Evaluation of corrosion mitigation of SS904l using inhibitors with statistical and morphological analysis
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Mar 9, 2025
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Abstract
This study evaluates the corrosion resistance of SS904L stainless steel, a highly alloyed material known for its exceptional performance in acidic environments, to address the need for optimized corrosion mitigation strategies. Corrosion inhibitors were utilized to enhance the material's durability, with the weight loss method employed to assess corrosion under varying conditions of temperature and pressure. Experiments tested inhibitor concentrations ranging from 0–5 mg per 100 mL over exposure durations of 24, 48, and 72 hours. Statistical analyses using ANOVA and regression confirmed a significant improvement in corrosion resistance with appropriate inhibitor concentrations. The Kesternich test provided comparative insights into the corrosion rate, validating the inhibitors' efficacy under simulated harsh conditions. Morphological analyses via X-Ray Diffraction (XRD) and Scanning Electron Microscopy (SEM) revealed the formation of protective layers on the metal surface, contributing to enhanced durability. These findings emphasize the critical role of corrosion inhibitors in extending the service life of SS904L and establish a relationship between inhibitor concentration, exposure time, and corrosion performance, paving the way for advanced corrosion mitigation strategies.
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References
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[2] Y. D. B. A. Puraditya, D. D. Mahendra, and P. H. Setyarini, “Characteristics of Bio-ceramic Coating on Corrosion Rate of Stainless Steel 316L and Titanium (Ti-6Al-4V),” Mechanics Exploration and Material Innovation, vol. 1, no. 1, pp. 20–26, Jan. 2024, doi: 10.21776/ub.memi.2024.001.01.3.
[3] Y. Hu et al., “Crevice Corrosion Behavior of Stainless Steels in a Flue Gas Desulfurization Environment,” Journal of Materials Engineering and Performance, vol. 32, no. 23, pp. 10567–10581, Dec. 2023, doi: 10.1007/s11665-023-07888-4.
[4] K. Chandra, A. P. Singh, A. Mahanti, N. Kumar, V. Gautam, and V. Kain, “Comparative corrosion behaviour of stainless steels and their welds in wet-process phosphoric acid,” Corrosion Engineering, Science and Technology, vol. 56, no. 5, pp. 483–494, Jul. 2021, doi: 10.1080/1478422X.2021.1916237.
[5] N. P. Parahdiba, H. Salafy, A. Marizki, and A. N. Camila, “Effect of Heat Treatment Variation on Grain Boundary Corrosion of Austenitic Stainless Steel,” Mechanics Exploration and Material Innovation, vol. 1, no. 3, pp. 94–101, 2024, doi: 10.21776/ub.memi.2024.001.03.4.
[6] C. Wang et al., “Crevice Corrosion Behavior of Several Super Stainless Steels in a Simulated Corrosive Environment of Flue Gas Desulfurization Process,” Journal of Chinese Society for Corrosion and Protection, vol. 39, no. 1, pp. 43–50, 2019, doi: 10.11902/1005.4537.2017.215.
[7] A. Rajesh Kannan, S. Mohan Kumar, N. Pravin Kumar, N. Siva Shanmugam, A. S. Vishnu, and Y. Palguna, “Process-microstructural features for tailoring fatigue strength of wire arc additive manufactured functionally graded material of SS904L and Hastelloy C-276,” Materials Letters, vol. 274, p. 127968, Sep. 2020, doi: 10.1016/j.matlet.2020.127968.
[8] R. van der Merwe, “Corrosion characteristics of mild steel storage tanks in fluorine-containing acid,” Journal of the Southern African Institute of Mining and Metallurgy, vol. 116, no. 10, pp. 921–926, 2016, doi: 10.17159/2411-9717/2016/v116n10a5.
[9] N. Rojas et al., “Coated stainless steels evaluation for bipolar plates in PEM water electrolysis conditions,” International Journal of Hydrogen Energy, vol. 46, no. 51, pp. 25929–25943, Jul. 2021, doi: 10.1016/j.ijhydene.2021.03.100.
[10] K. Venkatesan et al., “Investigation of machining performance in SS904L alloy under hybrid cooling conditions,” Canadian Metallurgical Quarterly, pp. 1–19, Oct. 2024, doi: 10.1080/00084433.2024.2413242.
[11] S. Rajendran, A. R. Kannan, B. Suresha, and N. S. Shanmugam, “Studies on the Fatigue Performance of Wire and Arc Additive Manufactured SS 904L,” in Proceedings of the International Conference on Industrial and Manufacturing Systems (CIMS-2020), 2022, pp. 343–352. doi: 10.1007/978-3-030-73495-4_24.
[12] A. Rajesh Kannan, S. Mohan Kumar, R. Pramod, N. Pravin Kumar, N. Siva Shanmugam, and Y. Palguna, “Microstructure and mechanical properties of wire arc additive manufactured bi-metallic structure,” Science and Technology of Welding and Joining, vol. 26, no. 1, pp. 47–57, Jan. 2021, doi: 10.1080/13621718.2020.1833140.
[13] M. Forouzanmehr et al., “Detection and Analysis of Corrosion and Contact Resistance Faults of TiN and CrN Coatings on 410 Stainless Steel as Bipolar Plates in PEM Fuel Cells,” Sensors, vol. 22, no. 3, p. 750, Jan. 2022, doi: 10.3390/s22030750.
[14] S. S. Prabu, K. D. Ramkumar, and N. Arivazhagan, “Investigation on the fusion zone microstructures and mechanical integrity of AISI 904L and Inconel 625 weld joints,” Materials Research Express, vol. 6, no. 8, p. 086540, May 2019, doi: 10.1088/2053-1591/ab1883.
[15] H. Dai, S. Shi, L. Yang, C. Guo, and X. Chen, “Recent progress on the corrosion behavior of metallic materials in HF solution,” Corrosion Reviews, vol. 39, no. 4, pp. 313–337, Aug. 2021, doi: 10.1515/corrrev-2020-0101.
[16] T. Zhao et al., “Cavitation erosion/corrosion synergy and wear behaviors of nickel-based alloy coatings on 304 stainless steel prepared by cold metal transfer,” Wear, vol. 510–511, p. 204510, Dec. 2022, doi: 10.1016/j.wear.2022.204510.
[17] L. D. Bobbio, B. Bocklund, Z.-K. Liu, and A. M. Beese, “Tensile behavior of stainless steel 304L to Ni-20Cr functionally graded material: Experimental characterization and computational simulations,” Materialia, vol. 18, p. 101151, Aug. 2021, doi: 10.1016/j.mtla.2021.101151.
[18] Y. Leng, D. Yang, P. Ming, and C. Zhang, “A comparative study of corrosion resistance evaluation of bipolar plate materials for proton exchange membrane fuel cell,” eTransportation, vol. 10, p. 100139, Nov. 2021, doi: 10.1016/j.etran.2021.100139.
[19] S. Mohan Kumar et al., “Microstructural Features and Mechanical Integrity of Wire Arc Additive Manufactured SS321/Inconel 625 Functionally Gradient Material,” Journal of Materials Engineering and Performance, vol. 30, no. 8, pp. 5692–5703, Aug. 2021, doi: 10.1007/s11665-021-05617-3.
[20] T. S. Senthil, S. Ramesh Babu, M. Puviyarasan, and V. Dhinakaran, “Mechanical and microstructural characterization of functionally graded Inconel 825 - SS316L fabricated using wire arc additive manufacturing,” Journal of Materials Research and Technology, vol. 15, pp. 661–669, Nov. 2021, doi: 10.1016/j.jmrt.2021.08.060.
[21] R. Aslam, M. Mobin, S. Zehra, and J. Aslam, “A comprehensive review of corrosion inhibitors employed to mitigate stainless steel corrosion in different environments,” Journal of Molecular Liquids, vol. 364, p. 119992, Oct. 2022, doi: 10.1016/j.molliq.2022.119992.
[22] O. Sanni, A. P. I. Popoola, and O. S. I. Fayomi, “The inhibitive study of egg shell powder on uns n08904 austenitic stainless steel corrosion in chloride solution,” Defence Technology, vol. 14, no. 5, pp. 463–468, Oct. 2018, doi: 10.1016/j.dt.2018.07.015.