIS). Preliminary results show that the amplitude of the coating impedance decreases with an increase in the applied strain level and the length of environmental exposure. The EIS characteristics and changes are found to correlate well with variations in coating cracking and degradation features observed on post-test samples using both optical microscopy and scanning electron microscopy. These results demonstrate that this new experimental method can be used to simulate and examine coating behaviour under the effects of complex high pressure pipeline mechanical, electrochemical and environmental conditions.

Mechanical properties, in vitro corrosion and biocompatibility of newly developed biodegradable Mg-Zr-Sr-Ho alloys for biomedical applications

Our previous studies have demonstrated that Mg-Zr-Sr alloys can be anticipated as excellent biodegradable implant materials for load-bearing applications. In general, rare earth elements (REEs) are widely used in magnesium (Mg) alloys with the aim of enhancing the mechanical properties of Mg-based alloys. In this study, the REE holmium (Ho) was added to an Mg-1Zr-2Sr alloy at different concentrations of Mg1Zr2SrxHo alloys (x = 0, 1, 3, 5 wt. %) and the microstructure, mechanical properties, degradation behaviour and biocompatibility of the alloys were systematically investigated. The results indicate that the addition of Ho to Mg1Zr2Sr led to the formation of the intermetallic phases MgHo3, Mg2Ho and Mg17Sr2 which resulted in enhanced mechanical strength and decreased degradation rates of the Mg-Zr-Sr-Ho alloys. Furthermore, Ho addition (≤5 wt. %) to Mg-Zr-Sr alloys led to enhancement of cell adhesion and proliferation of osteoblast cells on the Mg-Zr-Sr-Ho alloys. The in vitro biodegradation and the biocompatibility of the Mg-Zr-Sr-Ho alloys were both influenced by the Ho concentration in the Mg alloys; Mg1Zr2Sr3Ho exhibited lower degradation rates than Mg1Zr2Sr and displayed the best biocompatibility compared with the other alloys.

Occurrence of anodic current and corrosion of steel in aqueous media under fluctuating cathodic protection potentials

Excursion of cathodic protection (CP) potential from the designed "safe" CP level resulting from various forms of electrical interference signals are observed rather frequently in industrial applications, in particular in the pipeline industry; however, the influence of such potential fluctuations on the corrosion behavior of steel under CP conditions does not yet appear to be fully understood. In this work, the effects of anodic transients that periodically shift the potential of a CP protected steel electrode from-1,200 mVAg/AgCl to-750 mVAg/AgCl on the corrosion of a steel electrode in aqueous media was investigated using square wave polarization. Anodic currents were measured that lasted for significant periods of time upon stepping the CP potential up to a less cathodic potential at various frequencies (1 h, 30 s, 10 s, 5 s, and 1 s). Part of such anodic currents is found to cause steel corrosion, and this is explained on the basis of understanding the Fe/H2O equilibrium.

Corrosion behaviour of direct current and active screen plasma carburised AISI 316 stainless steel in boiling sulphuric acid solutions

Active screen plasma is a recently developed plasma surface alloying technique, which has shown potential for addressing some drawbacks associated with conventional direct current plasma processes. In this study, the corrosion performance of untreated, direct current and active screen plasma carburised AISI 316 was investigated by immersion in a boiling solution of sulphuric acid. The experimental results show that the corrosion behaviour of expanded austenite produced by low temperature plasma carburising is controlled by the type and density of surface defects; the corrosion properties of the active screen plasma carburised material are superior to that produced by direct current plasma because of the significantly reduced edge effect and surface defects; and the bias level used in the active screen carburising treatment has a profound effect on the corrosion performance of the material. Based on the experimental results, the corrosion mechanisms involved are discussed.