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Eingeladener Vortrag
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In the late 1980s, a new type of corrosion appeared in drinking water installations where galvanized steel pipes failed forming a deep groove with no corrosion at the other surfaces. The reason was discussed quite fiercely between failure analysts and material suppliers. In the end the discussion lead to the solution: inductive welded pipes of a certain sulphur content were prone to selective corrosion. The history of the arguments is discussed using old communications between Wilhelm Schwenk and Wolfgang Stichel, who later published the results in a paper unfortunately only I german.
Thus the knowledge got lost and new cases based on the same material problems are observed in application of so-called C-Steel piping systems. Failure cases are shown.
The screening of coatings shows that the modification by adding individual pigment was not sufficient to protect carbon steel even during a short-term exposure, indicated by the discoloration after only seven days of exposure.
Electrochemical tests indicated that the coating cathodically protects carbon steel or slows down the corrosion reaction.
A long-term exposure test confirmed that the PANI/SiO2 modified coating successfully protects the carbon steel in the Sibayak artificial geothermal water at 150 °C for 6 months.
The copper alloyed stainless steel 1.4542 (X5CrNiCuNb16-4) is used in different areas due to its good mechanical properties and corrosion resistance. Strength and corrosion resistance can be adjusted by the heat treatment, which is of importance for the application of this alloy. The mechanical properties (strength and hardness) are attributed to the dispersive precipitation of the copper rich ε–Phase. The additional precipitation of chromium carbides can reduce the corrosion resistance. Different ageing states were produced to investigate the precipitation behaviour with various methods. Furthermore, the influence of cold-rolling on the precipitation behaviour was studied in comparison to a solution annealed state without deformation. The microstructure was studied by SEM and the variations of hardness and magnetic proportion were characterised. The electrochemical potentiodynamic reactivation (EPR) was used to determine the corrosion resistance and detect chromium depletion in all heat-treated states. The results show that a work hardening accelerates the precipitation rate, while ageing at 600 °C reduces the corrosion resistance due to chromium depletion.
Analyzing the performance of discrete galvanic anode systems using electrochemical investigations
(2021)
Corrosion of reinforcement is one of the major reasons in questioning the service life of building structures. The application of cathodic protection techniques plays a big role in controlling the corrosion process to ensure a longer service life of building structures. This systematic study compares the efficiency and durability of various discrete galvanic zinc anode systems available in the current market using different criteria for measuring efficiency such as potential measurements, electrolyte resistance measurements and several polarization methods to determine the polarizability of the anodes. The results to validate the performance of long-time exposure of discrete zinc anodes in concrete medium are discussed.
The performance of functional coatings and adhesively joined hybrid components relies strongly on the stability of the polymer-metal interface. With the increasing utilization of multi-material structures in the automotive and aerospace industry, it is of great scientific and technical interest to understand the processes leading to interface degradation and to develop novel strategies to increase corrosion and delamination resistance.
The aim of this project is to develop thin epoxy-based films and their carbon nanofiller loaded composites on aluminium alloy AA2024-T3 as a model system and to investigate their interfacial stability under corrosive and coupled corrosive-mechanical load. Spin coating was used for the layer-by-layer deposition of poly[(o-cresyl glycidyl ether)-co-formaldehyde] and poly-(ethylenimine) bi-layers. Atomic force microscopy (AFM) results indicate a very homogeneous and dense film with low surface roughness. Carbon nanofillers were introduced either by mixing into the coating components or in between individual layers to control the separation between the carbon nanofillers and alloy surface. The film chemistry and barrier properties were characterized by means of spectroscopic and electrochemical methods, respectively. The degradation and delamination behavior of the epoxy-based films was characterized by means of in situ AFM corrosion experiments. The quantitative imaging (QI) mode allowed the observation of hydrogen-generation induced blister formation during exposure to corrosive electrolyte and how the local corrosion processes evolved with exposure time. Complementary energy dispersive X-ray spectroscopy (EDX) analysis was performed to correlate the corrosion behavior with the different intermetallic particle chemistries and distributions. The presentation will summarize our results on the effect of interface chemistry and carbon nanofiller – alloy separation on the initiation of local corrosion processes on thin film covered AA2024-T3 aluminium alloys.
The double loop electrochemical potentiodynamic reactivation (EPR) method is a standardised procedure for detecting and quantifying sensitisation on austenitic, ferritic and ferritic-austenitic stainless-steel grades. This sensitisation is caused by microstructural alternations, as the formation of chromium carbides, nitrides or sigma-phases, which generate local chromium depleted zones nearby. The latter strongly influence the corrosion resistance and the electrochemical response of a stainless steel during electrochemical potentiodynamic reactivation, providing important information on the degree of chromium depletion. In case of martensitic stainless steels, which are used for cutlery and surgical instruments, the heat treatment has a strong impact on the microstructure, the material properties and especially on the corrosion resistance. To study this interaction, the EPR method was modified for the application on martensitic stainless steels with about 13 wt.-% chromium. Different H2SO4 concentrations and EPR-parameters were tested and compared on two standard martensitic stainless-steel grades (AISI 420 A / X20Cr13 and AISI 420 C / X46Cr13) to define applicable parameters. Afterwards, these parameters were used to study the effect of austenitisation time and cooling rate on the corrosion resistance of both martensitic stainless steels. The response of both alloys was different due to the different carbon levels, which will be explained by microstructural investigations in detail. All results allow postulating a process window, in which chromium depletion is suppressed and an optimised corrosion resistance is guaranteed. Based on this research, the modified EPR-test is now used to control the heat treatment and its impact on the corrosion resistance of martensitic stainless steels in the cutlery industry. The EPR-test is thus an interesting alternative for manufacturers, processors, users and researchers to the time-consuming exposition test normally used to characterise the corrosion resistance of martensitic stainless steels.
Metal reducing bacteria (MRB) are capable of utilizing different metals, such as iron, chromium, manganese or uranium as well as many organic compounds, as electron acceptors for their metabolism. Via direct and indirect electron transfer processes MRB are able to convert insoluble passive film species like Fe(III)-oxides to soluble Fe(II)-oxides and hydroxides. This weakening of the passive film not only leads to an acceleration of the general corrosion processes, but also increases the susceptibility of stainless steels to pitting corrosion. Electron transfer mechanisms are not yet fully understood and the role of bacteria in corrosion processes is controversially discussed in the literature. Moreover, recent research indicates that the secretion of electron shuttles like riboflavins by MRB also contributes to the extracellular electron transfer.
This project aims at clarifying the chemical and electrochemical interaction mechanisms of MRB with stainless steel surfaces. To investigate the changes in the oxide chemistry on the stainless steel surface in the presence of biomolecules and MRB a new flow cell has been designed and constructed which enables the collection of XANES (X-ray Absorption Near Edge Structure) spectra in fluorescence mode at the Fe K-edge and electrochemical analysis. Availability of oxygen and the pre-exposure of the MRB to Fe(III) during cultivation have been investigated as parameters with significant effect on the corrosion rates. XANES analysis is supplemented by ex-situ X-Ray Photoelectron Spectroscopy (XPS) and Fourier Transform Infrared Reflection Absorption Spectroscopy (FT-IRRAS) to complete the surface characterisation in terms of the oxide chemistry and the composition of organic residues. Complementary electrochemical quartz crystal microbalance (e-QCM) measurements have been performed to quantify the kinetics of bacterial attachment and biofilm formation. Together with the frequency shift, the evolution of the dissipation signal has been analyzed to investigate the changes in viscosity and structure of the biofilm from initial stages up to maturation. Scanning Electron Microscopy (SEM) and Atomic Force Microscopy (AFM) has been used to study the structure and viscoelastic properties of the biofilms after e-QCM experiments.
The presentation will summarize our results on the effects of individual surface and environment related parameters on the chemical/electrochemical interaction mechanisms of MRB leading to passive film degradation on stainless steel surfaces and provide useful insights from a fundamental aspect for the development of novel mitigation strategies for microbiologically influenced corrosion.