Corrosion is a ubiquitous and costly problem for a variety of industries. Understanding and reducing the cost of corrosion remain primary interests for corrosion professionals and relevant asset owners. The present study summarises the findings that arose from the landmark “Study of Corrosion Status and Control Strategies in China”, a key consulting project of the Chinese Academy of Engineering in 2015, which sought to determine the national cost of corrosion and costs associated with representative industries in China. The study estimated that the cost of corrosion in China was approximately 2127.8 billion RMB (~ 310 billion USD), representing about 3.34% of the gross domestic product. The transportation and electronics industries were the two that generated the highest costs among all those surveyed. Based on the survey results, corrosion is a major and significant issue, with several key general strategies to reduce the cost of corrosion also outlined.

This work introduces a new self-healing superhydrophobic coating based on dual actions by the corrosion inhibitor benzotriazole (BTA) and an epoxy-based shape memory polymer (SMP). Damage to the surface morphology (e.g., crushed areas and scratches) and the corresponding superhydrophobicity are shown to be rapidly healed through a simple heat treatment at 60 °C for 20 min. Electrochemical impedance spectroscopy (EIS) and scanning electrochemical microscopy (SECM) were used to study the anti-corrosion performance of the scratched and the healed superhydrophobic coatings immersed in a 3.5 wt% NaCl solution. The results revealed that the anti-corrosion performance of the scratched coatings was improved upon the incorporation of BTA. After the heat treatment, the scratched superhydrophobic coatings exhibited excellent recovery of their anti-corrosion performance, which is attributed to the closure of the scratch by the shape memory effect and to the improved inhibition efficiency of BTA. Furthermore, we found that the pre-existing corrosion product inside the coating scratch could hinder the scratch closure by the shape memory effect and reduce the coating adhesion in the scratched region. However, the addition of BTA effectively suppressed the formation of corrosion products and enhanced the self-healing and adhesion performance under these conditions. Importantly, we also demonstrated that these coatings can be autonomously healed within 1 h in an outdoor environment using sunlight as the heat source.

In this study, a new self-healing shape memory polymer (SMP) coating was prepared to protect the aluminum alloy 2024-T3 from corrosion by the incorporation of dual-function microspheres containing polycaprolactone (PCL) and the corrosion inhibitor 8-hydroxyquinoline (8HQ). The self-healing properties of the coatings were investigated via scanning electron microscopy (SEM), electrochemical impedance spectroscopy (EIS) and scanning electrochemical microscopy (SECM) following the application of different healing conditions. The results demonstrated that the coating possessed a triple-action self-healing ability enabled by the cooperation of the 8HQ inhibitor, the SMP coating matrix and the melted microspheres. The coating released 8HQ in a pH-dependent fashion and immediately suppressed corrosion within the coating scratch. After heat treatment, the scratched coating exhibited excellent recovery of its anti-corrosion performance, which was attributed to the simultaneous initiation of scratch closure by the shape memory effect of the coating matrix, sealing of the scratch by the melted microspheres, and the synergistic effect of corrosion inhibition by 8HQ.

In this work, the atmospheric corrosion of carbon steels was monitored at six different sites (and hence, atmospheric conditions) using Fe/Cu-type atmospheric corrosion monitoring technology over a period of 12 months. After analyzing over 3 million data points, the sensor data were interpretable as the instantaneous corrosion rate, and the atmospheric “corrosivity” for each exposure environment showed highly dynamic changes from the C1 to CX level (according to the ISO 9223 standard). A random forest model was developed to predict the corrosion rate and investigate the impacts of ten “corrosive factors” in dynamic atmospheres. The results reveal rust layer, wind speed, rainfall rate, RH, and chloride concentration, played a significant role in the corrosion process.