In order to enhance the corrosion resistance of aluminum alloys, mussel adhesive protein (MAP) was intercalated into layered double hydroxide (LDH) grown onto an Al substrate. The results from X-ray diffraction (XRD), attenuated total reflectance Fourier transform infrared spectroscopy (ATR-FTIR) and energy dispersive spectroscopy (EDS) measurements all confirmed that part of the positively charged MAP can be successfully intercalated into the LDH based on the strong second reactivity. MAP is able to form complexes with the metal cations and hydroxides, leading to less positive charges on the hydroxide layers of the LDH. The intercalation results in the removal of the previously intercalated anions from the interlayer space of the LDH, which maintains the charge balance and lamellar structure. The MAP intercalated LDH film can provide effective corrosion protection to the Al substrate.

The requirement for sustainable and environmentally friendly materials has led to the exploration of lignin as a potential candidate for protective coatings in various industrial applications. Recent researches demonstrate the feasibility of lignin-based coatings for enhancing wear and corrosion resistance. The lignin improved the coating's barrier properties and prevented corrosive electrolytes from contacting the metal. The lignin additives also functionalised wear resistance coating. This review points out the improvements in using lignin extraction to produce high-quality materials suitable for corrosion and wear resistance coating purposes. However, the application of lignin in coatings faces significant challenges, primarily due to its heterogeneous and complex nature, which complicates the attainment of uniform and reliable coating qualities. Moreover, it emphasises the need for further studies on lignin to harness lignin's potential. Future research needs include the development of standardised methods for lignin characterisation and modification, the exploration of novel lignin-based composites and the evaluation of lignin coatings in real-world applications. This review probes into the burgeoning field of lignin-based coatings, evaluating their potential for wear and corrosion resistance, and discusses the current state of research, challenges and future directions in this promising area.

Passivity refers to spontaneous formation of a passive film on the surface of metals. High stability of the passive film on advanced alloys relies on the repassivation ability of the alloys in corrosive environments. Two Ni-base superalloys (Ni-22Cr-9Mo-5Fe-2Nb and Ni-18Cr-3Mo-20Fe-5Nb) are studied to elucidate the mechanism of repassivation through a combination of multimodal in-situ synchrotron X-ray measurements, electrochemical measurements, and first principles calculations. The synchrotron X-ray analyses enabled in-situ probing of the passive film and the hidden subsurface alloy layer. The results reveal chemical and structural evolutions of both the passive film and the underlying subsurface alloy layer under transpassive condition. The first principles calculations demonstrate a crucial role of the subsurface alloy layer in the repassivation of the alloys. Upon passivity breakdown at high electrochemical potentials, the passive film rich in Cr oxide becomes highly defective with vacancies, and metal dissolution leads to generation of vacancies (mainly Ni) in the subsurface alloy layer. This promotes repassivation process by enhanced outward Cr diffusion strengthening the metal bond (more Cr-Ni bonds) in the subsurface alloy layer and, together with the enrichment of high valence Mo- and Nb-oxides in the passive film, lead to repassivation when the high potential is removed, which is different from Fe-rich alloys.

Nano-scale chemical inhomogeneity in surface oxide films formed on a V- and N-containing martensite stainless steel and tempering heating induced changes are investigated by a combination of synchrotron- based hard X-ray Photoelectron emission spectroscopy (HAXPES) and microscopy (HAXPEEM) as well as microscopic X-ray absorption spectroscopy (μ-XAS) techniques. The results reveal the inhomogeneity in the oxide films on the micron-sized Cr2N- and VN-type particles, while the inhomogeneity on the martensite matrix phase exists due to localised formation of nano-sized tempering nitride particles at 600 °C. The oxide film formed on Cr2N-type particles is rich in Cr2O3 compared with that on the martensite matrix and VN-type particles. With the increase of tempering temperature, Cr2O3 formation is faster for the oxidation of Cr in the martensite matrix than the oxidation of Cr nitride-rich particles.

Corrosion and wear pose significant challenges to equipment operating in harsh environments. Thus, protective coatings are needed. Anti-corrosion and anti-wear coatings are traditionally fossil-based and often contain environmentally harmful additives. Achieving anti-corrosion and anti-wear coatings based on environmentally benign and sustainable materials is important and a significant challenge. This work focused on the development of organosolv lignin-based polyurethane (OS_lignin-PU) coatings. The coatings were synthesised and evaluated for corrosion protection using electrochemical impedance spectroscopy (EIS) and for wear properties using nanoindentation and nano scratch measurements. EIS revealed that the optimal lignin content for corrosion protection purposes in the OS_lignin-PU coatings was 15 wt%. Moreover, addition of 15 wt% lignin to the OS_lignin-PU coatings also enhanced their wear resistance, as evidenced by reduced thickness loss during tribometer tests. The nano scratch measurements revealed that OS_lignin-PU coatings containing 15 wt% lignin exhibited the lowest scratch depth and friction coefficient. It is found that the developed lignin-containing coating exhibits remarkable corrosion and wear resistance, making it a promising sustainable material in various applications for pursuing sustainable development.

The pitting potential, intrinsic surface acidity, point of zero charge of passive film on Al are studied using first-principles calculations to establish their relationships. Influences of alloying elements Zn, Cr, Nb, Si, Mo and Sc on adsorption of NH3 and NaCl, pHpzc of Al2O3 and pitting susceptibility of Al are investigated. The efficiency for enhancing pitting resistance of Al is evaluated, yielding the ratios Si: Zn: Cr: Mo: Nb: Sc = 1.8: − 0.3: 1: 1.9: 1.4: 0.2. A model for the dependence of pitting potential on the concentration of alloying elements in Al alloy matrix is developed, based on effects of alloying elements on the surface charge of passive film. The effects of Sc on pitting potential and pHpzc of Al oxide are predicted based on the calculated results, which are supported by electrochemical measurement, XPS analysis and contact angle titration.

Corrosion results in large costs and environmental impact but can be controlled by thin oxide films that passivate the metal surfaces and hinder further oxidation or dissolution in an aqueous environment. The structure, chemistry, and thickness of these oxide films play a significant role in determining their anti-corrosion properties and the early-stage oxidation dynamics affect the properties of the developed oxide. Here, we use in situ X-ray Photoelectron Spectroscopy (XPS) to study the early-stage oxidation of a Ni-Cr-Mo alloy at room temperature and up to 400 degrees C. Cr and Mo begin to oxidize immediately after exposure to O2, and Cr3+, Mo4+, and Mo6+ oxides are formed. In contrast, Ni does not contribute significantly to the oxide film. A self-limiting oxide thickness, which did not depend on temperature below 400 degrees C, is observed. This is attributed to the consumption of available Cr and Mo near the surface, which results in an enrichment of metallic Ni under the oxide. The self-limited oxide thickness is 6-8 angstrom, which corresponds to 3-4 atomic layers of cations in the oxide. At 400 degrees C, sublimation of Mo6+ oxide is observed, resulting in the formation of an almost pure layer of Cr2O3 on the alloy surface. Lastly, a mechanism is presented that explains the formation of the bi-layer oxide structure observed for Ni-Cr-Mo alloys, which involves the enhanced migration of hexavalent Mo ions in the electric field, which drives mass transport during oxidation according to both the Cabrera Mott model and the Point Defect Model.

Corrosion causes significant challenges in industrial settings, leading to economic losses and safety concerns. Previously, we developed a lignin-polydimethylsiloxane (lignin-PDMS) coating that exhibited high corrosion resistance. However, the adhesion of the developed lignin-PDMS coating to carbon steel was limited, affecting its overall performance. To address this, we incorporated dopamine (DOPA), known for its strong adhesive properties, as a pre-treatment before applying the coating. It was found that the adhesion and corrosion resistance of lignin-PDMS coated steel could be improved by adjusting the pH value of the DOPA solution. The steel treated with pH 4.5 DOPA solution showed two times higher adhesion strength to the coating than non-treated steel. After the DOPA treatment, the coating can maintain high barrier property for at least 3 months in 1 M NaCl solution, which is even better than commercial gelcoat, demonstrating super corrosion protection. Quartz Crystal Microbalance with Dissipation (QCM-D) and X-ray Photoelectron Spectroscopy (XPS) analyses confirmed the DOPA deposition on the steel surface. Our findings show that the DOPA-lignin-PDMS system is an environmentally friendly and efficient solution for enhancing the durability of steels in corrosive environments.

Corrosion and wear remain significant challenges for materials, causing substantial economic losses and safety risks. Anti-corrosion and anti-wear coatings provide an effective solution. However, traditional coatings are often fossil-based and contain heavy metals, posing environmental concerns. The drive for eco-friendly coatings has led to the exploration of green materials. This study combined lignin, an abundant organic material, and polydimethylsiloxane (PDMS), a known hydrophobic material, to address the challenges. Organosolv lignin was functionalised with (3-Aminopropyl)triethoxysilane (APTES), then chemically grafted on PDMS for the final coating synthesis. The optimised coating achieved through an eco-friendly process, exhibiting enhanced hydrophobicity and barrier properties, showing excellent long-term corrosion resistance in NaCl solution. The optimal coating formulation contained 15 wt% lignin and 40 wt% PDMS, demonstrating a high corrosion resistance (measured impedance of 1010 Ω·cm2), which remains effective even after 3 weeks of immersion in 1 M NaCl solution. This coating also showed good wear resistance, with a low friction coefficient evident from nano scratch tests.

Effect of tempering temperature on the composition of the passive film of a martensitic tool alloy was studied by synchrotron-based hard/soft X-ray photoelectron spectroscopy and electrochemical analyses. The contents of Cr and Mo in the passive film are affected by precipitation of tempering carbides. Increase of tempering temperature from 200 to 525°C leads to enhanced formation of Cr/Mo-rich tempering carbides and Cr depletion. Tempering at 525°C results in a Cr content < 11 at% in the underlying metallic layer and formation of a Cr-deficient defective passive film, and thus loss of passivity for the tool alloy in corrosive conditions.