Boundary Element Method (BEM) Analysis for Galvanic Corrosion of Hot Dip Galvanized Steel Immersed in Seawater

A numerical analysis of galvanic corrosion of hot-dip galvanized steel immersed in seawater was presented. The analysis was based on the boundary element methods (BEMs) coupled with Newton-Raphson iterative technique to treat the nonlinear boundary conditions, which were determined by the experimental polarization curves. Results showed that galvanic current density concentrates on the boundary of steel substrate and zinc coating, and the sacrificial protection of zinc coating to steel substrate results in overprotection of steel cathode. Not only oxygen reduction but also hydrogen reduction could occur as cathode reactions, which probably led up to the adsorption and absorption of hydrogen atoms. Flat galvanized steel tensile sample shows a brittle behavior similar to hydrogen embrittlement according to the SSRT (show strain rate test) in seawater.

Corrosion behaviour of hot dip zinc and zinc-aluminium coatings on steel in seawater

A comparative investigation of hot dip Zn-25Al alloy, Zn-55Al-Si and Zn coatings on steel was performed with attention to their corrosion performance in seawater. The results of 2-year exposure testing of these at Zhoushan test site are reported here. In tidal and immersion environments, Zn-25Al alloy coating is several times more durable than zinc coating of double thickness. At long exposure times, corrosion rate for the Zn-25Al alloy coating remains indistinguishable from that for the Zn-55Al-Si coating of similar thickness in tidal zone, and is two to three times lower than the latter in immersion zone. The decrease in tensile strength suggested that galvanized and Zn-55Al-Si coated steel suffer intense pitting corrosion in immersion zone. The electrochemical tests showed that all these coatings provide cathodic protection to the substrate metal; the galvanic potentials are equal to - 1,050, - 1,025 and - 880 mV (SCE) for zinc, Zn-25Al alloy and Zn-55Al-Si coating, respectively, which are adequate to keep the steel inside the immunity region. It is believed that the superior performance of the Zn-25Al alloy coating is due to its optimal combination of the uniform corrosion resistance and pitting corrosion resistance. The inferior corrosion performance by comparison of the Zn coating mainly results from its larger dissolution rate, while the failure of the Zn-55Al-Si coating is probably related to its higher susceptibility to pitting corrosion in seawater.

Effect of Process Conditions on Microstructure and Corrosion Resistance of Cold-Sprayed Ti Coatings

Ti and Ti alloys can be applied to steels as a protective coating in view of its excellent resistance to corrosive environment. Cold spraying, as a new coating technique, has potential advantages in fabrication of Ti coating in comparison with conventional thermal spraying techniques. In this study, Ti coatings were prepared on carbon steel substrates by cold spraying via controlling the process conditions. The microstructure of coatings was observed by SEM. The porosity of coatings was estimated by image analysis and the bond strength was tested for comparison of the process conditions. Potentiodynamic polarization and open-circuit potential (OCP) measurements were performed to understand the corrosion behavior of the coatings. The SEM examination shows that the coatings become more compact with the increases of pressure and temperature of driving gas. The potentiodynamic polarization curves indicate that the coating which has lower porosity has lower corrosion current. The polarization and OCP measurement reveal that cold-sprayed Ti coating can provide favorable protection to carbon steel substrate. The polishing treatment of coating surface polishes the rough outer layer including the small pores as well as decreases the actual surface area of the coating, leading to the considerable improvement of corrosion resistance.

Corrosion fatigue of welded joints of steel for marine platform

Experiments on the corrosion fatigue behaviour of welded joints of the steel for marine platform in air and seawater, and of the joints in seawater with cathodic protection, yielded data for linear regression to obtain fatigue life curves (Delta S-N-f). The laws of corrosion fatigue in welded joints of test steel are discussed with reference to those of A(587) and A(131) steel. In these experiments, the fatigue damage occurring at all welded joints around the weld interface resulted in the cracks and fractures. The fatigue life of the specimens in seawater with cathodic protection is longer than that in seawater Without protection.

The performance of a cathodic protection system in reinforced concrete structure: Monitoring and Service Life Modelling

The use of cathodic protection in reinforced concrete is becoming increasingly common with such systems being installed on a number of structures throughout the United Kingdom and Ireland. However the prescribed design lives (or service life) of each cathodic protection system vary widely. The aim of this project was to assess the effectiveness of a sacrificial anode cathodic protection system and to predict its design life through a series of laboratory based experiments. The experimental plan involved casting a number of slabs which represented a common road bridge structure. The corrosion of the steel within the experimental slabs was then accelerated prior to installation of a cathodic protection system. During the experiment corrosion potential of the steel reinforcement was monitored using half-cell measurement. Additionally the current flow between the cathodic protection system and the steel reinforcement was recorded to assess the degree of protection. A combination of theoretical calculations and experimental results were then collated to determine the design life of this cathodic protection system. It can be concluded that this sacrificial anode based cathodic protection system was effective in halting the corrosion of steel reinforcement in the concrete slabs studied. Both the corrosion current and half-cell potentials indicated a change in passivity for the steel reinforcement once sacrificial anodes were introduced. The corrosion current was observed to be sensitive to the changes to the exposure environment. Based on the experimental variables studied the design life of this sacrificial anode can be taken as 26 to 30 years.

Design and Programming of Cathodic Protection for SHIPS

In order to minimize the risk of failures or major renewals of hull structures during the ship's expected life span, it is imperative that the precaution must be taken with regard to an adequate margin of safety against any one or combination of failure modes including excessive yielding, buckling, brittle fracture, fatigue and corrosion. The most efficient system for combating underwater corrosion is 'cathodic protection'. The basic principle of this method is that the ship's structure is made cathodic, i.e. the anodic (corrosion) reactions are suppressed by the application of an opposing current and the ship is there by protected. This paper deals with state of art in cathodic protection and its programming in ship structure

The corrosion inhibition mechanism of new rare earth cinnamate compounds — electrochemical studies

A combination of linear polarisation resistance (LPR) and cyclic potentiodynamic polarisation (CPP) measurements demonstrated that the lanthanum-4 hydroxy cinnamate compound could inhibit both the cathodic and anodic corrosion reactions on mild steel surfaces exposed to 0.01 M NaCl solutions. However, the dominating response was shown to vary with inhibitor concentration. At the concentrations for which the highest level of protection was achieved, both REM-4 hydroxy cinnamate (REM being lanthanum and mischmetal) displayed a strong anodic behaviour for mild steel and their inhibition performance, including their resistance against localised attack, improved with time.

Electrochemical impedance spectroscopy (EIS) measurements and modelling were carried out so as to propose a simple electrical model and correlate the extracted parameters to the inhibition mechanism put forward for REM-cinnamate based compounds. The results supported the high corrosion inhibition performance of the compounds as well as the build-up of a protective film with time. Based on a two-layer model the results suggested that the upper layer of the inhibitor film seemed to offer less resistance to the diffusion of electrochemically active species than the highly resistive inner layer at the film/metal interface.

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.

Corrosion impact on drinking water distribution systems : a review and future research direction

At present water treatment and distribution is of high priority to ensure that communities have access to safe and affordable drinking water. Current information states that in the United States a total annual cost of $36 billion (US) is spent replacing aging infrastructure, lost water from unaccounted-for leaks, corrosion inhibitors, internal mortar linings, external coatings, and cathodic protection as a result of corrosion. In order to reduce the cost incurred as a result of corrosion in the water distribution industry, it is essential that better corrosion management and preventative strategies are implemented. However through investigation of research previously undertaken by others, it was found that there was a lack of study of corrosion within distribution systems in the tropics taking into account the related seasonal temperature variations. To assist in the development of management strategies to improve the outcomes of drinking water distribution systems, the authors propose to implement a pilot study involving the installation of a corrosion reactor based on standard corrosion assessment technologies in a water distribution system located in the tropics.

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

Electrochemical impedance spectroscopy and surface characterization techniques to study carbon dioxide corrosion product scales

Electrochemical impedance spectroscopy (EIS) was used to study carbon dioxide (CO2) corrosion product scales and their effects on further CO2 corrosion. Objectives were to determine the suitability of EIS for studying corrosion scales and to investigate the influence of environmental factors on scale formation. EIS provided useful information about protective abilities and electrochemical properties of corrosion scales. CO2 corrosion scales formed at high-temperature and pressure provided better protection than those formed at low-temperature and pressure. The level of protection of the scale formed at higher temperature and pressure increased with exposure time. EIS results were compared with coupon weight-loss measurements. Scales were analyzed using a combination of Fourier transform infrared (FTIR) analysis, x-ray diffraction (XRD), and electron microscopy.

Wire beam electrode : a new tool for studying localised corrosion and other heterogeneous electrochemical processes

Heterogeneous electrochemical processes are very common in industry and are important, but difficult topics in electrochemical and corrosion science studies. Traditional electrochemical techniques which employ a conventional one-piece electrode have major limitations in studying heterogeneous electrochemical processes since the one-piece electrode has major difficulties in measuring electrochemical parameters from local areas of the electrode surface. In order to overcome this problem, a multi-piece electrode, namely the wire beam electrode, has been developed. This new electrode enables the measurement of electrochemical parameters from local areas over a working electrode surface and thus it can be used to study heterogeneous electrochemical processes. This paper describes how this new electrode was applied in studying several typical heterogeneous electrochemical processes including water-drop corrosion, corrosion under non-uniform organic films and cathodic protection.

Studies of CO2 corrosion product scales using electrochemical impedance spectroscopy and surface characterisation techniques

Electrochemical impedance spectroscopy (EIS) was used to study carbon dioxide (CO2) corrosion product scales and their effects on further CO2 corrosion. Objectives were to determine the suitability of EIS for studying corrosion scales and to investigate the influence of environmental factors on scale formation. EIS provided useful information about protective abilities and electrochemical properties of corrosion scales. CO2 corrosion scales formed at high-temperature and pressure provided better protection than those formed at low-temperature and pressure. The level of protection of the scale formed at higher temperature and pressure increased with exposure time. EIS results were compared with coupon weight-loss measurements. Scales were analyzed using a combination of Fourier transform infrared (FTIR) analysis, x-ray diffraction (XRD), and electron microscopy