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Coatings
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Corrosion/Wear Mechanisms and Protective Methods
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Corrosion/Wear Mechanisms and Protective Methods

A special issue of Coatings (ISSN 2079-6412). This special issue belongs to the section "Corrosion, Wear and Erosion".

Deadline for manuscript submissions: closed (25 December 2024) | Viewed by 6893

Special Issue Editor

Dr. Hejie Yang

E-Mail Website
Guest Editor
School of Material Science and Engineering, Xi’an Jiao Tong University, Xi'an, China
Interests: electrochemical corrosion behavior and mechanism in the microzone of materials; composition design and preparation of new corrosion-resistant materials; surface anti-corrosion/wear technology; development of superhydrophobic meter interface characteristics

Special Issue Information

Dear Colleagues,

During the utilization of materials, their service life is often reduced due to factors such as oxidation, wear, corrosion, and erosion in different service environments. Corrosion and wear pose significant challenges across a wide range of industries, including manufacturing, metallurgy, marine engineering, aerospace, energy, automotive engineering, and more. It is essential to comprehend the underlying mechanisms and implement appropriate prevention and protection measures to extend the lifespan of materials.

This Special Issue aims to provide an inclusive platform for academia to share their innovative approaches, theoretical insights, and experimental findings in the areas of corrosion, wear, erosion and wear corrosion protection. We welcome original research papers from scholars and researchers spanning various disciplines relevant to corrosion and wear mechanisms. Research areas of interest include, but are not limited to:

  • Analysis of corrosion and wear mechanisms
  • Techniques for assessing corrosion and wear
  • Monitoring and control strategies for corrosion and wear
  • Protective coatings for corrosion and wear resistance
  • Surface treatments aimed at enhancing material protection
  • Exploration of novel protective materials and coatings

We look forward to receiving your contributions!

Dr. Hejie Yang 
Guest Editor

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 100 words) can be sent to the Editorial Office for announcement on this website.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Coatings is an international peer-reviewed open access monthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2600 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

  • surface wear
  • corrosion and erosion
  • surface modification
  • protective coating

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Further information on MDPI's Special Issue polices can be found here.

Published Papers (5 papers)

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Research

18 pages, 12467 KiB  
Article
Aluminum Foil Surface Etching and Anodization Processes for Polymer 3D-Printing Applications
by Yunki Jung, Han Su Kim, Young-Pyo Jeon, Jin-Yong Hong and Jea Uk Lee
Coatings 2024, 14(9), 1205; https://doi.org/10.3390/coatings14091205 - 19 Sep 2024
Viewed by 1246
Abstract
Extrusion-based polymer three-dimensional (3D) printing, specifically fused deposition modeling (FDM), has been garnering increasing interest from industry, as well as from the research and academic communities, due to its low cost, high speed, and process simplicity. However, bed adhesion failure remains an obstacle [...] Read more.
Extrusion-based polymer three-dimensional (3D) printing, specifically fused deposition modeling (FDM), has been garnering increasing interest from industry, as well as from the research and academic communities, due to its low cost, high speed, and process simplicity. However, bed adhesion failure remains an obstacle to diversifying the materials and expanding the industrial applications of the FDM 3D-printing process. Therefore, this study focused on an investigation of the surface treatment methods for aluminum (Al) foil and their applications to 3D printer beds to enhance the bed adhesion of a 3D-printed polymer filament. Two methods of etching with sodium hydroxide and anodization with phosphoric acid were individually used for the surface treatment of the Al foil beds and then compared with an untreated foil. The etching process removed the oxide layer from the Al foil and increased its surface roughness, while the anodizing process enhanced the amount of hydroxide functional groups and contributed to the formation of nano-holes. As a result, the surface-anodized aluminum foil exhibited a higher affinity and bonding strength with the 3D-printed polymers compared with the etched and pristine foils. Through the increase in the success rate in 3D printing with various polymers, it became evident that utilizing surface-treated Al foil as a 3D printer bed presents an economical solution to addressing bed adhesion failure. Full article
(This article belongs to the Special Issue Corrosion/Wear Mechanisms and Protective Methods)
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13 pages, 12260 KiB  
Article
Failure Causes Analysis of Circumferential Cracking on Gathering Pipeline in M Oil and Gas Field
by Xuehui Zhao, Zicheng Zhang, Zhiwu He, Yan Han and Juntao Yuan
Coatings 2024, 14(6), 770; https://doi.org/10.3390/coatings14060770 - 18 Jun 2024
Viewed by 963
Abstract
The gathering and transportation pipeline experienced corrosion cracking failure after 2 years of operation. This paper conducted an analysis on the reasons for the pipeline failure by integrating background information on its usage, as well as observations, analyses, and detection of the morphology [...] Read more.
The gathering and transportation pipeline experienced corrosion cracking failure after 2 years of operation. This paper conducted an analysis on the reasons for the pipeline failure by integrating background information on its usage, as well as observations, analyses, and detection of the morphology of failure samples. The results indicated that the fracture originated from the inner wall of the pipeline and extended to the outer wall along the wall thickness until complete fracture occurred. Based on microstructure analysis of the fracture and original microcracks at the top of the pipeline, it was determined that the fracture was a multi-source brittle fracture, spreading in both inter-granular and trans-granular forms with obvious radial quasi-cleavage fractures accompanied by secondary cracks. EDS analysis revealed that the element S was present in all zones related to fracture initiation, spreading, and transient zones. XRD analysis showed that corrosion products on the fracture surface were mainly composed of FeS, indicating the presence of H2S in the service environment leading to sulfide stress corrosion cracking characteristics in line with pipeline failure. It is recommended to confirm the source of H2S in the service medium and test residual stress within the same pipeline for potential risk assessment regarding cracking in other areas. Full article
(This article belongs to the Special Issue Corrosion/Wear Mechanisms and Protective Methods)
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20 pages, 4080 KiB  
Article
Research on the Corrosion Inhibition Behavior and Mechanism of 1-Hydroxy-1,1-ethyledine Disodium Phosphonate under an Iron Bacteria System
by Ping Xu, Yuxuan Zhao and Pengkai Bai
Coatings 2024, 14(5), 580; https://doi.org/10.3390/coatings14050580 - 7 May 2024
Viewed by 979
Abstract
Regenerated water serves as a supplementary source for circulating cooling water systems, but it often fosters microbial growth within pipelines. Given its widespread use as a corrosion inhibitor, understanding HEDP’s efficacy in microbial environments and its impact on microorganisms is imperative. This study [...] Read more.
Regenerated water serves as a supplementary source for circulating cooling water systems, but it often fosters microbial growth within pipelines. Given its widespread use as a corrosion inhibitor, understanding HEDP’s efficacy in microbial environments and its impact on microorganisms is imperative. This study established an iron bacterial system by isolating and enriching iron bacteria. Through a comprehensive approach incorporating corrosion weight loss analysis, XPS analysis, SEM electron microscopy, as well as microbial and electrochemical testing, the corrosion inhibition behavior and mechanism of HEDP within the iron bacterial system were investigated. The findings reveal that within the iron bacterial system, HEDP achieves a corrosion inhibition rate of 76% following four distinct stages—weakening, strengthening, stabilizing, and further strengthening—underscoring its robust corrosion inhibition capability. Moreover, HEDP enhances the density of biofilms and elevates the activation energy of carbon steel interfaces. It alternates with oxygen to continuously suppress the activity of IRB while gradually inhibiting the activity of IOB. This process culminates in a corrosion inhibition mechanism where cathodic inhibition predominates, supported by anodic inhibition as a complementary mechanism. Full article
(This article belongs to the Special Issue Corrosion/Wear Mechanisms and Protective Methods)
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11 pages, 8897 KiB  
Article
Analysis of Causes and Protective Measures against Corrosion Perforation in the Shell-Side Outlet Flange of a Sour Water Steam Heater
by Haiming Liang, Zhihong Duan and Weiming Li
Coatings 2024, 14(3), 306; https://doi.org/10.3390/coatings14030306 - 1 Mar 2024
Viewed by 1370
Abstract
Heat exchangers, as essential devices for facilitating heat transfer, have found a variety applications in various industries. However, the occurrence of corrosion-related failures in real-world scenarios remains a prevalent problem that can lead to catastrophic incidents. This paper investigates the problem of corrosion [...] Read more.
Heat exchangers, as essential devices for facilitating heat transfer, have found a variety applications in various industries. However, the occurrence of corrosion-related failures in real-world scenarios remains a prevalent problem that can lead to catastrophic incidents. This paper investigates the problem of corrosion perforation on the outlet flange of a heat exchanger in a sour steam stripper from a petrochemical company. Failure analysis was performed using physical testing and chemical analysis, metallographic examination, microscopic observation, and energy spectrum analysis. Intergranular corrosion experiments and flow calculations were performed to verify the analysis. The results indicate that the main cause of the flange corrosion perforation was the formation of a highly concentrated NH4HS aqueous solution during the cooling process of the NH3, H2S, and water vapor in the fluid passing through the heat exchanger, and the velocity was too high, which triggered alkali-sour water washout corrosion. To prevent the recurrence of similar corrosion perforations, recommendations for material and process optimization are proposed to effectively reduce the safety production risks in refinery units and provide valuable information for the safe long-term operation of a sour steam stripper. Full article
(This article belongs to the Special Issue Corrosion/Wear Mechanisms and Protective Methods)
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19 pages, 6241 KiB  
Article
Investigating the Impact of Physical Vapour Deposition (PVD)-Coated Cutting Tools on Stress Corrosion Cracking Susceptibility in Turning Super Duplex Stainless Steel
by Edinei Locks, Qianxi He, Jose M. DePaiva, Monica Guimaraes, Abul Fazal Arif, Stephen C. Veldhuis and Joey R. Kish
Coatings 2024, 14(3), 290; https://doi.org/10.3390/coatings14030290 - 28 Feb 2024
Cited by 3 | Viewed by 1732
Abstract
This work aimed to ascertain the corresponding influences of several PVD-coated cutting tools on the susceptibility of the machined surface of super duplex stainless steel (SDSS) to stress corrosion cracking. Coatings comprised of AlCrN, AlCrN/TiSiN, and AlTiN were applied to cemented carbide cutting [...] Read more.
This work aimed to ascertain the corresponding influences of several PVD-coated cutting tools on the susceptibility of the machined surface of super duplex stainless steel (SDSS) to stress corrosion cracking. Coatings comprised of AlCrN, AlCrN/TiSiN, and AlTiN were applied to cemented carbide cutting tools using the PVD method; these were then used to turn the outer surface of the SDSS tube section. During the cutting process, the material presents the following combination of features: (i) a tendency for strain hardening, reflected in microstructural modifications and residual stresses of the machined surface and (ii) high temperatures in the cutting region, reducing the tool life. The goal of this work was to evaluate the surface integrity (work hardening and corrosion behaviour) of the SDSS obtained after the machining process (finish turning) with cemented carbide tools coated with three different PVD coatings. Full article
(This article belongs to the Special Issue Corrosion/Wear Mechanisms and Protective Methods)
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