A review of techniques for the monitoring of cathodic shielding and corrosion under disbonded coatings

The mitigation of external corrosion of energy pipelines by a combination of barrier coatings and Cathodic Protection (CP) is not always effective. Even when design specifications are properly met, the shielding of cathodic protection current from reaching steel surface by disbonded barrier coatings, often referred to as cathodic shielding, may lead to severe corrosion problems such as deep pitting, high and near neutral pH Stress Corrosion Cracking (SCC) and Microbiologically Induced Corrosion (MIC). Unfortunately, current indirect assessment methods used in the pipeline industry have serious difficulties in detecting such corrosion problems. This paper provides a brief review of current techniques and their limitations when being applied under complex buried pipeline environmental conditions. The main purpose is to identify potential methods that could be utilised in the design of new monitoring probes specific for the monitoring of cathodic shielding and corrosion of disbonded coatings in the pipeline industry.

Monitoring cathodic shielding and corrosion under disbonded coatings

This work presents a novel corrosion monitoring probe designed for simulating the conditions developed under disbonded coatings and for measuring current densities and their distribution over a simulated pipeline surface. The probe’s concept was experimentally evaluated via immersion tests under Cathodic Protection (CP) in high resistivity aqueous solution. Under the disbonded area, anodic currents as well as cathodic currents were both measured. Anodic current densities were used to calculate metal losses by means of Faraday’s law. Calculated corrosion patterns were compared with corrosion damage observed at the probe’s surface after a period of test. The probe’s working principles are explained in terms of simple electrochemistry.

Microstructures, mechanical and corrosion properties and biocompatibility of as extruded Mg-Mn-Zn-Nd alloys for biomedical applications

Extruded Mg-1Mn-2Zn-xNd alloys (x=0.5, 1.0, 1.5 mass %) have been developed for their potential use as biomaterials. The extrusion on the alloys was performed at temperature of 623K with an extrusion ratio of 14.7 under an average extrusion speed of 4mm/s. The microstructure, mechanical property, corrosion behavior and biocompatibility of the extruded Mg-Mn-Zn-Nd alloys have been investigated in this study. The microstructure was examined using X-ray diffraction analysis and optical microscopy. The mechanical properties were determined from uniaxial tensile and compressive tests. The corrosion behavior was investigated using electrochemical measurement. The biocompatibility was evaluated using osteoblast-like SaOS2 cells. The experimental results indicate that all extruded Mg-1Mn-2Zn-xNd alloys are composed of both α phase of Mg and a compound of Mg7Zn3 with very fine microstructures, and show good ductility and much higher mechanical strength than that of cast pure Mg and natural bone. The tensile strength and elongation of the extruded alloys increase with an increase in neodymium content. Their compressive strength does not change significantly with an increase in neodymium content. The extruded alloys show good biocompatibility and much higher corrosion resistance than that of cast pure Mg. The extruded Mg-1Mn-2Zn-1.0Nd alloy shows a great potential for biomedical applications due to the combination of enhanced mechanical properties, high corrosion resistance and good biocompatibility.

Microstructure and corrosion of AA2024

AA2024-Tx is one of the most common high-strength aluminium alloys used in the aerospace industry. This article reviews current understanding of the microstructure of sheet AA2024-T3 and chronicles the emergence of new compositions for constituent particles as well as reviews older literature to understand the source of the original compositions. The review goes on to summarise older and more recent studies on corrosion of AA2024-T3, drawing attention to areas of corrosion initiation and propagation. It pays particular attention to modern approaches to corrosion characterisation as obtained through microelectrochemical techniques and physicochemical characterisation, which provide statistical assessment of factors that contribute to corrosion of AA2024. These approaches are also relevant to other alloys.

Simultaneous improvement in the strength and corrosion resistance of Al via high-energy ball milling and Cr alloying

The corrosion resistance and mechanical properties of nanocrystalline aluminium (Al) and Al-20. wt.%Cr alloys, synthesized by high-energy ball milling followed by spark plasma sintering, were investigated. Both alloys exhibited an excellent combination of corrosion resistance and compressive yield strength, which was attributed to the nanocrystalline structure, extended solubility, uniformly distributed fine particles, and homogenous microstructure induced by high-energy ball milling. This work demonstrates the possibilities of developing ultra-high strength Al alloys with excellent corrosion resistance, exploiting conventionally insoluble elements or alloying additions via suitable processing routes.

Influence of cooling rate on the microstructure and corrosion behavior of Al-Fe alloys

The effect of Fe in Al is technologically important for commercial Al-alloys, and in recycled Al. This work explores the use of the novel rapid solidification technology, known as direct strip casting, to improve the recyclability of Al-alloys. We provide a comparison between the corrosion and microstructure of Al-Fe alloys prepared with wide-ranging cooling rates (0.1. °C/s to 500. °C/s). Rapid cooling was achieved via direct strip casting, while slow cooling was achieved using sand casting. Corrosion was studied via polarisation and immersion tests, followed by surface analysis using scanning electron microscopy and optical profilometry. It was shown that the corrosion resistance of Al-Fe alloys is improved with increased cooling rates, attributed to the reduced size and number of Fe-containing intermetallics.

Evaluation of WC-17Co and WC-10Co-4Cr thermal spray coatings by HVOF on the fatigue and corrosion strength of AISI 4340 steel

It is known that chromium electroplating is related to the reduction in the fatigue strength of base metal. However, chromium results in protection against wear and corrosion combined with chemical resistance and good lubricity. Environmental requirements are an important point to be considered in the search for possible alternatives to hard chrome plating. Aircraft landing gear manufactures are considering WC thermal spray coating applied by the high-velocity oxygen-fuel (HVOF) process an alternative candidate, which shows performance at least comparable to results, obtained for hard chrome plating. The aim of this study is to compare the influence of WC-17Co and WC-10Co-4Cr coatings applied by HVOF process and hard chromium electroplating on the fatigue strength of AISI 4340 steel, with and without shot peening. S-N curves were obtained in axial fatigue test for base material, chromium plated and tungsten carbide coated specimens. Tungsten carbide thermal spray coating results in higher fatigue strength when compared to hard chromium electroplated. Shot peening prior to thermal spraying showed to be an excellent alternative to increase fatigue strength of AISI 4340 steel. Experimental data showed higher axial fatigue and corrosion resistance in salt fog exposure for samples WC-10Co-4Cr HVOF coated when compared with WC-17Co. Fracture surface analysis by scanning electron microscopy (SEM) indicated the existence of a uniform coverage of nearly all substrates. (C) 2004 Elsevier B.V. All rights reserved.

Evaluation of WC-10Ni thermal spraying coating by HVOF on the fatigue and corrosion AISI 4340 steel

Shot peening is a surface process widely used to improve the fatigue strength of materials, through compressive residual stresses induced in their surface layers. Considering mechanical components for high responsible applications, wear and corrosion control is currently accomplished by the use of coated materials.In the case of chrome plating or hard anodizing, lower fatigue strength in comparison to uncoated parts are associated to high residual tensile stresses and microcracks density. Under constant or variable amplitude loading microcracks will propagate and cross the interface coating substrate without impediment.The aim of the present study is to analyze the influence of WC-10Ni coating applied by HVOF process on the axial fatigue strength of AISI 4340 steel. The shot peening effect on the fatigue performance of coated AISI 4340 steel was also evaluated. The fractured fatigue specimens were investigated using a scanning electron microscope in order to obtain information about the crack initiation points. (C) 2010 Published by Elsevier Ltd.

Electrochemical stability and corrosion resistance of Ti-Mo alloys for biomedical applications

Fundação de Amparo à Pesquisa do Estado de São Paulo (FAPESP)

Laser weld: microstructure and corrosion study of Ag-Pd-Au-Cu alloy of the dental application

The laser Welding process was introduced into dentistry by the end of the 1980s, resulting on a great impulse to that area with the development of cheaper and smaller equipment, using simpler technique. This allowed greater use of that process on the confection of prostheses compared to the brazing process since the heat source for that process is a concentrated light beam of high power, which minimizes distortion problems on the prosthetic pieces. Ag-Pd-Au-Cu alloy used on the confection of dental implant prostheses was observed before and after subjection to the laser welding process. The microstructure was analyzed with the. use of optic microscopy and the corrosion resistance was studied by the traditional electrochemical techniques and by electrochemical impedance, under environmental conditions simulating the aggressiveness found in the mouth cavity. A structural change was detected on the weld area, which presented a refined microstructure deriving from the high-speed cooling. The base metal out of the weld area presented a fusion coarse microstructure. The electrochemical essays showed differences on the potentiodynamic polarization behavior in both weld and metal base areas, indicating superior corrosion resistance in the weld area. The impedance spectra were characterized by capacitive distorted components, presenting linear impedance in the low frequencies area. (C) 2002 Elsevier B.V. B.V. All rights reserved.

Microstructure and corrosion resistance of inorganic-organic (ZrO2-PMMA) hybrid coating on stainless steel

Zirconia-polymethylmetacrylate hybrids prepared by a sol-gel method were deposited by dip-coating on stainless steel to improve the resistance against wet corrosion. The effect of the concentration of polymethylmetacrylate and the number of coating applications on the microstructure and corrosion performance of coated samples was investigated. The microstructural properties of samples was analyzed by scanning electron and atomic force microscopy, adhesion tests and profilemeter measurements. The electrochemical corrosion was evaluated through potentiodynamic polarization curves at room temperature. Results show that the sample prepared with 17 vol.% of polymethylmethacrylate has a maximum corrosion resistance, smaller roughness, are hermetic and adherent to the substrate. This film increases the life time of the stainless steel by a factor 30. (C) 1999 Elsevier B.V. B.V. All rights reserved.