The influence of sunlight on the localized corrosion of UNS S31600 in natural seawater

Testing the Test: A Comparative Study of Marine Microbial Corrosion under Laboratory and Field Conditions

Microbially influenced corrosion (MIC) is an aggressive type of corrosion that occurs in aquatic environments and is sparked by the development of a complex biological matrix over a metal surface. In marine environments, MIC is exacerbated by the frequent variability in environmental conditions and the typically high diversity of microbial communities; hence, local and in situ studies are crucial to improve our understanding of biofilm composition, biological interactions among its members, MIC characteristics, and corrosivity. Typically, material performance and anticorrosion strategies are evaluated under controlled laboratory conditions, where natural fluctuations and gradients (e.g., light, temperature, and microbial composition) are not effectively replicated. To determine whether MIC development and material deterioration observed in the laboratory are comparable to those that occur under service conditions (i.e., field conditions), we used two testing setups, in the lab and in the field. Stainless steel (SS) AISI 316L coupons were exposed to southeastern Pacific seawater for 70 days using (i) acrylic tanks in a running seawater laboratory and (ii) an offshore mooring system with experimental frames immersed at two depths (5 and 15 m). Results of electrochemical evaluation, together with those of microbial community analyses and micrographs of formed biofilms, demonstrated that the laboratory setup provides critical information on the early biofilm development process (days), but the information gathered does not predict deterioration or biofouling of SS surfaces exposed to natural conditions in the field. Our results highlight the need to conduct further research efforts to understand how laboratory experiments may better reproduce field conditions where applications are to be deployed, as well as to improve our understanding of the role of eukaryotes and the flux of nutrients and oxygen in marine MIC events.

Effect of Tidal Cycles on Bacterial Biofilm Formation and Biocorrosion of Stainless Steel AISI 316L

The effects of tidal cycles associated with the water level on the biocorrosion of stainless steel AISI 316L were studied. Steel coupons were exposed to different conditions of immersion in mesocosms fed by fresh seawater either continuously or in accordance with the periodicity of natural tides. After 5 and 15 weeks, all coupons were found to have undergone ennoblement associated with the formation of a biofilm. Analysis of the composition of the bacterial community using denaturing gradient gel electrophoresis (DGGE) revealed differences in the biological succession. After 15 weeks, exposure to the simulated tidal conditions resulted in biofilms with lesser bacterial richness; the corresponding rate of corrosion, as determined by weight loss, was about 40 times lower compared to the case for the continuous exposure to seawater. Phylogenetic analysis of selected DGGE bands and the inspection of biofilm morphologies revealed that the faster rate of corrosion was associated with the presence of iron-oxidizing Zetaproteobacteria and eukaryotic photosynthetic microorganisms. On the other hand, intermittent exposure to seawater resulted in the succession of microorganisms resistant to the stress associated with sudden environmental changes, which was associated with a low rate of corrosion.

Microstructure and Corrosion Resistance of Zn-Al Diffusion Layer on 45 Steel Aided by Mechanical Energy

In harsh environments, the corrosion damage of steel structures and equipment is a serious threat to the operational safety of service. In this paper, a Zn-Al diffusion layer was fabricated on 45 steel by the Mechanical Energy Aided Diffusion Method (MEADM) at 450 °C. The microstructure and composition, the surface topography, and the electrochemical performance of the Zn-Al diffusion layer were analyzed before and after corrosion. The results show that the Zn-Al diffusion layer are composed of Al₂O₃ and Γ₁ phase (Fe11Zn40) and δ₁ phase (FeZn_6.67, FeZn_8.87, and FeZn_10.98) Zn-Fe alloy. There is a transition zone with the thickness of about 5 μm at the interface between the Zn-Al diffusion layer and the substrate, and a carbon-rich layer exists in this zone. The full immersion test and electrochemical test show that the compact corrosion products produced by the initial corrosion of the Zn-Al diffusion layer will firmly bond to the Zn-Al diffusion layer surface and fill the crack, which plays a role in preventing corrosion of the corrosive medium and reducing the corrosion rate of the Zn-Al diffusion layer. The salt spray test reveals that the initial corrosion products of the Zn-Al diffusion layer are mainly ZnO and Zn₅(OH)₈Cl₂H₂O. New corrosion products such as ZnAl₂O₄, FeOCl appear at the middle corrosion stage. The corrosion product ZnAl₂O₄ disappears, and the corrosion products Zn(OH)₂ and Al(OH)₃ appear at the later corrosion stage.

The relationship between alloying elements and biologically produced ennoblement in natural waters

A range of stainless steels, nickel-chromium and nickel-chromium-molybdenum alloys were exposed to coastal seawater from Mandapam (Indian Ocean) and freshwater from a perennial pond. Biofilms from both test waters produced an ennoblement of the open circuit potential (OCP) on all alloys as expected, which was slower but substantially larger in freshwater. In both waters an interesting relationship was perceived between the plateau OCP (Emax) and the mass percentage of the major alloying elements. In particular, iron exhibited strong positive correlations with Emax (r(2) ≥ 0.77; p < 0.0005), while the sum of chromium, nickel and molybdenum presented significant negative correlations (r(2) ≤ -0.81; p = 0.0002). Consistent with the regression analyses, Euclidean distance clustering yielded patterns where Inconel-600 and the nickel-chromium-molybdenum alloys had the smallest similarities of OCP with other alloys. The results emphatically reinforce a key role for surface passive films in the ennoblement phenomenon in natural waters.

Stainless steel in coastal seawater: sunlight counteracts biologically enhanced cathodic kinetics

The influence of sunlight of varying intensity on the performance of UNS S30400 stainless steel (SS) was explored under conditions of natural biofilm development in coastal seawater. In a series of tests performed outdoors under an opaque roof, a range of shades were fashioned to impart varied amounts of diurnal light. These were an ambient level where the underwater illumination was ~ 5% of full sunlight, two intermediate ranges of lighting with ~ 2.5% and ~ 1% of the daylight, and a condition of full darkness. In comparison with the dark, increments of sunlight rendered the SS progressively less aggressive as cathodes in galvanic couples with UNS C70600 alloy. Likewise, welded SS with pre-initiated localized corrosion sites exhibited substantially lower rates of propagation with light. Thus, biofilms and sunlight affected cathodic kinetics in opposite ways. Surface analytical tests showed that the accumulation of manganese (Mn) within the biofilms was small relative to reports from waters of lower salinity. These results not only reveal that extremely low amounts of sunlight are adequate to offset the microbial effect, but also highlight the lack of convincing evidence for Mn cycling as a potent mechanism for enhanced cathodic kinetics in full-strength seawater.

Sunlight-enhanced calcareous deposition on cathodic stainless steel in natural seawater

In replicate series of experiments in natural seawater, one in full darkness and the other in a 1:1 diurnal cycle with as little as ~5% of natural solar illumination, sunlight promoted calcareous deposition on cathodic stainless steel surfaces. As exemplified by scanning electron microscopy, the deposit that formed under the natural diurnal cycle, in the presence of photosynthetic biofilms, was composed of finer calcareous crystals that provided more compact and more uniform surface coverage than the one formed in the dark. The light-enhanced deposit also possessed better scale properties, as suggested by X-ray analysis and electrochemical measurements. Sunlight enhancement of calcareous deposition looked all the more conspicuous when day and night regimes were examined independently. These results not only bear important implications for cathodic protection in marine waters, but also provide an intriguing analogy to coral reef calcification.

Review--Interactions between diatoms and stainless steel: focus on biofouling and biocorrosion

There is a considerable body of information regarding bacterially enhanced corrosion, however, this review focuses on diatoms (unicellular algae) whose contribution to biocorrosion is less well studied. The reasons why diatoms have been neglected in studies of biocorrosion in natural waters are discussed and the question whether diatoms should be considered as inert with respect of electrochemical processes is considered. A particular focus is given to the case of stainless steels (SS), which are widely used in variety of applications in natural waters. Basic information on the cell biology of diatoms is included in the review, particularly with respect to their ability to 'sense' and adhere to surfaces. Investigations at the nanoscale are reviewed as these studies provide information about the behavior of cells at interfaces. Recent advances include the use of atomic force microscopy (AFM), although only a few studies have been applied to diatoms. Regarding the electrochemical behavior of SS, the mechanisms by which diatoms influence the potential ennoblement process is discussed. Such studies reveal the association of diatoms, in addition to bacteria, with biocorrosion processes.