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The purpose of this paper is to quantitatively assess the pit growth rate on AISI 304L and AISI 316 austenitic stainless steels in natural seawater and 3.5 wt.% NaCl solutions through electrochemical measurements during the potentiostatic growth of pits.

A quantitative characterisation was carried out based on chronoamperometric measurements. The volume of dissolved metal per pit was calculated from the charge registered and Faraday's law, considering both, hemispherical and semi‐elliptical pit shapes and the density of the steels. Empirical growth laws for maximum pit depth as a function of polarisation time were obtained and compared with pits volumetric profile obtained from optical microscopy analysis and mechanical removal of material on both steels.

Electrochemical‐based calculations of localised metal dissolution per pit present acceptable fit with the real volume of dissolved metal on hemispherical pits.

The paper presents the quantitative relationship of the corrosion pit growth rate of stainless steels in chloride containing solution determined by chronoamperometry (electrochemical technique) through the Faraday law's, with the mechanical removal of material (pit profile) through the density of metal.

Corrosion is one of the common damage mechanisms in many engineering structures such as marine structures, petroleum pipelines, aerospace and nuclear reactor. However, the service performance of metal materials and structures is gradually degenerating with the increase of service life due to the rapid growth of corrosion damages. Thus, the coupled effects for corrosion damage in reliability analysis should be considered urgently. Then, the purpose of this paper is to develop the corrosion damage physical model and the corresponding reliability analysis methods, which consider the coupled effect of corrosion damage.

A failure physical model, considering the coupled effect of pitting growth, crack and crack propagation, is presented in this paper. Sequentially, the corrosion reliability with respect to pitting physical damage can be investigated. The presented pitting damage physical model is formulated as time-variant performance limit state functions, which include the crack transition, crack growth and fracture failure mechanics. The first-passage failure criterion is used to construct the corrosion reliability framework, involving in the pitting damage model with the increase of service life.

Results demonstrate that the multiplicative dimensional reduction (MDR) method behaves much better than FORM no matter in accuracy or efficiency. The proposed corrosion reliability method is applicable for dealing with the damage failure model of the structural pitting corrosion.

The MDR method is used to calculate the corrosion reliability index of a given structure with fewer function calls. Finally, an aeronautical metal material is used to demonstrate the efficiency and precision of the proposed corrosion reliability method when the failure physical model considering the coupled effects of mechanical stresses and corrosion environment is adopted.

The purpose of this paper is to predict the life of a corroding metallic structure in seawater so that uncertain and unpredictable failures of a structure, leading to accidents, can be prevented.

Pitting has been known to show a large scatter in the measurable parameters such as corrosion rate, maximum pit depth, time to perforation and so on. Scatter results from the influence on pit development on metal surface heterogeneity and from variations in the corrosive environment over time. All these facts suggest that randomness is an inherent and unavoidable characteristic of pitting corrosion over time, so that stochastic models have been developed to formulate pit depth as a function of parameters influencing the process. Since chloride penetrates the passive film of the metal surface, Cl ion distribution into the metal has been mapped by finite element method (FEM).

The maximum pit depth which decides the onset of perforation or leakage has been modeled by the following equation: d=36.31(ΔE)^0.68×(Δt)^0.35. Cl ion distribution within a pit and outside has been modeled for better understanding of pit initiation which till today is not fully understood.

Perforation and leakage of a tank, container, or pipeline occur when the depth of pitting reaches the section thickness of the material of which the metallic structures are made. The pitting corrosion is localized and occurs at any spot or site where electrochemical conditions (ΔE Equation (9)) are prone to pitting. This leads to unpredictable failures of the structures which may look polished and undamaged under naked eyes. In most metallic structures, pitting may be present at some spots, but failures occur only when the depth predicted by the model Equation (9) reaches the section thickness of the material. Thus, determining pipe to soil potential gives a guide to go for maintenance before pit depth reaches the material thickness, and thereby unpredictable failure can be prevented. Second, the map generated by FEM showing Cl distribution throws much information and light on movement of Cl ions from passive layer into the pit, which leads to its growth. This helps scientists and researchers to understand the mechanism and gives much insights on finding new methods for protection of structures.

The work will guide the engineers and researchers to prevent unpredictable failures of structures leading to accidents and human and property loss and prevent environment pollution from spilling of oil from tank and pipeline.

This is an original work based on several laboratory-generated simulated experimental data.

This paper aims to construct the E-pH diagrams for AISI 316L stainless steel in chloride solutions containing SO₄²⁻ ions and therefore investigate the role of SO₄²⁻ ions on pitting corrosion of stainless steel.

A cyclic potentiodynamic polarisation method was performed to obtain polarisation curves at different pH. From these curves, corrosion, primary passivation, pitting and repassivation potentials were determined and plotted as a function of pH giving the E-pH diagram.

The addition of SO₄²⁻ ions to 10,650 ppm NaCl solution up to 3,000 ppm widened the passivation regime of the E-pH diagram mainly by shifting the pitting corrosion potential to the noble direction. This indicated the inhibiting role of SO₄²⁻ on the nucleation of new pits in the transpassive region. It also stabilised the pitting corrosion potential at the pH ranging from 5 to 11. However, at pH 7, it caused the pit area to increase, implying the catalytic role of SO₄²⁻ on the pit growth. Finally, it did not change the types of ions dissolved in solutions after pitting.

The diagrams can be used as a guideline in industries to determine the passivation regime of the AISI 316L stainless steel in chloride- and sulphate-containing solutions.

This paper reported the E-pH diagrams for the AISI 316L stainless steel in chloride solutions containing SO₄²⁻ ions. The roles of pH and SO₄²⁻ ions on pitting corrosion were innovatively discussed using a point defect model.

Most supersonic aircraft were manufactured using 2A70 aluminum alloy. The purpose of this paper is to study the corrosion mechanism and fatigue behavior of an aircraft in a semi-industrial atmospheric corrosive environment, alternating effects of corrosion and fatigue were used to simulate the aircraft’s ground parking corrosion and air flight fatigue.

For this purpose, the aluminum alloy samples were subjected to pre-corrosion and alternating corrosion-fatigue experiments. The failure mechanisms of corrosion and corrosion fatigue were analyzed using microscopic characterization methods of electrochemical testing, X-ray diffraction and scanning electron microscopy. Miner’s linear cumulative damage rule was used to predict the fatigue life of aluminum alloy and to obtain its safe fatigue life.

The results showed that the corrosion damage caused by the corrosive environment was gradually connected by pitting pits to form denudation pits along grain boundaries. The deep excavation of chloride ions and the presence of intergranular copper-rich phases result in severe intergranular corrosion morphology. During cyclic loading, alternating hardening and softening occurred. The stress concentration caused by surface pitting pits and denudation pits initiated fatigue cracks at intergranular corrosion products. At the same time, the initiation of multiple fatigue crack sources was caused by the corrosion environment and the morphology of the transient fracture zone was also changed, but the crack propagation rate was not basically affected. The polarization curve and impedance analysis results showed that the corrosion rate increases first, decreases and then increases. Fatigue failure behavior was directly related to micro characteristics such as corrosion pits and microcracks.

In this research, alternating effects of corrosion and fatigue were used to simulate the aircraft’s ground parking corrosion and air flight fatigue. To study the corrosion mechanism and fatigue behavior of an aircraft in a semi-industrial atmospheric corrosive environment, the Miner’s linear cumulative damage rule was used to predict the fatigue life of aluminum alloy and to obtain its safe fatigue life.

In this study, super duplex stainless steel (SDSS) was heat-treated. The purpose of this study is to assess the effect of the cooling rate after heat treatment on the pitting corrosion of SDSS.

The heat treatment from 1,000°C to 1,300°C was applied to SDSS to check the effect of the cooling rate.

The heat treatment temperature produced a different SDSS microstructure, and the cooling rate led to the growth of austenite. The casted SDSS indicated the presence of heterogeneous austenite, and the precipitation secondary phase under 1.6 per cent precipitated to bare metal. By applying heat treatment and cooling SDSS, its corrosion resistance changes because of the change in the chemical composition. The cooling rate at 5,600 J/s has the highest critical pitting temperature (CPT) at 1,100°C, and the cooling rate at 1.6 J/s has the highest CPT at 1,200°C. Low cooling rate (0.4 J/s) made the secondary phase at all temperature range.

The effect of secondary phase not consider because that is well known to decreasing corrosion resistance.

Solution annealing is taken into account to optimize the corrosion resistance. But that is not consider the cooling rate at each temperature. This study assessed the effect of the cooling rate at each temperature point.

Manufacturers need to know the effect of the cooling rate to optimize the corrosion resistance, and this study can be applied in the industrial scene.

SDSS is hard the optimization because SDSS is a dual-phase stainless steel. Corrosion resistance can be optimized by controlling heat treatment temperature and the cooling rate. Anyone not studied the effect of the cooling rate at each temperature. The effect of the cooling rate should be considered to optimize the corrosion resistance.

Duplex stainless steels are excellent materials for industrial applications and their use has increased in the oil, chemical, petroleum (offshore), and electric power industries. Pitting resistance equivalent (PRE) is the first parameter used to characterise the pitting and crevice corrosion resistance. Nevertheless, there are other aspects to be considered, such as the precise values of the PRE in the α and γ phases and the selective corrosion processes that may occur at grain boundaries. This paper indicates that α/γ and α/σ interfaces are preferential sites for the nucleation and growth of pits and for consequent selective corrosion, with increasing tendency in the ferritic phase. In addition, the selective dissolution potential is more reactive (and therefore, is of greater significance) than the pitting potential.

The paper aims to focus on the recognition of corrosion product morphologies of AA5083‐H321 corroding aluminum‐magnesium alloys used in the manufacture of aluminum high speed boats and submarines during flow induced corrosion in seawater.

All experiments were conducted in a 3.5 percent NaCl solution as the simulated marine environment. Hydrodynamic conditions were created by an rotating cylinder electrode (RCE) system. Morphological characterization of the surface was undertaken using SEM and EDAX techniques. Cyclic polarization tests were used to determine the electrochemical behavior of the alloy.

The results obtained reveal that the pit density on the sample surface increased with increasing the rotation speed. The enhanced flow condition also enhanced the tendency for intermetallic particles, including submicron size Al(Mg,Mn) inclusions, to promote pitting corrosion of the alloy. An interesting result was that crystallographic pitting occurred at rotation speeds greater than 5 m/s.

In the selection of corrosion control methods for high speed aluminum‐hulled boats, control of erosion corrosion was determined to be more important than any other form of corrosion.

Provides information about the contribution of mechanical and electrochemical corrosion phenomena in corrosion of high speed aluminum boats under hydrodynamic conditions. Characterization of new intermetallic particles in aluminum‐magnesium alloys that can promote pitting during flow induced corrosion in marine environments. Provides new information about the origin of crystallographic pitting attack on aluminum.

The purpose of this paper is to investigate the electrochemical corrosion behavior of type 444 stainless steel (SS) in synthetic tap water from 25°C to 80°C, i.e. the operation environment of the electric water heater.

The corrosion behavior was studied by using electrochemical measurements such as electrochemical impedance spectroscopy and polarization curve. The specimen surfaces were observed with scanning electron microscopy. The passive films were characterized with X-ray photoelectron spectroscopy.

In the typical tap water, 444 SS passivates spontaneously under different temperatures. The passive films formed at higher temperatures contain relatively less Cr-species and more Cl⁻ ions, resulting in lower polarization resistances. The stable pitting corrosion takes place in the potential region of oxygen evolution as the temperature increases to about 55°C. The critical Cl⁻ concentration of pitting corrosion reduces from about 160 mg L⁻¹ to 60 mg L⁻¹ with changing temperature from 25°C to 80°C.

The pitting corrosion probability was assessed through the statistical analysis of tap water quality. The results are useful for the application of 444 SS as well as the design of electric water heater.

This paper shows the variation of polarization resistance, pitting potential, passive film composition and critical pitting chloride concentration with the temperature of tap water. It is of great significance for the development and application of SS in tap water environments.

Pitting inhibition efficiency of SO₄⁻ and NO₃⁻ on AISI 316L stainless steel in contact with Cl⁻-containing fiber dyeing solutions together with the influence of the anions on absorption behavior of the solutions were investigated. The purpose of the study is to experimentally determine an optimized dyeing solution efficient on both – inhibition of the steel’s pitting and exhaustion of the dyes dissolved.

Methods such as electrochemical cyclic polarization, UV-visible range spectrophotometry and scanning electron microscopy have been used to assess the performance of two inhibitors on both pitting inhibition of the steel and dissolving ability over the reactive dyes. To find out a promising dyeing solution mixture in both aspects, Cl content of the original dyeing solution was replaced gradually with the inhibiting anions, where the total anionic content was kept constant to unchange the dye exhaustion potential of the solution. Then, those solutions came out with diverse pitting inhibition, and dye absorption levels were compared together for reducing/avoiding the pitting issues of the reactive dyeing vessels of the industry.

Rather high absorption levels detected by visible range spectrophotometry on the solutions showing sound inhibition levels indicated possibility of unaltered reactive dyeing qualities with an enhanced vessel lifetime as the inhibitive anions replace Cl⁻. Nitrate performed better than sulfate both on inhibition and absorption in the dyeing solutions. Also, 316L vessels became open to an extra anodic protection in inhibitor added solutions.

The findings are valid for a certain group of reactive dyes and dyeing solutions held at 70°C. However, the testing methods are available to almost any dyeing solution and dyeing temperature.

The work presents a combined testing of pitting inhibition and absorption behavior of dyeing solutions involving Cl⁻ that has not been reported so far. It shows that solution recipes least harmful to the steel vessels can be outlined for various reactive or other types of dye groups.