In this work, the intrinsic reason for the premature failure of a 316 stainless steel heat exchanger tube in geothermal water environment is disclosed. The chemical composition of the tube was tested, and the microstructure was examined for material inspection. Fracture morphology and secondary cracks were analyzed, and electron backscattered diffraction was applied to explore the crack propagation mode. The corrosion morphology was observed. The electrochemical behavior was studied with cyclic polarization and double-loop electrochemical potentiokinetic reactivation. It is found that the main failure cause was stress corrosion cracking (SCC). Attacked by chloride ions, the tube is susceptible to SCC under the residual stress as a result of the substandard Mo and Ni content. The SCC mechanism is localized anodic dissolution, and the propagation mode is a mixture of transgranular SCC and intergranular SCC.

The behavior and mechanisms of the stress-assisted microbiologically influenced corrosion (MIC) of X80 pipeline steel induced by sulfate-reducing bacteria (SRB) were investigated using focused ion beam-scanning electron microscopy (FIB). Electrochemical results show that SRB and stress have a synergistic effect on the corrosion of X80 steel. SRB accelerated the transformation of Fe₃O₄ into iron-sulfur compounds and may have caused the film breakage of X80 steel products. The obtained FIB results provide direct evidence that SRB promotes the corrosion of X80 steel.

Selecting appropriate materials is crucial for mitigating the severe economic and safety challenges posed by microbiologically induced corrosion (MIC) in marine and industrial settings. This study focuses on the MIC behavior of 316L austenitic stainless steel and 2205 duplex stainless steel that is caused by the metabolic activities of D. vulgaris during a life span of 7 days. Cell counts, weight loss, electrochemical measurements, and surface characterization were employed to evaluate the materials’ resistance to MIC. Specifically, 2205 DSS exhibited a 60% lower weight loss (0.02 vs. 0.05 mg/cm²), a 42% lower maximum pit depth (2.11 vs. 3.64 μm), and an orders-of-magnitude lower corrosion current density (0.094 vs. 2.0 μA cm⁻²) compared to 316L SS, demonstrating its superior resistance to D. vulgaris MIC. XRD and XPS analyses revealed that although FeS formed on both materials, FeS₂—a thermodynamically stable deep-sulfidation product—was only present on 316L, indicating a more advanced corrosion stage. The absence of FeS₂ on 2205 suggests limited sulfide corrosion progression. These findings confirm the advantage of duplex stainless steel in mitigating D. vulgaris-induced corrosion and provide insights into the selection of materials for MIC-prone environments.

In this study, X80 steel square specimens were immersed in a culture of sulfate-reducing bacteria (SRB), Desulfovibrio vulgaris, and the impact of gravity sedimentation on biofilm formation was investigated in three different directions (upward, sideward, and downward). A systematic investigation of biocorrosion induced by different biofilm formations during the lifespan of one D. vulgaris was illustrated using cell counts, weight loss measurements, biofilm observations, pit profiles, electrochemical tests, and X-ray diffraction (XRD). The results indicate that the gravitational field, which is an objective existence of the Earth, significantly affects the adhesion and formation of D. vulgaris biofilm, which directly determines the MIC behavior. The thickest D. vulgaris biofilm formed on the upward-facing X80 square specimens, followed by the side-facing X80 square specimens, while the thinnest and porous biofilms formed on the downward-facing X80 square specimens, induced significantly different degrees of microbiologically influenced corrosion (MIC) behaviors on the X80 steel.

In this study, dried biomass of the alga Chlorella vulgaris was ground into a powder as an eco-friendly, low-cost inhibitor to mitigate the corrosion of carbon steel in acidic solutions. Electrochemical and weight loss measurements, surface morphology observations, adsorption isotherms, activation energy, and potential of zero charge calculations were applied to evaluate the inhibition performance. Electrochemical results indicate that C. vulgaris powder can simultaneously inhibit both the anodic and cathodic corrosion processes of carbon steel, demonstrating good inhibition performance and classifying it as a mixed-type inhibitor with both anodic and cathodic characteristics. Weight loss data further confirm that at a concentration of 300 mg/L, the corrosion inhibition efficiency reaches 88%. The fitted adsorption isotherm reveals that the adsorption of Chlorella vulgaris powder on the carbon steel surface follows the Langmuir model. Density functional theory (DFT) and molecular dynamics simulations indicate that the excellent inhibition performance is attributed to the combined effects of physisorption and chemisorption of constituents such as amino acids and cellulose present in C. vulgaris.