Surface characterization and electrochemical corrosion behaviour of 304 stainless steel in aqueous media

A formulation consisting 100 ppm of 3-phosphonopropionic acid, 50 ppm of Zn²⁺ and 150 ppm of Tween 80 (polyoxyethylene sorbitan monooleate) offered 97.4% inhibition to the corrosion of 304 austenitic stainless steel immersed in a groundwater environment. This formulation functioned as a mixed inhibitor. The protective film was analysed by luminescence, XRD and FTIR spectra and pit morphology and was also observed by scanning electron microscopy. Electronic Publication     

Protective properties of redox polymer film deposited on stainless steel

We propose a novel composite organic-inorganic coating in the form of a redox polymer film for protection of stainless steel against general corrosion in strong acid medium (2 M H₂SO₄). We utilize an anion exchange polymer, protonated poly(4-vinylpyridine), into which hexacyanoferrate anions have been introduced. Owing to the presence of Fe(CN)₆^3–/4– at the interface formed by the film and the steel, a sparingly soluble metal hexacyanoferrate (mostly Prussian blue, PB) is formed as an overcoating on the steels surface, presumably on the passive (metal oxide) layer. The redox polymer film on the steel seems to act as a composite three-dimensional bilayer-type coating in which hexacyanoferrate(III,II) anions (that are capable of effective charge storage) exist in the outer portions of the film, whereas the inner PB layer improves the systems overall adherence and stability. By analogy to a conducting polymer (e.g. polyaniline, polypyrrole), introduction of the redox polymer composite film leads to stabilization of the steel substrates potential within the passive range.Contribution to the 3rd Baltic Conference on Electrochemistry, Gdansk-Sobieszewo, Poland, 23–26 April 2003Dedicated to the memory of Harry B. Mark, Jr. (28 February 1934–3 March 2003)     

Polydopamine supported preparation method for solid-phase microextraction coatings on stainless steel wire

In this paper, we introduced a novel and versatile route to prepare solid-phase microextraction coatings on the chemically inert stainless steel wire. Polydopamine films can be created on metallic substrates by an oxidant-induced polymerization and subsequently support various secondary reactions to prepare functional surfaces. In the present work, polydopamine-bioactivated stainless steel wire was successfully modified by nanostructured hydroxyapatite. Extraction performance of the fiber was assessed on several polycyclic aromatic hydrocarbons in water solutions. Extraction mechanism was suggested based on the correlation of partition coefficients and LogPs. Both aqueous and solid real life samples were used to test the reliability of the solid-phase microextraction-gas chromatography method; some analytes were detected and quantified.     

Electrochemical behaviour of SiO2 sol-gel coatings on stainless steel

SiO₂ coatings onto stainless steel substrates have been prepared by sol-gel in order to study the performance and mechanism of attack in different corrosive solutions. The electrochemical behaviour of the samples has been evaluated by Electrochemical Impedance Spectroscopy using NaCl and HCl as electrolytes. Comparative tests have been performed on samples with one and two silica layers as well as on uncoated ones. SiO₂ coatings produce no important protection of stainless steels subjected to electrochemical corrosion. This behaviour may be explained by micropores and microcracks produced during the coating sintering.     

EIS study on passive films of AISI 304 stainless steel in oxygenous sulfuric acid solution

Electrochemical impedance spectroscopy (EIS) and Kramers–Kronig (K–K) transforms were made on American Iron and Steel Institute (AISI) 304 stainless steel (SS) in naturally aerated sulfuric acid solution at room temperature. The K–K relations testify that the systems under investigation comply with the linearity, causality, and stability constraints of linear system theory (LST) and thereby validate the EIS data. The polarization resistance decreased with removing of passive film and pitting formed in the passive layer, due to layer thinning or pitting caused by chloride. The impedance data for 304 SS with passive films can be accurately modeled using individual components of the equivalent circuits. The polarization resistances (Rp) of the 304 SS can be confirmed by Nyquist plots and estimated from the anodic polarization curves. The reaction model of the dissolution‐passivation process of 304 SS in acid solution is proposed. Copyright © 2009 John Wiley & Sons, Ltd.     

EIS and XPS studies on passive film of AISI 304 stainless steel in dilute sulfuric acid solution

Electrochemical impedance spectroscopy and XPS studies on AISI 304 stainless steel in naturally aerated 0.5 M H₂SO₄ solution were carried out at room temperature. The valuable model of the metal/solution interphase was established, and the reliable equivalent electrical circuits in the solution were presented. The analysis of the chemical composition of passive film on AISI 304 stainless steel was carried out by XPS. The passive film of AISI 304 stainless steel is composed of oxyhydroxides, Fe₂O_3, FeO, Cr₂O₃, NiO, sulfate, sulfite, and sulfide (FeS, NiS). It is reported that the ferrous sulfide film formed on AISI 304 stainless steel in the dilute sulfuric acid solution. The possible process in which sulfuric acid is reduced to sulfite and sulfide is proposed. The galvanic interaction of sulfide inclusions with the base alloy is introduced. Copyright © 2011 John Wiley & Sons, Ltd.     

Sol-gel alumina coatings on stainless steel for wear protection

The aluminium oxide films on austenitic steel are prepared from sols of re-dispersed boehmite nano powders in water. After dip-coating of the sol, a heat treatment including drying, calcination and annealing in vacuum at temperatures up to 1100°C is performed to obtain crack-free coatings of a thickness up to 6 μm. XRD measurements detect α- and γ-alumina, a TiO_x-phase at the metal/coating interface and a gradient of phase formation in the coating. The strong adhesion on the substrates is due to the layered assembly and gradient composition of the coating caused by an inter-diffusion of metal cations and oxygen in the metal/oxide interface during heat treatment. Residual stress measurements by X-rays result in compressive stresses of 2–4 GPa in the alumina coatings. The pin-on-disc test shows a remarkable improvement of wear resistance obtained by sol-gel coatings. The α-alumina content and the compressive stress of the coatings correlate with wear resistance of the coatings.     

Exploration of the potentials of imidazole-based inhibitor package for heat exchanger-type stainless steel during acid cleaning operation

Protecting heat exchanger alloys from corrosion during acid cleaning is sacrosanct and necessitates the development and application of highly–efficient environmentally–friendly corrosion inhibitors. In the present work, gravimetry, electrochemical impedance spectroscopy (EIS), cyclic potentiodynamic polarization (CPDP), cyclic voltammetry and scanning electron microscopy-energy dispersive x-ray spectrophotometry (SEM-EDX) have been employed to investigate the potential of 1–benzylimidazole and its mixture with potassium iodide (KI) for the mitigation of stainless steel (SS316L) corrosion in 1 M HCl solution at 60 °C. After short immersion time, 1–benzylimidazole is found to decrease the weight loss and corrosion rate of the substrate and impacts an inhibition efficiency of ≈ 65% at 2000 ppm dosage. The inhibitor adsorption followed the Freundlich isotherm. The synergism significantly lowers the rate of anodic half–reactions involving Fe and Cr oxidation which, in turn, boosts the inhibitor efficiency to > 80% through a competitive synergism. SEM-EDX characterization confirm that the passive layer formed in the presence of 1–benzylimidazole + KI significantly mitigated against the propagation of localized pitting corrosion. Prolonged immersion time, up to 72 h, lowers the inhibition efficiency of 1–benzylimidazole + KI mixture to 74 %.     

A zirconia-polyester glycol coating on differently pretreated AISI 316L stainless steel: corrosion behavior in chloride solution

The effect of zirconia and zirconia-polyester glycol hybrid coatings on the corrosion resistance of mechanically polished or anodized AISI 316 stainless steel (316L), was studied by potentiodynamic polarization and electrochemical impedance spectroscopy in 0.1 M NaCl and scanning electron microscope and atomic force microscopy examinations. The deposition of zirconia coatings was achieved by the sol–gel technique by immersing the samples in either the inorganic polymer or the organic–inorganic polymer mixture. From potentiodynamic and impedance measurements, the grade of protection is reduced with the exposure time to the electrolyte, which is mainly associated with lost of film adhesion and, consequently, detachment from the metal substrate. However, the uncoated anodized sample revealed an unexpected corrosion behavior; the anodic film formed during anodizing readily increased the corrosion resistance of the 316L stainless steel in 0.1 M NaCl, revealing a considerable reduction in the corrosion current density and an increase in the pitting potential.     

Sol-gel ZrO2 coatings for chemical protection of stainless steel

ZrO₂ coatings deposited on 316 L stainless steel sheets were synthesized by sol-gel method using Zr(OC₃H₇)₄ as precursor and isopropanol, glacial acetic acid, and water as solvents for application with ultrasounds. Different solutions for dip-coating were prepared with compositions varying between 0.025 and 0.9 mol/dm³ of ZrO₂. X-ray diffraction shows that the films densified at 800°C are crystalline with a tetragonal structure. The thickness of the coatings varied from 0.35–0.75 m. The influence of the ZrO₂ coatings on the corrosion behavior of stainless steel substrates in aqueous NaCl was studied through potentiodynamic polarization curves at 1 mV/s. The values of the electrochemical parameters allow for an explanation of the role of the films in the increased resistance of steel against corrosion in moderately aggressive environments.     

Effect of the silica content on the physico-chemical and relaxation properties of hybrid polymer/silica nanocomposites of P(EMA-co-HEA)

Poly(ethyl methacrylate-co-hydroxyethyl acrylate) 70/30 %wt/silica, P(EMA-co-HEA)/SiO₂, nanocomposites, with silica contents ranging from 0 to 30 %wt, were synthesized and studied as promising candidate materials for the synthetic matrix of scaffolds for bone substitutes or dentin regeneration. The physico-chemical properties of the hybrids were studied by calorimetry and by contact angle measurements on the surfaces. The dynamic-mechanical and compression properties were analysed. Intermediate silica contents in the range from 10 to 20 %wt of silica rendered co-continuous interpenetrated structures, in which silica produced a reinforcing effect in the polymeric matrix and at the same time conferred bioactivity to the surfaces by improving surface wettability, making these hybrids appropriate for the proposed application. On the contrary, silica percentages below 10 %wt formed disconnected inorganic aggregates at the nanoscale dispersed in the copolymer matrix, which did not modify significantly the copolymer properties. Silica contents above 20 %wt formed denser inorganic networks with few terminal silanol groups available at the surfaces, much more rigid and hardly manageable samples.     

Positron annihilation study on interaction between hydrogen and defects in AISI 304 stainless steel

Interaction between hydrogen and defects in AISI 304 stainless steel was investigated by positron annihilation lifetime spectra (PALS) and coincidence Doppler broadening (CDB) measurements. PALS results show that long lifetime component τ₂ is about 260–270 ps, and does not change with current density, which is ascribed to the formation of three-dimensional vacancy cluster of 5–7 vacancies. Furthermore, the CDB ratio curves show that an obvious peak appears in the high-momentum region after hydrogen charging, and the peak site does not vary with current density. The mechanism of interaction between hydrogen with defects is discussed.     

Synthesis and Properties of Cerium and Titanium Oxide Thin Coatings for Corrosion Protection of 304 Stainless Steel

Powders and thin coatings of ceria and titania were synthesized from aqueous and solvent-based precursors. Thin coatings were deposited on polished 304 stainless steel coupons by dipping them in the appropriate sol-gel oxide precursors. The coatings were subsequently densified and crystallized at several hundreds of degrees. It was possible to obtain dense titania coatings by applying thin coatings of cerium dioxide prior to titania on stainless steel substrates. Underlayer ceria coatings proved to be pivotal in obtaining dense titania coatings and preserving the integrity of the stainless steel while going through the high temperature treatments. The effect of processing parameters such as the atmosphere of heat-treatment, and temperature on the microstructure and crystal structure of the films and powders of ceria and titania was investigated. X-ray diffraction was used to identify the crystal structure of films and powders upon heat-treatment. Electrochemical measurements in NaCl, and analytical techniques such as SEM and EDX were used to evaluate the corrosion performance and pitting morphology of coated samples. A composite coating of ceria and titania was able to prevent crevice corrosion and increase the pitting resistance of the 304 stainless steel relative to the uncoated substrate.     

Electrochemical and XPS studies on corrosion behaviours of AISI 304 and AISI 316 stainless steels under plastic deformation in sulphuric acid solution

The corrosion behaviours of austenitic stainless steels were investigated by electrochemical methods under plastic deformation with constant strain in the naturally aerated 0.5 M H₂SO₄ + 0.2 M KCl solution at room temperature. The work addresses the influence of plastic deformation and molybdenum element on the corrosion resistance of austenitic stainless steels in the test solution. Electrochemical impedance spectroscopy presents the decreasing charge transfer resistance (R_t) and polarization resistance (R_p) values with the immersion time for AISI 304 stainless steel under constant strain deformation, and the increasing R_t and R_p values with the immersion time for AISI 316 stainless steel. The analysis of the chemical composition of the corrosion products was carried out by XPS. Molybdenum addition in AISI 316 stainless steel affects significantly the corrosion resistance because of its high ability to form Mo (VI) and MoCl₅ insoluble compounds in acid medium. Copyright © 2011 John Wiley & Sons, Ltd.     

Study on the variation of morphology and separation behavior of the stainless steel supported membranes at high temperature

Palladium composite membranes were prepared on stainless steel (SUS) supports modified by nickel submicron powder and colloidal silica sols. Permeation tests of the palladium composite membranes were carried out at high temperature in order to observe the thermal stability of the membrane. The palladium composite membrane failed with formation of plenty of pinholes in the presence of hydrogen at high temperature. The failure of the composite membrane was verified by comparing the nitrogen permeance before hydrogen permeation test with that after hydrogen permeation test and comparing the H₂/N₂ selectivity for single gas permeation test with that for mixture gas permeation test. The variation of the membrane surface due to the failure of the membrane was characterized in scanning electron microscopy (SEM) and energy dispersive X-ray spectrometer (EDS) analyses. As a result, it can be concluded that reducible metal oxides can be attributed to the failure of the composite membranes resulting from reduction of the metal oxides by hydrogen whichever position in the membrane the metal oxides are layered.     

Dispersion of silica nano-particles in sol-gel hybrid resins for fabrication of multi-scale hybrid nanocomposite

Multi-scale hybrid nanocomposites containing both ∼15 nm silica colloids and ∼2 nm oligosiloxanes in a methacryl polymer matrix were newly designed and fabricated. Colloidal silica sols were dispersed in methacryl oligosiloxanes nano-hybrid resins synthesized by sol-gel reaction of methacryloxypropylmethoxysilane and diphenylsilanediol. On the basis of TEM and SANS analyses, it was confirmed that the silica colloids were compatibly dispersed and different sizes of colloidal silica and oligosiloxanes co-exist in the solutions. Multi-scale hybrid nanocomposites fabricated by UV and thermal curing with incorporation of silica colloids in the nano-hybrid materials show enhanced mechanical and thermal characteristics.     

疏水型纳米TiO_2膜的制备、表征及耐蚀性能研究

以乙酰乙酸乙酯(EAcAc)作稳定剂和阻聚剂制备超微TiO2溶胶,用提拉法在AISI316L不锈钢上构筑一层纳米TiO2膜,经水热后处理有效消除膜中的龟裂现象,经氟硅烷基化制备成疏水型纳米TiO2膜.用胶粒分布仪测定溶胶颗粒分布,接触角测试仪测定表面疏水性、XRD、SEM表征膜的形貌、结构,电化学线性极化法测定疏水型纳米TiO2膜在模拟体液(Ringer溶液)中的电化学行为.结果表明:TiO2膜呈多孔有序纳米膜,颗粒分布均匀,粒径约为15～18nm,厚度约375nm,TiO2为锐钛矿型,疏水型纳米膜可使不锈钢腐蚀电流降低3个数量级,其耐腐蚀性大幅度提高.     

Two layered silica protective film made by a spray-and-dip coating method on 304 stainless steel

The silica coating has attracted much attention because of its superior corrosion resistance with almost no harm to human health and to the environment. In this study, a two layered silica film was tried to get an enhanced corrosion resistance. The silica film was prepared on the hairline finish 304 stainless steel surfaces by-a-spray- and subsequent-dip-coating process. The spray coating solution was prepared by mixing sodium silicate solution, silica colloid, tetraethyl orthosilicate (TEOS), methyltriethoxysilane (MTES), ethanol, and distilled water. Then the solution was sprayed onto the stainless steel surface, and was dried and heat treated. The dip coating solution was prepared by a simple mixing of TEOS and acidic water into ethanol, and the prior spray coated sample was dipped into the solution. The outer dip coated layer was intended to cover spray coated rough and porous layer and hence to enhance the corrosion resistance. A homogeneous and crack free surface was successfully obtained after the dip coating. The prepared silica film was characterized using scanning electron microscopy, potentiodynamic polarization scan, and electrochemical impedance spectroscopy. The two layered film showed an enhanced corrosion resistance. The enhancement was attributed to a protecting effect of the dip coated layer where the diffusion of ionic species was successfully impeded.     

Inhibition effect of hexadecyl pyridinium bromide on the corrosion behavior of some austenitic stainless steels in H2SO4 solutions

The inhibition effect of hexadecyl pyridinium bromide (HDPB) as a cationic surfactant on the corrosion behavior of some Egyptian austenitic stainless steel SS 304L, SS 316H and SS 304H in 0.5 M H₂SO₄ solutions was investigated by using potentiodynamic polarization technique and electrochemical impedance spectroscopy (EIS). The results indicate that HDPB is a good inhibitor for the samples under investigation in 0.5 M H₂SO₄ solutions. In addition, the inhibition efficiency η% increases with the inhibitor concentration while decreases with the increasing temperature referring to physical adsorption. The adsorption of the inhibitor obeys a Temkin adsorption isotherm. Polarization curves show that HDPB is a mixed inhibitor in H₂SO₄ solutions. The results obtained from polarization and impedance measurements are in good agreement. Activation-free energies, enthalpies, and entropies for the inhibition process of HDPB were determined.     

Deposition studies of carbon particles on stainless steel surfaces from hydrocarbon media

The adsorption isotherms for carbon particles of about 200 nm size, in the presence of various combinations of a terminally functionalised (amine) polyisobutylene polymer and alkylpropoxylate/alkylbutoxylate surfactant molecules, on 7 μm diameter stainless steel beads from isooctane solutions have been obtained. The deposition of carbon particles on stainless steel plates was achieved using a flow-cell and analysed using scanning electron microscopy. The flow-cell was also used to study the “cleaning” properties of various polymer/surfactant solutions, in their ability to remove deposited particles. It was found that the polymer molecules were much more effective dispersants and stabilisers for the carbon particles, but the surfactant molecules were much better at effecting anti-deposition and subsequent removal of deposited carbon particles, and provide carried adsorbed polymer chains.