Recent developments in corrosion inhibitors based on rare earth metal compounds

Rare earth organic compounds can provide an environmentally safe and non-toxic alternative to chromates as corrosion inhibitors for some steel and aluminium applications. For steel lanthanum 4-hydroxy cinnamate offers corrosion protection and reduces the susceptibility to hydrogen embrittlement. Recent work has also indicated that it inhibits the corrosion of steel in environments containing high levels of carbon dioxide. For aluminium alloys, cerium diphenyl phosphate provides excellent corrosion inhibition in chloride environments, and reduces susceptibly to stress corrosion cracking. Furthermore, for both steel and aluminium alloys filiform corrosion can be suppressed when rare earth inhibitor compounds are added as pigments to polymer coatings. The levels of inhibition observed are thought to be due to synergistic effects between the rare earth and organic parts of these novel compounds, and are related to the various species that may be present in the complex chemical conditions that develop in solution close to a metal surface. This paper reviews some of the published research conducted by the group at Deakin University over recent years.©2014 Institute of Materials, Minerals and Mining.

Rare earth 4-hydroxycinnamate compounds as carbon dioxide corrosion inhibitors for steel in sodium chloride solution

A series of rare earth 4-hydroxycinnamate compounds including Ce(4OHCin)3, La(4OHCin)3, and Pr(4OHCin)3 has been synthesized and evaluated as novel inhibitors for carbon dioxide corrosion of steel in CO2-saturated sodium chloride solutions. Electrochemical measurements and surface analysis have shown that these REM(4OHCin)3 compounds effectively inhibited CO2 corrosion by forming protective inhibiting deposits that shut down the active electrochemical corrosion sites on the steel surface. Inhibition efficiency was found to increase in the order Ce(4OHCin)3 < La(4OHCin)3 < Pr(4OHCin)3 and with increase in inhibitor concentration up to 0.63 mM. Detailed insights into corrosion inhibition mechanism of these compounds in carbon dioxide environment are also provided.

The nature of the surface film on steel treated with cerium and lanthanum cinnamate based corrosion inhibitors

The corrosion inhibition mechanisms of new cerium and lanthanum cinnamate based compounds have been investigated through the surface characterisation of the steel exposed to NaCl solution of neutral pH. Attenuated Total Reflectance-Fourier Transform Infrared (ATR-FTIR) spectroscopy was used to identify the nature of the deposits on the metal surface and demonstrated that after accelerated tests the corrosion product commonly observed on steel (i.e. lepidocrocite, γ-FeOOH) is absent. The cinnamate species were clearly present on the steel surface upon exposure to NaCl solution for short periods and appeared to coordinate through the iron. At longer times the Rare Earth Metal (REM) oxyhydroxide species are proposed to form as identified through the bands in the 1400–1500 cm⁻¹ region. These latter bands have been previously assigned to carbonate species adsorbed onto REM oxyhydroxide surfaces. The protection mechanism appears to involve the adsorption of the REM–cinnamate complex followed by the hydrolysis of the REM to form a barrier oxide on the steel surface.

Recent developments in corrosion inhibitors based on rare earth metal compounds

Rare earth organic compounds can provide an environmentally safe and non-toxic alternative to chromates as corrosion inhibitors for some steel and aluminium applications. For steel lanthanum 4-hydroxy cinnamate offers corrosion protection and reduces the susceptibility to hydrogen embrittlement. Recent work has also indicated that it inhibits the corrosion of steel in environments containing high levels of carbon dioxide. For aluminium alloys, cerium diphenyl phosphate provides excellent corrosion inhibition in chloride environments, and reduces susceptibly to stress corrosion cracking. Furthermore, for both steel and aluminium alloys filiform corrosion can be suppressed when rare earth inhibitor compounds are added as pigments to polymer coatings. The levels of inhibition observed are thought to be due to synergistic effects between the rare earth and organic parts of these novel compounds, and are related to the various species that may be present in the complex chemical conditions that develop in solution close to a metal surface. This paper reviews some of the published research conducted by the group at Deakin University over recent years.

Electrochemical and quantum chemical assessment of two organic compounds from pyridine derivatives as corrosion inhibitors for mild steel in HCl solution under stagnant condition and hydrodynamic flow

 In this study, the inhibitive performance of two pyridine derivatives as corrosion inhibitors for mild steel was examined under stagnant condition and hydrodynamic flow in HCl solution at 25. °C. Potentiodynamic polarization and electrochemical impedance spectroscopy (EIS) techniques were employed. To explore the inhibitors adsorption mechanism, Langmuir isotherm and quantum chemical studies were used. The results of electrochemical measurements show that the inhibitor concentration has a positive effect on its efficiency while for hydrodynamic condition, it is vice versa. Corrosion attack morphologies were observed at stagnant and hydrodynamic conditions to verify qualitatively the results obtained by electrochemical methods. © 2013 Elsevier Ltd.

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.

New 'green' corrosion inhibitors based on rare earth compounds

A series of rare earth organic compounds pioneered by our group have been shown to provide a viable alternative to theuse of chromates as corrosion inhibitors for some steel and aluminium applications. For example we have shown thatthe lanthanum 4-hydroxy cinnamate offers excellent corrosion mitigation for mild steel in aqueous environments whilerare earth diphenyl phosphates offer the best protection in the case of aluminium alloys. In both cases the protectionappears to be related to the formation of a nanometre thick interphase occurring on the surface that reduces theelectrochemical processes leading to metal loss or pitting. Very recent work has indicated that we may even be able toaddress the challenging issue of stress corrosion cracking of high strength steels. Furthermore, filiform corrosion can besuppressed when selected rare earth inhibitor compounds are added as pigments to a polymer coating. There is little doubtfrom the work thus far that a synergy exists between the rare earth and organic inhibitor components in these novelcompounds. This paper reviews some of the published research conducted by the senior author and colleagues over the past10 years in this developing field of green corrosion inhibitors

Rare earth cinnamates and their corrosion inhibition mechanisms for AS1020 steel

Speciation of the inhibitors lanthanum 2-hydroxy cinnamate and lanthanum 3-hydroxy cinnamate in solution has been evaluated and compared to the speciation of lanthanum 4-hydroxy cinnamate. The results have been correlated with corrosion inhibition efficiency for AS1020 steel in an aqueous chloride solution using a combination of analytical tools such as nuclear magnetic resonance (NMR) spectroscopy, electrospray mass spectrometry (ESMS), potentiodynamic polarisation.

Effect of single and double austenitization treatments on the microstructure and hardness of AISI D2 tool steel

This investigation is concerned with the study of effect of Double Austenitization (DA) and Single Austenitization (SA) heat treatment processes on microstructure and mechanical property of AISI D2type cold worked tool steel. To maximize hardness, tool steels are used in a quenched and tempered condition. This involves heating the material to the austenitizing temperature (~850-1100. °C), quenching at an appropriate rate to form martensite, and tempering to reduce the retained austenite content and induce toughness. The merits of DA treatment isto promote dissolution of carbides at the same time proscribe grain coarsening significantly was attempted in D2 tool steel. The study has found that DA treatment has induced high hardness with insignificant growth in grains. The increase in hardness is attributed to increase in carbon content in matrix due to dissolution of carbides; whereas finer grains due to role of inclusions.

Microstructure and hardness characterisation of laser coatings produced with a mixture of AISI 420 stainless steel and Fe-C-Cr-Nb-B-Mo steel alloy powders

Fe-C-Cr-Nb-B-Mo alloy powder and AISI 420 SS powder are deposited using laser cladding to increase the hardness for wear resistant applications. Mixtures from 0 to 100 wt.% were evaluated to understand the effect on the elemental composition, microstructure, phases, and microhardness. The mixture of carbon, boron and niobium in the Fe-C-Cr-Nb-B-Mo alloy powder introduces complex carbides into a Fe-based matrix of AISI 420 SS which increases its hardness. Hardness increased linearly with increasing Fe-C-Cr-Nb-B-Mo alloy, but substantial micro-cracking was observed in the clad layer at additions of 60 wt.% and above; related to a transition from a hypoeutectic alloy containing α-Fe/α' dendrites with an (Fe,Cr)2B and γ-Fe eutectic to primary and continuous carbo-borides M2B (where M represents Fe and Cr) and M23(B,C)6 carbides (where M represents Fe, Cr, Mo) with MC particles (where M represents Nb and Mo). The highest average hardness, for an alloy without micro-cracking, of 952 HV was observed in a 40 wt.% alloy. High stress abrasive scratch testing was conducted on all alloys at various loads (500, 1500, 2500 N). Alloy content was found to have a strong effect on the wear mode and the abrasive wear rate, and the presence of micro-cracks was detrimental to abrasive wear resistance.