XPS analysis of petroleum well tubing adherence

Undesired material adhered to the internal surface of the tubing wall of some petroleum wells is critical for crude oil production. Field samples of steel with petroleum solid adherence were characterized by means of x‐ray photoelectron spectroscopy, x‐ray diffraction and atomic absorption spectroscopy. The deposit naturally adhered on the steel surface is structurally formed by a thin, black and hard corrosion product layer (inner layer) ～15 µm thick under a thick, black and brittle organic deposit layer (outer layer) ～0.01 m thick composed mainly of hydrocarbons. This outer layer contains small amounts of barium sulphate (BaSO₄) co‐precipitated with organic compounds, which may contribute to the deposit's lack of cohesion. On the contrary, the inner layer of the deposit is firmly adhered to the steel substrate and contains clay minerals and iron compounds embedded in the hydrocarbon layer. Copyright © 2003 John Wiley & Sons, Ltd.     

Electrochemical and Surface Analysis Studies on the Carbon Dioxide Corrosion of X‐65 Carbon Steel

A comprehensive study of the CO₂ corrosion of carbon steel (X‐65) at low partial pressures of CO₂ is reported in this paper. Field emission scanning electron microscopy (FESEM), Raman spectroscopy (RS), synchrotron radiation‐grazing incidence X‐ray diffraction (SR‐GIXRD), and electrode kinetic studies have confirmed that chukanovite, magnetite and siderite are the main corrosion products at low partial pressures of CO₂. Chukanovite forms predominantly in the presence of CO₂, while magnetite was found to be the major corrosion product in the absence of CO₂, although the majority of previous work based on conventional ex‐situ materials characterization techniques has implied that siderite is the main corrosion product. Here, it is shown that the nature of corrosion products is strongly dependent on the experimental conditions at low pressures of CO₂, which has not been elucidated in previous studies. Accordingly, this study has made a significant contribution to identifying the true nature of corrosion scales formed at low partial pressures of CO₂ allowing the development of effective anti‐corrosive agents for the control and prevention of carbon steel corrosion at low CO₂ partial pressures.     

Characteristics of CO2 corrosion scale formed on P110 steel in simulant solution with saturated CO2

The SEM, X‐ray diffraction (XRD), and XPS were employed to systematically characterize the component and microstructure of the corrosion scale formed on P110 steel exposed to carbon dioxide (CO₂) environment. A loose and porous microstructure in corrosion scale was observed under turbulent flow condition for 120 h at 100 °C with a carbon dioxide partial pressure of 4 MPa in which the principal component was iron carbonate (FeCO₃), whereas at 160 °C the corrosion scale was composed mainly of FeCO₃ and a little amount of FeO(OH). In addition, complex carbonate (Mg,Fe)CO₃ was produced because some Fe positions in FeCO₃ lattice were substituted by Mg. It showed that a double‐layer structure of corrosion scale was observed at 160 °C compared with the result at 100 °C. Copyright © 2008 John Wiley & Sons, Ltd.     

Post‐oxidizing effects on surface characteristics of salt bath nitrocarburized AISI 02 tool steel type

The effect of post‐oxidizing treatment on the characteristics of modified surface layers produced by salt bath nitrocarburizing on the industrial American Iron and Steel Institute (AISI) 02 tool steel types is investigated. Nitrocarburizing treatment is performed for 6 h and 8 h at 570 °C and post‐oxidizing treatment for 30, 60 and 90 min at 520 °C, using argon–steam mixture. Formed layers are characterized by their basic properties such as thickness layer, depth, surface hardness and wear resistance. Detailed estimation of the modified metal surface quality, in terms of chemical composition, formed phases, microstructures and diffusion mechanisms are performed by metallographic techniques, EDX, X‐ray diffraction, scanning electron microscopy (SEM) and glow discharge optical electron spectroscopy (GDOES). The corrosion resistance was investigated in 0.4 M H₂SO₄ solutions, using steady‐state electrochemical polarization methods. The obtained results revealed the existence of a superficial oxide layer which consists of magnetite (Fe₃O₄) and hematite (Fe₂O₃) and the presence of an ε‐phase associated with a small amount of γ′‐phase. Important improvements in wear, microhardness and corrosion resistance occur after these treatments and it is specifically concluded that the sole application of a nitrocarburizing treatment does not significantly ameliorate the corrosion resistance of the as‐received steel. In fact, post‐oxidation treatment contributes to increase corrosion resistance by forming a dense magnetite layer and at the same time, it partially covers the compound layer pores. Copyright © 2009 John Wiley & Sons, Ltd.     

XPS depth profile study of porous zirconia films deposited on stainless steel by spray pyrolysis: the problem of substrate corrosion

Zirconia (ZrO₂) films of tissue‐like structure and narrow pore size distribution have been deposited by spray pyrolysis using aqueous zirconyl chloride octahydrate (ZrOCl₂·8H₂O) precursor solutions. Stainless‐steel sheets, protected or unprotected by a ZnO barrier layer, have been used as the substrate material held at 473 K. The ZnO barrier layers have been deposited on the stainless steel held at 523 K by spray pyrolysis using a zinc acetate precursor. Their property of corrosion protection to stainless steel has been proved by electrochemical polarization measurements in 0.5 M NaCl solution. A complementary study of XPS (depth profiling, mapping) and x‐ray diffraction has shown that the unprotected steel substrates were corroded during ZrO₂ film post‐annealing in air at T ≥ 773 K, whereas steel substrates protected with a compact barrier layer of crystalline ZnO before ZrO₂ film deposition did not show surface corrosion even after annealing up to 997 K. Copyright © 2004 John Wiley & Sons, Ltd.     

Corrosion behavior of electroless Ni–P/TiO2 nanocomposite coatings

Composite Ni–P/nano‐TiO₂ coatings were prepared by simultaneous electroless deposition of Ni–P and nano‐TiO₂ on a low carbon steel substrate. The deposition was carried out from stirred solutions containing suspended nano‐TiO₂ particles. The Ni–P and Ni–P/nano‐TiO₂ coatings before and after heat treatment were characterized by X‐ray diffraction, scanning electron microscopy and energy dispersive X‐ray spectroscopy. The micro‐structural morphologies of the coatings significantly varied with the nano‐TiO₂ content. The corrosion resistance of as‐plated and heat‐treated Ni–P and Ni–P/nano‐TiO₂ coatings was investigated by anodic polarization, Tafel plots and electrochemical impedance spectroscopic (EIS) studies in 3.5% NaCl solution. Ni–P/nano‐TiO₂ coating exhibited superior corrosion resistance over Ni–P coating. Copyright © 2015 John Wiley & Sons, Ltd.     

Effects of anodic oxidation on corrosion properties of Al coating by arc spraying in seawater

A layer of Al coatings was prepared on the S355 steel by arc spraying, which was conducted by anodic oxidation treatment; the morphologies, chemical element compositions and phases of Al coating, and anodic oxide layer were analyzed with field emission scanning electron microscope (FESEM), energy dispersive spectrometer (EDS) and X‐ray diffraction (XRD), respectively. The corrosion protections of Al coating before and after anodic oxidation were discussed with a seawater immersion test; the corrosion resistance mechanisms of Al coating and anodic oxide layer in the seawater were also investigated. The results show that the thickness of Al coating is about 300 µm by arc spraying, the sample surfaces become loose after seawater immersion corrosion and Cl^? and O^2? penetrate into the substrate from the cracks, destroying the binding properties of coating–substrate, and the coating fails. After anodic oxidation, the oxide layer is formed in the surface of Al coating with the thickness of about 30 µm; the corrosion products are mainly composed of Al(OH)₃, which barraged the holes caused by seawater corrosion. The corrosion cracks are formed during the corrosion, while the number and depth of cracks decrease obviously after anodic oxidation treatment. The corrosion of Al coating becomes the local corrosion after anodic oxidation treatment, and the grains are smaller, which are easily nucleated to form a new corrosion resistance layer. Copyright © 2015 John Wiley & Sons, Ltd.     

Influence of hydrothermal exposure on surface characteristics and corrosion behaviors of anodized titanium

Titanium surface was modified by anodization in phosphoric acid solution at the voltages of 100 and 250 V, respectively. Surface characteristics and corrosion behaviors of anodized titanium were investigated before and after hydrothermal exposure in 3.5 wt.% NaCl solution at 160 °C for 24 h. It was found that anodization at 100 and 250 V resulted in the formation of a dense and a porous TiO₂ layer, respectively. The existence of anatase in the oxide layers of the 250‐V samples was confirmed by X‐ray diffraction analysis but not in the oxide layers of the 100‐V samples. After the hydrothermal exposure, the surface morphology of the 100‐V sample changed significantly, and discrete nanorods were formed on the surface. In contrast, the 250‐V sample basically preserved their original surface structures after the exposure except that numerous closely packed nanoparticles emerged on the surface. X‐ray diffraction analysis indicated that the exposure transformed the amorphous oxides into crystalline anatase. The corrosion behavior investigation of anodized titanium showed that the hydrothermal exposure had slight influence on the corrosion resistance of the 100‐V samples but decreased the corrosion resistance of the 250‐V samples significantly. Copyright © 2014 John Wiley & Sons, Ltd.     

Corrosion resistances of passive films on low‐Cr steel and carbon steel in simulated concrete pore solution

The passive ranges of carbon steel rebar and 3Cr steel rebar in saturated Ca(OH)₂‐simulated concrete pore solution with pH 12.6 were determined by means of cyclic voltammetry and potentiodynamic polarization curves. Chronopotentiometry was used to obtain steady‐state conditions for the formation of passive films on rebar samples at different anodic potentials. Electrochemical impedance spectroscopy, Mott–Schottky and X‐ray photoelectron spectrometer curves were employed to compare the formed passive films at different potentials. Additionally, cyclic polarization curves were used to compare the corrosion resistances of formed passive films on the two rebars in saturated Ca(OH)₂‐simulated concrete pore solution with different concentration of Cl^?. The results show that the passive ranges of the two rebars are all between ?0.15 and +0.6 V, and more stable passive films can be formed on both rebars at the anodic potential of +0.3 V. In the absence of Cl^?, the stability and corrosion resistance of the passive film formed on the 3Cr rebar are better than those of CS rebar. The passive film of 3Cr steel has the relatively better pitting corrosion resistance than carbon steel in saturated Ca(OH)₂‐simulated concrete pore solution that contains different concentration of Cl^?. Copyright © 2016 John Wiley & Sons, Ltd.     

高温高压喷射湍流区中X70管线钢CO2腐蚀电化学特征

采用高温高压环路喷射装置并结合腐蚀微电极技术, 开展了湍流区中X70 管线钢CO₂腐蚀实验. 利用扫描电镜对不同实验时间的试样表面腐蚀产物微观形貌进行了观察和分析, 并进行了湍流区原位电化学测试和分析. 结果表明, 湍流区中X70 钢的CO₂腐蚀电化学特征与其表面所覆盖腐蚀产物膜层变化密切相关. 实验12 h内, 湍流区中X70钢表面从最初的基体与腐蚀产物共存, 转变为由疏松且不完整的膜层覆盖的特征. 实验12 h 后, 试样表面出现内外两层腐蚀产物膜, 内层膜堆垛致密, 外层膜疏松多孔, 同时湍流区中高切应力导致外层腐蚀产物脱落, 材料表面逐渐被完整致密的内层膜覆盖, 这是腐蚀速率持续下降的主要原因. 电化学结果表明, 实验12 h 内, 湍流区中X70 钢的腐蚀电位E_corr和线性极化电阻R_p不断下降; 电化学阻抗谱由高频容抗弧、中频容抗弧和低频感抗弧组成, 膜层电阻R_f缓慢增加, 电荷传递电阻R_t不断下降, 双电层电容C_dl和膜层电容C_f迅速下降; 12 h后, 腐蚀产物膜层对基体材料保护性随喷射时间延长逐渐增强, E_corr和R_p逐渐增大, 电化学阻抗谱中低频感抗弧逐渐收缩并在48 h 时消失, 最后转变为双容抗特征, R_f、R_t和C_dl随时间迅速增大, C_f趋于稳定.     

Analysis of corrosion scales formed on steel at high temperatures in hydrocarbons containing model naphthenic acids and sulfur compounds

Corrosive naphthenic acids and sulfur compounds in crude oils present a major challenge for refineries from a corrosion perspective. Although it is accepted that some sulfur compounds may form protective FeS scales on the metal surface and deter corrosion, attempting to correlate the characteristics of FeS scale with its protective properties has not been successful. Given the complex chemical compositions of real crudes, model sulfur compound and model naphthenic acids were used to mimic the corrosion by crude fractions in the present study. The iron sulfide scale formed by the model sulfur/acid compounds was challenged by naphthenic acids under high‐velocity conditions to examine its protectiveness against corrosion. Moreover, the scale was analyzed with transmission electron microscope/energy dispersive X‐ray spectroscopy technique, and a layer of iron oxide formed on the 5Cr steel was found when naphthenic acids were present in the solution. The iron oxide layer appeared to be important for maintaining protection against naphthenic acid corrosion, and further analysis revealed that it was composed of magnetite. Copyright © 2015 John Wiley & Sons, Ltd.     

In‐situ spectroelectrochemical study of the growth process of a lead decanoate coating as corrosion inhibitor for lead surfaces

We have monitored the growth of lead decanoate coatings in real time using electrochemical impedance spectroscopy (EIS) and synchrotron X‐ray diffraction in a unique environmental cell. The measurements involved the immersion of lead substrates in a 0.05 M sodium decanoate solution and the simultaneous collection of spectroscopic and electrochemical data as the coating deposits. In separate experiments, the surface morphology was investigated with SEM. The stratigraphy and thickness of layers after 6 h of treatment (?1.5 µm) was determined using RBS and ultra low energy SIMS combined with surface profilometry. Weight‐gain measurements were also carried out. Overall, the results are consistent with an initially parabolic process, due simply to diffusionally limited two‐dimensional growth across the surface from nucleation sites. This becomes linear over time as one‐dimensional vertical growth sets in at full coverage (layer closure). The X‐ray data and the microscopy show that the coating consists of fine, interlocking, randomly oriented flake‐shaped crystals, with no obvious epitaxial relationship to the lead substrate. The growth rate of the coating and its corrosion resistance are extremely sensitive to preparation method of the NaC₁₀ solution in ways which are still under investigation. Copyright © 2009 John Wiley & Sons, Ltd.     

Corrosion protection performance of ceria‐copolymer bilayer coating on low nickel stainless steel in 0.5 M H2SO4 medium

In this paper, we have reported the anti‐corrosion performance of ceria / poly (indole‐co‐pyrrole) (Ce/(poly(In‐co‐Py)) bilayer coating on low nickel stainless steel (LN SS). Electrochemical polymerization of (poly (In‐co‐Py)) was achieved on ceria‐coated LN SS (CeO₂/LN SS) in acetonitrile medium containing LiClO₄ (ACN‐LiClO₄) by cyclic voltammetric technique. The coatings were characterized by analytical techniques like Fourier transform infrared spectroscopy, scanning electron microscopy with energy dispersive analysis of X‐ray, respectively. The mechanical behavior of the coatings was studied using peel test, hardness and wear resistance tests. The corrosion defensive performance of this bilayer coating on LN SS was investigated using electrochemical techniques such as potentiodynamic polarization and electrochemical impedance spectroscopy in 0.5 M H₂SO₄. These results show that the bilayer coating on LN SS lowered the permeability of corrosive ions present in the acidic medium and thus acts as a barrier against the attack of corrosive environment. Copyright © 2012 John Wiley & Sons, Ltd.     

Mechanical property and corrosion resistance of zirconia/polydopamine nanocomposite multilayer films fabricated via a novel non‐electrostatic layer‐by‐layer assembly technique

Zirconia/polydopamine (ZrO₂/PDA) nanocomposite multilayer films were constructed on Si substrate via a novel nonelectrostatic layer‐by‐layer (NELBL) assembly technique. The building block of this technique is the newly reported dopamine molecule, which can be attached to almost all material surfaces and undergo oxidation‐polymerization to form PDA layers; more importantly, the outer hydroxyl groups of the PDA layer can chelated with certain inorganic oxide nanoparticles to generate oxide films. Thus, ZrO₂/PDA nanocomposite multilayer films were fabricated by sequential NELBL deposition of PDA and ZrO₂ nanoparticles. The formation of the ZrO₂/PDA nanocomposite multilayer films was monitored by the water contact angle (WCA) and ellipsometric thickness measurements, while the microstructure of the fabricated films was analyzed by means of atomic force microscope (AFM), field emission scanning electron microscope (FESEM), X‐ray photoelectron spectrum (XPS), and X‐ray diffraction (XRD) analysis. The mechanical and anticorrosion behaviors of the annealed ZrO₂/PDA nanocomposite multilayers were found to be greatly enhanced as compared with that of the annealed homogeneous ZrO₂ film. The better mechanical and anticorrosion behaviors of the annealed ZrO₂/PDA nanocomposite multilayers than the annealed homogeneous ZrO₂ film may be closely related to their special microstructure. Namely, the organic–inorganic hybrid microstructure of the annealed ZrO₂/PDA nanocomposite multilayers may largely account for the increased nanohardness and corrosion resistance. Copyright © 2010 John Wiley & Sons, Ltd.     

Laser treatment of A286 superalloy: corrosion resistance of the treated surface

Laser controlled melting of metal surface provides a local treatment with improved surface properties such as corrosion resistance. In the present study, laser surface treatment of iron base superalloy (A286) is carried out. The corrosion resistance of the laser‐treated surface is examined through potentiodynamic tests using 0.5 N NaCl solution. The microstructural and morphological changes in the laser‐treated layer are investigated incorporating scanning electron microscopy (SEM), X‐ray diffraction (XRD) and energy dispersive spectroscopy. The residual stress formed at the laser‐treated surface is measured using the XRD technique. It is found that laser treatment enhances corrosion resistance of A286 superalloy surface, which is attributed to the formation of fine grains and dense layer at the treated surface. Although locally scattered few corrosion induced microcracks are observed at the treated surface, they are not extended to form large cracks or crack network at the surface. Copyright © 2012 John Wiley & Sons, Ltd.     

Sulfonated salicylidene thiadiazole complexes with Co (II) and Ni (II) ions as sustainable corrosion inhibitors and catalysts for cross coupling reaction

Condensation of 2,5‐dihydrazinyl thiadiazole with 5‐sodium sulfonate salicylaldehyde afforded dibasic tetradentate pincer N,O,O,N‐salicyldiene thiadiazole ligand (H₂Sanp). The novel dipolar ligand formed para‐magnetic pincer complexes within Co (II) and Ni (II) ions (Co‐Sanp and Ni‐Sanp) under sustainable conditions. The water‐soluble ligand and its metal‐complexes were estimated by mass, IR and UV–Visible spectroscopy, EA (elemental analyses), TGA (Thermogravimetric analyses), magnetic susceptibility, and conductivity measurements. The catalytic reactivity of Co‐Sanp and Ni‐Sanp were evaluated in the Suzuki and Buchwald‐Hartwig cross coupling reaction in aqueous‐methanol binary mixtures. Both reactions of boronic acid or aryl amines with aryl halides gave high chemoselective yield of C―C or C―N product. The inhibition characteristics of H₂Sanp and its Ni‐ and Co‐complexes were performed for the C‐steel corrosion in 1.0 M HCl using electrochemical measurements and surface analysis methods. These methods indicated that the synthesized compounds have served as efficient mixed‐type corrosion inhibitors and their adsorption on the steel surface obeyed isotherm model of Langmuir. Co‐Sanp inhibitor displays the best corrosion inhibition efficiency, and the capacity is up to 97.11% at of 250 mg L^?1. Surface analysis confirms formation of protective layer on the C‐steel surface.     

SRB和CO2共存环境中X60管线钢腐蚀电化学特征

对X60管线钢在硫酸盐还原菌(SRB)和CO2共存环境中进行浸泡实验, 对浸泡不同时间后的腐蚀形态及膜层的组成进行观察和分析, 并对膜层覆盖的X60钢的腐蚀电化学参数特征进行分析. 结果表明, SRB吸附形成的微生物膜覆盖程度加大导致X60钢电位正移, 腐蚀产物FeS和FeCO3含量增加导致X60钢电位负移. X60钢表面膜层中腐蚀产物含量较低时, 仅有一个与电极电位有关的时间常数, 当膜层中腐蚀产物的含量高时, 增加了与腐蚀产物膜有关的时间常数. 在浸泡初期, 随微生物膜覆盖程度增加, X60钢的电荷传递电阻增大; 随腐蚀产物含量增加, 电荷传递电阻先下降后增大. 随浸泡时间的延长, X60钢双电层电容和膜层电容均增大.     

Uranium association with corroding carbon steel surfaces

We investigated the association of uranium with clean and corroded surfaces of 1010 carbon steel. Studying steel contaminated by uranium species will have an important effect on the development of methods used to clean radioactively contaminated metal waste. X‐ray photoelectron spectroscopy, synchrotron infrared microspectroscopy and laboratory‐based Fourier transform infrared analysis of steel surfaces exposed to uranyl nitrate showed the presence of crystallized hydrated uranyl oxides, uranyl hydroxides, iron oxyhydroxides and iron oxides. In general, heavily corroded areas physically shield the uranium species, which tended to associate spatially with hydroxyl groups and lepidocrocite. Lightly corroded areas contained uranium species with stronger axial U–O bonding. Infrared spectroscopy, Rutherford backscattering spectroscopy and energy‐dispersive spectroscopy mapping analysis revealed that the uranium species are well distributed within the upper micron of the thick corrosion layer and associated more with areas of high hydroxide content. Parameters such as the concentration of uranyl nitrate solution used to expose the carbon steel coupons, the method of contamination (dipped or sprayed with dilute uranyl nitrate solution) and the degree of corrosion (accelerated corrosion before and/or after contamination) played significant roles in the distribution and nature of the uranyl hydroxide/iron oxyhydroxide corrosion products found on the surface of all coupons. These factors must be considered in the development and optimization of decontamination processes for metal waste. Copyright © 2003 John Wiley & Sons, Ltd.     

Corrosion and wear resistance properties of multilayered diamond‐like carbon nanocomposite coating

Multilayered diamond‐like carbon (DLC) nanocomposite coating has been deposited on silicon and stainless steel substrates by combination of cathodic arc evaporation and magnetron sputtering. In order to make DLC coating adhered to metal substrate, a chromium interlayer has been deposited with constant bias voltage of −150 V applied to the substrate. Dense multilayered coating consists of metallic or nonmetallic and tetrahedral carbon (ta‐C) layers with total thickness of 1.44 μm. The coating has been studied for composition, morphology, surface nature, nanohardness, corrosion resistance, and tribological properties. The composition of the coating has been estimated by energy‐dispersive spectroscopy. Field‐emission scanning electron microscopy and atomic force microscopy have been used to study the surface morphology and topography. I_D/I_G ratio of ta‐C:N layer obtained from Raman spectroscopy is 1.2, indicating the disorder in the layer. X‐ray photoelectron spectroscopy studies of individual ta‐C:N, CrN, and Cr‐doped DLC layers confirm the presence of sp²C, sp³C, CrN, Cr₂N, and carbidic carbon, and sp²C, sp³C, and Cr carbide. Nanohardness studies show the maximum penetration depth of 70 to 85 nm. Average nanohardness of the multilayered DLC coating is found to be 35 ± 2.8 GPa, and Young's modulus is 270 GPa. The coating demonstrates superior corrosion resistance with better passivation behavior in 3.5% NaCl solution, and corrosion potential is observed to move towards nobler (more positive) values. A low coefficient of friction (0.11) at different loads is observed from reciprocating wear studies. Wear volume is lower at all loads on the multilayered DLC nanocomposite coating compared to the substrate.     

Nitridation of V5Al8 films with NH3 by Rapid Thermal Processing (RTP)

V₅Al₈ films (thickness about 100 nm) were deposited on sapphire substrates by RF‐sputtering and nitridated with NH₃ at 600‐1250 °C (1 min) in a RTP system. The as deposited and nitridated films were investigated by ESCA (electron spectroscopy for chemical analysis), XRD (X‐ray diffraction), XRR (X‐ray reflectometry), AFM (atomic force microscopy) and SEM (scanning electron microscopy). Formation of an aluminum nitride layer at the surface and precipitation of V(Al) in the bulk was found. In the temperature regime from 600 °C to 900 °C a considerable amount of oxygen is incorporated in the aluminum nitride layer. The roughness of the surface increased with increasing temperature and at 1250 °C a partially detaching of the AlN layer could be observed.