Assessing the corrosion protection property of coatings loaded with corrosion inhibitors using the real-time atmospheric corrosion monitoring technique

The atmospheric corrosion monitoring(ACM)technique has been widely employed to track the real-time corrosion behavior of metal materials.However,limited studies have applied ACM to the corrosion protection properties of organic coatings.This study compared a bare epoxy coating with one containing zinc phosphate corrosion inhibitors,both applied on ACM sensors,to observe their corrosion protection properties over time.Coatings with artificial damage via scratches were exposed to immersion and alternating dry and wet environments,which allowed for monitoring galvanic corrosion currents in real-time.Throughout the corrosion tests,the ACM currents of the zinc phosphate/epoxy coating were considerably lower than those of the blank epoxy coating.The trend in ACM current variations closely matched the results obtained from regular electrochemical tests and surface analysis.This alignment highlights the potential of the ACM technique in evaluating the corrosion protection capabilities of organic coatings.Compared with the blank epoxy coating,the zinc phosphate/epoxy coating showed much-decreased ACM current values that confirmed the effective inhibition of zinc phosphate against steel corrosion beneath the damaged coating.

Development and Application of On-Line Corrosion Monitoring Device for Condenser Tube

This paper introduces the development and industrial application of an on-line corrosion monitoring device for condenser tubes. Corrosion sensors are made up of representative condenser tubes chosen by eddy current test, which enable the monitoring result to be consistent with the corrosion of actual condenser tubes. Localized corrosion rate of condenser tubes can be measured indirectly by a galvanic couple made up of tube segments with and without pits. Using this technology, corrosion problems can be found in time and accurately, and anticorrosive measures be made more economic and effective. Applications in two power plants showed the corrosion measurements are fast and accurate.

Atmospheric Corrosion Monitoring of Field-exposed Q235B and T91 Steels in Zhoushan Offshore Environment Using Electrochemical Probes

This work aimed to in-situ monitor the atmospheric corrosion of steels exposed to Zhoushan offshore environment by using electrochemical noise（EN） technique. A portable EN monitoring system was established and two electrochemical probes（named as Q235 B and T91） were designed. Experimental results indicated that the noise resistance of T91 steel was higher than that of Q235 B steel, revealing that the corrosion resistance of T91 was higher than that of Q235 B. A 60-day monitoring result indicated that the noise resistance was well correlated with the weight loss data. Wavelet analyses results of EN data indicated that Q235 B underwent uniform corrosion and T91 suffered from localized corrosion, which was further confirmed by the surface observation. It is concluded that EN can be used as a new method to identify the corrosion form and corrosion resistance in atmospheric conditions.

Preparation and Properties of Embeddable Ag/Ag Cl Gelling Reference Electrode for Rebars Corrosion Monitoring in Concrete

Reference electrodes are a key part for corrosion monitoring and measurement of rebars in concrete. A reference electrode that can be buried in concrete is fabricated by using Ag/Ag Cl electrode and methyl cellulose gelling electrolyte. The stability, repeatability and anti-polarization of the reference electrode are investigated; the influences of the inner electrolyte loss, exterior OH- contamination, and temperature on the potential of the reference electrode are also investigated in this paper. The results show that the reference electrode has good stability, repeatability, and antipolarization. The influences of inner electrolyte loss, exterior OH- contamination, and temperature on the potential of the reference electrode are minimal. Therefore, it can be used for corrosion monitoring and measurement of rebars in concrete.

Preparation and performance of fluorescent sensing coating for monitoring corrosion of Al alloy 2024

A kind of fluorescent sensing coating was prepared for monitoring corrosion of aluminum alloys by incorporating phenylfluorone(PF) into acrylic paint as sensing material. The fluorescent dye PF reacts with aluminum ions on corroded aluminum substrate to occur fluorescence quenching observed in UV light. This paint system is sensitive to underlying corrosion processes through reacting with the Al3+ produced by anodic reaction accompanying corrosion. After a certain time, when the samples of Al alloy 2024 coated with PF-acrylic paint were immersed in 1 mol/L NaCl solution, fluorescence quenching spots can be seen with unaided eyes. With the development of corrosion process, the size of fluorescence quenching spots increases. Active corrosion areas on the sample surface were found under the fluorescence quenching spots by optical microscope. The corrosion areas can be observed more clearly by SEM, and many pits are found. This suggests that the fluorescence quenching spots are the sites of produced Al3+ by the anodic reaction of the local attack of the coated Al alloy substrate in the chloride solution and the corrosion process of the coated Al alloy can be monitored on-line by the sensing coating. The sensitivity of this coating system for detection of anodic reaction associated with corrosion was determined by applying constant charge current and measuring the charge, at which fluorescence quenching is detected in the coating with unaided eyes. Visual observation of coated samples can detect fluorescence change resulting from a charge corresponding to an equivalent hemispherical pit with approximate depth of 50 μm.

Corrosion monitoring system design for coating wire of steel in ocean

The monitoring system design used in anti-corrosion of coating wire of steel in ocean were concerned. A corrosion monitoring system adapting to corrosion observation of coating wire of steel was introduced in details, including design and choice of software and hardware. This system will play an important role in the collection, procession, demonstration, deposition and accident alarm of corrosion data of oceanic coating wire of steel.

Conductivity Method as a New Monitoring Technique for Corrosion and Corrosion Inhibition Processes of Zinc Metal

The electrical conductivity method was successfully applied as a new monitoring technique to monitor the corrosion and corrosion inhibition processes of zinc metal. Measurements of electrical conductivity at 20.0°C of three different corrosive solutions (HCl, NaOH, and NaCl) were performed with two different concentrations (0.10 and 1.00 M) containing zinc sheets in the absence and presence of four different concentrations of sodium lignosulfonate (1.0, 5.0, 10.0, and 20.0 mM). The analysis of curves that illustrates the changes in electrical conductivity of these solutions provides qualitative information about the strength of corrosion as well as the extent of corrosion inhibition behavior. The results obtained from electrical conductivity measurements revealed that sodium lignosulfonate was an effective corrosion inhibitor in acidic medium (for both 0.10 and 1.00 M HCl) in which it converted into lignosulfonic acid, but was less effective in salt and alkaline media.

Monitoring of the Corrosion on a Steel Sheet-Pile Marine Breakwater by Systematic Thickness Measurements

In Quepos, Pacific of Costa Rica, it was finished on 2010 the first phase of a marina, including two mix breakwaters, with rubble mound （rocks and concrete units）, and 25 circular steel sheet piles cofferdam cells, filled with sand and gravel. The maintenance plan, considers tracking sheet pile corrosion, comparing ＂actual＂ against expected rates, checking structural limits, and programming countermeasures if accelerated corrosion is identified. Specific control sections, along the breakwaters, both inside and outside the basin, were established. In each section, thicknesses were measured every meter from the top of the steel cell to seabed using an ultrasonic equipment, and an underwater transducer. Both land crew, and divers for submerged portions, were used. The measurements campaigns are for several years from 2011 to 2016. Sectors of the breakwater with varied corrosion attack levels could be differentiated. Also, corrosion rates and lifespans were estimated, both general for the structures, and specific for each section and level. In turn, this allowed to identify maintenance priorities, defining sites where measures of corrosion protection should initiate, as well, to have confidence in the structural capacity and safety of the breakwaters.

Monitoring of the Corrosion on a Steel Sheet-pile Marine Breakwater by Systematic Thickness Measurements

In Quepos,Pacific of Costa Rica,it was finished on 2010 the first phase of a marina,including two mix breakwaters,with rubble mound(rocks and concrete units),and 25 circular steel sheet piles cofferdam cells,filled with sand and gravel.The maintenance plan,considers tracking sheet pile corrosion,comparing'actual'against expected rates,checking structural limits,and programming countermeasures if accelerated corrosion is identified.Specific control sections,along the breakwaters,both inside and outside the basin,were established.In each section,thicknesses were measured every meter from the top of the steel cell to seabed using an ultrasonic equipment,and an underwater transducer.Both land crew,and divers for submerged portions,were used.The measurements campaigns are for several years from 2011 to 2016.Sectors of the breakwater with varied corrosion attack levels could be differentiated.Also,corrosion rates and lifespans were estimated,both general for the structures,and specific for each section and level.In turn,this allowed to identify maintenance priorities,defining sites where measures of corrosion protection should initiate,as well,to have confidence in the structural capacity and safety of the breakwaters.

Comparative investigation on copper atmospheric corrosion by electrochemical impedance and electrical resistance sensors

Electrochemical impedance(EIS)and thin electrical resistance(ER)sensors were invented for atmospheric corrosion measurement of copper(Cu)during cyclic wetting−drying/high−low temperature tests and field exposure tests.Three-month field exposure results showed that average corrosion rate of Cu measured by ER sensor was well in accordance with that by weight loss method.During cyclic wetting−drying test,EIS was proven to reflect sensitively time of wetting and drying on the surface of sensor.Although corrosion rate obtained from EIS had a similar tendency to that obtained from ER sensors,the former was more dependent on environmental humidity than the latter.When relative humidity was low than 60%,corrosion rate of Cu measured by EIS was much lower than that by weight loss method,mainly attributing to the fact that impedance sensor failed to detect corrosion current of interlaced Cu electrodes due to the breakdown of conductive passage composed of absorbed thin liquid film under low humidity condition.Promisingly,ER sensor was proven to be more suitable for atmospheric corrosion monitoring than electrochemical techniques because it could sensitively monitor thickness loss of Cu foil according to the Ohmic law,no matter how dry or wet the sensor surface is.

On-line Monitoring of Epoxy Resin Exposed to Acid Solution

In this study, a new on-line health monitoring technology for the determination of the penetration of environment solution into epoxy resin was pursued. A corrosion sensor including plastic optical fiber and pH indicator was fabricated. The color-change layer of this sensor appeared after immersion in sulfuric acid solution, which could be examined by using optical fiber and spectrophotometer. The results showed that the penetration of sulfuric acid was detected by adding bromophenol blue （BPB） in the corrosion sensor. This system could be applied to on-line health monitoring of chemical equipment structures.

Study on the Corrosion inhibitor and Fog Suppressor for Chemical Pickling of Iron and Steel

A new type of corrosion inhibitor and fog suppressor composed of Nitrogen-containing alkaloid,water-soluble butadiene lower polymer, and inorganic electrolyte has been investigated by gravimetric and electrochemical method. Effects or this chemicals on pickling rate and hydrogen penetration into iron and steel material in 50～150 g/L HCI or/and H2SO4 solutions at 20～70℃ temperature were examined. The amount of acid fog escaping from the surface of air-liquid was determined by chemical titration. The results indicate that the efficiency of inhibition and suppression depends on film properties by which mean a barrier film on the interface of bare mild steel/solution or an unsolvable liquid membrane as hydrophibic effect.In present work the film-forming mechanism by in situ and chemistry-mechanics effect is also discussed.

Research on Integrated Monitoring and Prevention System for Stray Current in Metro

On the basis of analyzing the influencing factors and harmfulness of stray current, and discussing the existing problems of monitoring and prevention system for stray current, the integrated monitoring and prevention system for stray current in metro was developed. A net system of distributed computers for monitoring was set up. It can monitor the distribution of stray current in metro and the corrosion of the metal structure in the whole line. According to the situation of monitoring it can also control the drainage of its tank to reach the best effect and eliminate the negative effect of polarity drainage. By using the new type unilateral electric device, the problem of burning the rail by electric arc can be avoided. The unilateral electric device can be connected with the monitoring net system directly to realize the monitor in line and improve the reliability of the device.

Instantly Investigating the Adsorption of Polymeric Corrosion Inhibitors on Magnesium Alloys by Surface Analysis under Ambient Conditions

Surface engineering of magnesium alloys requires adequate strategies, processes and materials permitting corrosion protection. Liquid formulations containing corrosion inhibitors often are to be optimized according to the demands of the respective substrate and following the service conditions during its application. As an interdisciplinary approach, a combination of several techniques for instantly monitoring or elaborately analyzing the surface state of magnesium was accomplished in order to characterize the performance of new adsorbing sustainable amphiphilic polymers which recently were developed to facilitate a multi-metal corrosion protection approach. The application of established techniques like Contact Angle measurements and X-ray Photoelectron Spectroscopy investigations was supplemented by introducing related and yet faster online-capable and larger-scale techniques like Aerosol Wetting Test and Optically Stimulated Electron Emission. Moreover, an inexpensive setup was configured for scaling the inset and the extent of degradation processes which occur at local electrochemical circuits and lead to hydrogen bubble formation. Using these analytical tools, changes of the surface state of emeried AM50 samples were investigated. Even in contact with water, being a moderate corrosive medium, the online techniques facilitated detecting surface degradation of the unprotected magnesium alloy within some seconds. In contrast, following contact with a 1 weight% formulation of a polymeric corrosion inhibitor, surface monitoring indicated a delay of the onset of degradation processes by approximately two orders of magnitude in time. Mainly based on the spectroscopic investigations, the corrosion inhibiting effects of the investigated polymer are attributed to the adsorption of a primary polymer layer with a thickness of a few nanometers which occurs within some seconds. Immersion of magnesium for several hours brings up a protective film with around ten nanometers thickness.

高含硫气田开发腐蚀控制关键技术进展与发展方向

随着四川盆地高含硫气田的持续上产,深层/超深层、特高含H2S气体等愈发恶劣的工况环境对气田腐蚀控制提出了更高要求。围绕高含硫气田腐蚀控制难点及需求,系统梳理总结了近年来高含硫气田在材料腐蚀分析与评选、缓蚀剂防腐、腐蚀监/检测、腐蚀控制管理信息化4大方面取得的腐蚀控制技术最新研究进展和开发效果,提出了腐蚀控制关键技术的发展方向和建议。研究结果表明:①形成了H2S分压大于1 MPa条件下的腐蚀分析和耐蚀材料评选技术体系,建成了国内唯一高含硫气田腐蚀与防护现场试验基地,支撑了国产化双金属复合管、耐蚀合金的大规模应用;②自主研发了集输系统碳钢配套用长效膜缓蚀剂、抑泡缓蚀剂和防冻缓蚀剂新体系并实现了国产化工业应用,性能较国际同类产品提高16%,同步解决了易发泡、水合物堵塞等生产问题;③研发了钢质管道全线腐蚀风险分布定量评价技术,形成了基于腐蚀单元划分及风险排序的野外远程在线集群监/检测体系,实现了全区域、全系统、全流程覆盖;④建立了腐蚀异常数据智能识别和腐蚀地图构建技术,自主研发了具备大数据管理、腐蚀预测、风险评估及实时预警、腐蚀控制管理功能的腐蚀智能诊断与管控平台,形成了腐蚀信息化管理能力。结论认为,中国高含硫气田腐蚀控制技术已全面实现国产化,建议在金属/非金属耐蚀新材料全生命周期适应性、多因素耦合下腐蚀机理、多功能缓蚀剂研发、腐蚀智能化管控应用等方面加强技术攻关,强化科研生产一体化和生产运行腐蚀综合管理,助力中国高含硫气田开发迈上新台阶。

燃煤锅炉温度场与高温腐蚀气氛场同步在线检测装置开发及应用

燃煤锅炉主燃区燃烧场的经济性、安全性和环保性对于智慧电厂建设具有重要意义。其中,水冷壁近壁面高温腐蚀H_(2)S和CO气体浓度的实时在线监测尤为重要。为实现燃煤锅炉主燃区温度场和高温腐蚀气氛场的同步测量,基于红外热成像原理,采用Optris-PI1M小型红外热成像仪,基于LabVIEW温度实时采集应用软件,在炉膛的观察口对主燃区温度场进行连续监测。以低成本1.5μm附近的通信波段激光器作为测量高温腐蚀气体H_(2)S和CO的激光光源,并结合波长调制光谱技术和频分复用技术,以实现H_(2)S和CO气体浓度的同步检测。线性度实验表明,其线性拟合相关系数为0.9995。将研制的同步检测仪器对某300 MW四角切圆燃煤锅炉的主燃区的温度场和气氛场进行了现场应用试验。现场测试结果表明,锅炉主燃区温度主要分布范围在1300~1400℃,最高温度达到了1500℃;同时得到了锅炉主燃区的H_(2)S和CO浓度分布,H_(2)S浓度在12~125 mg/m^(3)的范围内波动,而CO浓度主要分布在10%~20%之间,最高可达22%;炉内H_(2)S和CO的浓度呈正相关,氧气浓度保持在1%以下,由于厌氧燃烧会导致两种气体的含量增加,从而造成对水冷壁近壁面的高温腐蚀。

电阻探针腐蚀监测技术的研究进展

介绍了电阻探针腐蚀监测系统和监测原理,综述了当前国内外电阻探针腐蚀监测技术的研究进展,重点分析了有关电阻探针腐蚀监测系统在电阻探针、监测数据处理和监测数据传输方向的研究现状,总结了电阻探针腐蚀监测技术在大气环境、水环境和土壤环境3种不同环境下应用的研究进展,最后对电阻探针腐蚀监测技术进行了展望,以为电阻探针腐蚀监测技术的发展和应用提供新的思路和指导意义。

典型介质环境下探针腐蚀监测局部流场分布规律研究

在油田站场管道中,腐蚀穿孔时常发生,威胁油气田安全生产。因此,电阻探针通常被应用于不同介质下的管道腐蚀监测。为了提高腐蚀监测的有效性,基于流体力学计算(CFD)有限元模拟,研究了不同介质环境下电阻探针的局部流场分布规律。结果发现,介质为水的探针扰流和剪切力都达到最大,且探针最大剪切力始终出现在套筒孔的两侧。

基于VMD-HT和深度学习的流噪环境腐蚀损伤声发射识别模型

对在役管道进行腐蚀声发射监测的过程中,管内介质流动产生的噪声同样会被传感器接收,导致腐蚀信号被覆盖从而引发误判。针对这一问题,提出了一种基于变分模态分解(VMD)、希尔伯特变换(HT)和深度双向门限循环单元神经网络(BiGRU)的流噪环境腐蚀损伤声发射识别模型。该模型能够将原始信号自适应地转化成多个本征模态分量,并提取各分量的瞬时频率及谱熵构建多维时序特征矩阵,进而建立原始信号与多维特征之间的映射关系。为验证该方法的有效性,对在役管道进行腐蚀声发射监测试验。结果表明,所提模型在流噪环境下具有良好的鲁棒性,监测数据的识别准确率达96.3%,可作为一种解决在役管道腐蚀声发射监测的新方案。