A Grey-Fuzzy Based Approach for the Optimization of Corrosion Resistance of Rebars Coated with Ternary Electroless Nickel Coatings

Document Type : Regular Article

Authors

1 Assistant Professor, Department of Mechanical Engineering, Birla Institute of Technology, Mesra, Ranchi – 835215, India

2 Associate Professor, Department of Civil Engineering, Heritage Institute of Technology, Kolkata – 700107, India

Abstract

Corrosion is an important phenomenon that occurs at concrete-rebar interface and affects the life of structures in coastal environments. Fe-600 grade steel is used in India for construction purposes especially in seismic zones. Hence, the corrosion of the rebars and its optimization is necessary to increase the lifetime of structures. In this regard, the present investigation examines the applicability of electroless Ni-P based ternary coatings as candidates for corrosion protection and obtains an optimal bath formulation. Investigation of electrochemical corrosion phenomenon (potentiodynamic polarization) was carried out in 3.5% NaCl to simulate saline coastal environment. Ni-P coatings with Cu and W inclusion were considered due to their proven corrosion resistance. The bath constituents such as nickel sulphate (Ni source), sodium hypophosphite (reducing agent and source of P) and the tungsten / copper concentration were varied to get various elemental composition following a sequential experimental design i.e. Taguchi’s L9 orthogonal array. A grey based fuzzy reasoning approach was proposed to optimize the bath and achieve enhanced corrosion resistance. The optimized coatings exhibited initiation of passivation which could prove to be beneficial for the health of the structure in the long-run. A noble corrosion potential and lower corrosion current density could be obtained in the coated rebars from the grey fuzzy methodology.

Keywords

Main Subjects

References

[1]     Sanjurjo A, Hettiarachchi S, Lau KH, Cox P, Wood B. Coatings for corrosion protection of steel used in reinforced concrete. Surf Coatings Technol 1992;54–55:224–8. https://doi.org/10.1016/S0257-8972(09)90054-8.
[2]     Pei X, Noël M, Fam A, Green M. Development length of steel reinforcement with corrosion protection cementitious coatings. Cem Concr Compos 2015;60:34–43. https://doi.org/10.1016/j.cemconcomp.2015.04.003.
[3]     Song Y, Wightman E, Kulandaivelu J, Bu H, Wang Z, Yuan Z, et al. Rebar corrosion and its interaction with concrete degradation in reinforced concrete sewers. Water Res 2020;182:115961. https://doi.org/10.1016/j.watres.2020.115961.
[4]     Samson G, Deby F, Garciaz J-L, Lassoued M. An alternative method to measure corrosion rate of reinforced concrete structures. Cem Concr Compos 2020;112:103672. https://doi.org/10.1016/j.cemconcomp.2020.103672.
[5]     Cabrini M, Lorenzi S, Coffetti D, Coppola L, Pastore T. Inhibition Effect of Tartrate Ions on the Localized Corrosion of Steel in Pore Solution at Different Chloride Concentrations. Buildings 2020;10:105. https://doi.org/10.3390/buildings10060105.
[6]     Bolzoni F, Brenna A, Beretta S, Ormellese M, Diamanti M V, Pedeferri MP. Progresses in prevention of corrosion in concrete. IOP Conf. Ser. Earth Environ. Sci., vol. 296, IOP Publishing; 2019, p. 12016.
[7]     Sadati S, Arezoumandi M, Shekarchi M. Long-term performance of concrete surface coatings in soil exposure of marine environments. Constr Build Mater 2015;94:656–63. https://doi.org/10.1016/j.conbuildmat.2015.07.094.
[8]     James A, Bazarchi E, Chiniforush AA, Panjebashi Aghdam P, Hosseini MR, Akbarnezhad A, et al. Rebar corrosion detection, protection, and rehabilitation of reinforced concrete structures in coastal environments: A review. Constr Build Mater 2019;224:1026–39. https://doi.org/10.1016/j.conbuildmat.2019.07.250.
[9]     Sagüés AA, Pech-Canul MA, Shahid Al-Mansur AKM. Corrosion macrocell behavior of reinforcing steel in partially submerged concrete columns. Corros Sci 2003;45:7–32. https://doi.org/10.1016/S0010-938X(02)00087-2.
[10]   Shi J, Ming J. Influence of defects at the steel-mortar interface on the corrosion behavior of steel. Constr Build Mater 2017;136:118–25. https://doi.org/10.1016/j.conbuildmat.2017.01.007.
[11]    Pradhan B, Bhattacharjee B. Rebar corrosion in chloride environment. Constr Build Mater 2011;25:2565–75. https://doi.org/10.1016/j.conbuildmat.2010.11.099.
[12]   Manera M, Vennesland Ø, Bertolini L. Chloride threshold for rebar corrosion in concrete with addition of silica fume. Corros Sci 2008;50:554–60. https://doi.org/10.1016/j.corsci.2007.07.007.
[13]   Wang D, Ming J, Shi J. Enhanced corrosion resistance of rebar in carbonated concrete pore solutions by Na2HPO4 and benzotriazole. Corros Sci 2020;174:108830. https://doi.org/10.1016/j.corsci.2020.108830.
[14]   Wu M, Shi J. Beneficial and detrimental impacts of molybdate on corrosion resistance of steels in alkaline concrete pore solution with high chloride contamination. Corros Sci 2021;183:109326. https://doi.org/10.1016/j.corsci.2021.109326.
[15]   Kumar S, Yang E-H, Unluer C. Investigation of chloride penetration in carbonated reactive magnesia cement mixes exposed to cyclic wetting–drying. Constr Build Mater 2021;284:122837. https://doi.org/10.1016/j.conbuildmat.2021.122837.
[16]   Cascudo O, Pires P, Carasek H, de Castro A, Lopes A. Evaluation of the pore solution of concretes with mineral additions subjected to 14 years of natural carbonation. Cem Concr Compos 2021;115:103858. https://doi.org/10.1016/j.cemconcomp.2020.103858.
[17]   Liu S, Zhu M, Ding X, Ren Z, Zhao S, Zhao M, et al. High-Durability Concrete with Supplementary Cementitious Admixtures Used in Corrosive Environments. Crystals 2021;11:196. https://doi.org/10.3390/cryst11020196.
[18]   Baltazar-Zamora MA, M. Bastidas D, Santiago-Hurtado G, Mendoza-Rangel JM, Gaona-Tiburcio C, Bastidas JM, et al. Effect of Silica Fume and Fly Ash Admixtures on the Corrosion Behavior of AISI 304 Embedded in Concrete Exposed in 3.5% NaCl Solution. Materials (Basel) 2019;12:4007. https://doi.org/10.3390/ma12234007.
[19]   Söylev TA, Richardson MG. Corrosion inhibitors for steel in concrete: State-of-the-art report. Constr Build Mater 2008;22:609–22. https://doi.org/10.1016/j.conbuildmat.2006.10.013.
[20]   Pan C, Chen N, He J, Liu S, Chen K, Wang P, et al. Effects of corrosion inhibitor and functional components on the electrochemical and mechanical properties of concrete subject to chloride environment. Constr Build Mater 2020;260:119724. https://doi.org/10.1016/j.conbuildmat.2020.119724.
[21]   Luo H, Su H, Dong C, Li X. Passivation and electrochemical behavior of 316L stainless steel in chlorinated simulated concrete pore solution. Appl Surf Sci 2017;400:38–48. https://doi.org/10.1016/j.apsusc.2016.12.180.
[22]   Tian Y, Liu M, Cheng X, Dong C, Wang G, Li X. Cr-modified low alloy steel reinforcement embedded in mortar for two years: Corrosion result of marine field test. Cem Concr Compos 2019;97:190–201. https://doi.org/10.1016/j.cemconcomp.2018.12.019.
[23]   Mukhopadhyay A, Sahoo S. Corrosion Protection of Construction Steel. Handb. Res. Dev. Trends Ind. Mater. Eng., IGI Global; 2020, p. 327–47.
[24]   Tang F, Chen G, Brow RK, Volz JS, Koenigstein ML. Corrosion resistance and mechanism of steel rebar coated with three types of enamel. Corros Sci 2012;59:157–68. https://doi.org/10.1016/j.corsci.2012.02.024.
[25]   Tang F, Chen G, Volz JS, Brow RK, Koenigstein M. Microstructure and corrosion resistance of enamel coatings applied to smooth reinforcing steel. Constr Build Mater 2012;35:376–84. https://doi.org/10.1016/j.conbuildmat.2012.04.059.
[26]   Gao Z. Corrosion damage of reinforcement embedded in reinforced concrete slab 2016.
[27]   Tang F, Chen G, Brow RK. Chloride-induced corrosion mechanism and rate of enamel- and epoxy-coated deformed steel bars embedded in mortar. Cem Concr Res 2016;82:58–73. https://doi.org/10.1016/j.cemconres.2015.12.015.
[28]   Pour-Ali S, Dehghanian C, Kosari A. Corrosion protection of the reinforcing steels in chloride-laden concrete environment through epoxy/polyaniline–camphorsulfonate nanocomposite coating. Corros Sci 2015;90:239–47. https://doi.org/10.1016/j.corsci.2014.10.015.
[29]   Sohail MG, Salih M, Al Nuaimi N, Kahraman R. Corrosion performance of mild steel and epoxy coated rebar in concrete under simulated harsh environment. Int J Build Pathol Adapt 2019;37:657–78. https://doi.org/10.1108/IJBPA-12-2018-0099.
[30]   Rajitha K, Mohana KNS, Mohanan A, Madhusudhana AM. Evaluation of anti-corrosion performance of modified gelatin-graphene oxide nanocomposite dispersed in epoxy coating on mild steel in saline media. Colloids Surfaces A Physicochem Eng Asp 2020;587:124341. https://doi.org/10.1016/j.colsurfa.2019.124341.
[31]   Khodair ZT, Khadom AA, Jasim HA. Corrosion protection of mild steel in different aqueous media via epoxy/nanomaterial coating: preparation, characterization and mathematical views. J Mater Res Technol 2019;8:424–35. https://doi.org/10.1016/j.jmrt.2018.03.003.
[32]   Tang F, Bao Y, Chen Y, Tang Y, Chen G. Impact and corrosion resistances of duplex epoxy/enamel coated plates. Constr Build Mater 2016;112:7–18. https://doi.org/10.1016/j.conbuildmat.2016.02.170.
[33]   Wang Y, Kong G, Che C, Zhang B. Inhibitive effect of sodium molybdate on the corrosion behavior of galvanized steel in simulated concrete pore solution. Constr Build Mater 2018;162:383–92. https://doi.org/10.1016/j.conbuildmat.2017.12.035.
[34]   Pokorný P, Tej P, Kouřil M. Evaluation of the impact of corrosion of hot-dip galvanized reinforcement on bond strength with concrete – A review. Constr Build Mater 2017;132:271–89. https://doi.org/10.1016/j.conbuildmat.2016.11.096.
[35]   Li L, Wang J, Xiao J, Yan J, Fan H, Sun L, et al. Time-dependent corrosion behavior of electroless Ni–P coating in H2S/Cl− environment. Int J Hydrogen Energy 2021;46:11849–64. https://doi.org/10.1016/j.ijhydene.2021.01.053.
[36]   Li J, Zeng H, Luo J-L. Probing the corrosion resistance of a smart electroless Ni-P composite coating embedded with pH-responsive corrosion inhibitor-loaded nanocapsules. Chem Eng J 2021;421:127752. https://doi.org/10.1016/j.cej.2020.127752.
[37]   Yu Q, Zhou T, He Y, Liu P, Wang X, Jiang Y, et al. Annealed high-phosphorus electroless Ni–P coatings for producing molds for precision glass molding. Mater Chem Phys 2021;262:124297. https://doi.org/10.1016/j.matchemphys.2021.124297.
[38]   Cui C, Du H, Liu H, Xiong T. Corrosion behavior of the electroless Ni-P coating on the pore walls of the lotus-type porous copper. Corros Sci 2020;162:108202. https://doi.org/10.1016/j.corsci.2019.108202.
[39]   Verdi P, Monirvaghefi SM. Electroless Ni-P Plating of Carbon Steel via Hot Substrate Method and Comparison of Coating Properties with those for Conventional Method. J Mater Eng Perform 2020;29:7915–28. https://doi.org/10.1007/s11665-020-05286-8.
[40]   Krishnan KH, John S, Srinivasan KN, Praveen J, Ganesan M, Kavimani PM. An overall aspect of electroless Ni-P depositions—A review article. Metall Mater Trans A 2006;37:1917–26. https://doi.org/10.1007/s11661-006-0134-7.
[41]   Singh DDN, Ghosh R. Electroless nickel–phosphorus coatings to protect steel reinforcement bars from chloride induced corrosion. Surf Coatings Technol 2006;201:90–101. https://doi.org/10.1016/j.surfcoat.2005.10.045.
[42]   Mukhopadhyay A, Sahoo S. Corrosion protection of reinforcement steel rebars by the application of electroless nickel coatings. Eng Res Express 2019;1:15021.
[43]   Mukhopadhyay A, Sahoo S. Improving corrosion resistance of reinforcement steel rebars exposed to sulphate attack by the use of electroless nickel coatings. Eur J Environ Civ Eng 2021:1–16. https://doi.org/10.1080/19648189.2021.1886177.
[44]   Mukhopadhyay A, Sahoo S. Corrosion performance of steel rebars by application of electroless Ni-PW coating: An optimization approach using grey relational analysis. FME Trans 2021;49:445–55.
[45]   Mukhopadhyay A, Sahoo S. Optimized electroless Ni-Cu-P coatings for corrosion protection of steel rebars from pitting attack of chlorides. Eng Trans 2021;69:315–32.
[46]   Sajid HU, Kiran R, Bajwa DS. Soy-protein and corn-derived polyol based coatings for corrosion mitigation in reinforced concrete. Constr Build Mater 2022;319:126056. https://doi.org/10.1016/j.conbuildmat.2021.126056.
[47]   Sharma N, Sharma S, Sharma SK, Mahajan RL, Mehta R. Evaluation of corrosion inhibition capability of graphene modified epoxy coatings on reinforcing bars in concrete. Constr Build Mater 2022;322:126495. https://doi.org/10.1016/j.conbuildmat.2022.126495.
[48]   Lin J., Lin C. The use of the orthogonal array with grey relational analysis to optimize the electrical discharge machining process with multiple performance characteristics. Int J Mach Tools Manuf 2002;42:237–44. https://doi.org/10.1016/S0890-6955(01)00107-9.
[49]   T M, P R, Es G, P S, Ksr. A. Experimental Investigation of Coconut Oil with Nanoboric Acid During Milling of Inconel 625 Using Taguchi-Grey Relational Analysis. Surf Rev Lett 2021;28:2150008. https://doi.org/10.1142/S0218625X21500086.
[50]   Nagaraj Y, Jagannatha N, Sathisha N, Niranjana SJ. Parametric optimization on hot air assisted hybrid machining of soda-lime glass using Taguchi based grey relational analysis. Multiscale Multidiscip Model Exp Des 2021;4:169–85. https://doi.org/10.1007/s41939-020-00085-z.
[51]   Lian G, Xiao S, Zhang Y, Jiang J, Zhan Y. Multi-objective optimization of coating properties and cladding efficiency in 316L/WC composite laser cladding based on grey relational analysis. Int J Adv Manuf Technol 2021;112:1449–59. https://doi.org/10.1007/s00170-020-06486-1.
[52]   Prasath V, Krishnaraj V, Geetha Priyadarshini B, Kanchana J. Multi-objective optimization of Pulsed direct current magnetron sputtered titanium nitride thin film using Grey relational analysis. Proc Inst Mech Eng Part L J Mater Des Appl 2021;235:100–13. https://doi.org/10.1177/1464420720951899.
[53]   LA. Z. Fuzzy sets. Information Control 1965;8:338–353.
[54]   Kumar H, Harsha A. Taguchi optimization of various parameters for tribological performance of polyalphaolefins based nanolubricants. Proc Inst Mech Eng Part J J Eng Tribol 2021;235:1262–80. https://doi.org/10.1177/1350650120972294.
[55]   Nguyen H-P, Pham V-D. Single objective optimization of die- sinking electrical discharge machining with low frequency vibration assigned on workpiece by taguchi method. J King Saud Univ - Eng Sci 2021;33:37–42. https://doi.org/10.1016/j.jksues.2019.11.001.
[56]   Sharifi E, Sadjadi SJ, Aliha MR., Moniri A. Optimization of high-strength self-consolidating concrete mix design using an improved Taguchi optimization method. Constr Build Mater 2020;236:117547. https://doi.org/10.1016/j.conbuildmat.2019.117547.
[57]   Dagdevir T, Ozceyhan V. Optimization of process parameters in terms of stabilization and thermal conductivity on water based TiO2 nanofluid preparation by using Taguchi method and Grey relation analysis. Int Commun Heat Mass Transf 2021;120:105047. https://doi.org/10.1016/j.icheatmasstransfer.2020.105047.
[58]   Kumaran ST, Ko TJ, Kurniawan R. Grey fuzzy optimization of ultrasonic-assisted EDM process parameters for deburring CFRP composites. Measurement 2018;123:203–12. https://doi.org/10.1016/j.measurement.2018.03.076.
[59]   Soepangkat BOP, Pramujati B, Effendi MK, Norcahyo R, Mufarrih AM. Multi-objective Optimization in Drilling Kevlar Fiber Reinforced Polymer Using Grey Fuzzy Analysis and Backpropagation Neural Network–Genetic Algorithm (BPNN–GA) Approaches. Int J Precis Eng Manuf 2019;20:593–607. https://doi.org/10.1007/s12541-019-00017-z.
[60]   Siva Sankara Raju, Srinivasa Rao G, Samantra C. Wear behavioral assessment of Al-CSAp-MMCs using grey-fuzzy approach. Measurement 2019;140:254–68. https://doi.org/10.1016/j.measurement.2019.04.004.
[61]   Moganapriya C, Rajasekar R, Sathish Kumar P, Mohanraj T, Gobinath VK, Saravanakumar J. Achieving machining effectiveness for AISI 1015 structural steel through coated inserts and grey-fuzzy coupled Taguchi optimization approach. Struct Multidiscip Optim 2021;63:1169–86. https://doi.org/10.1007/s00158-020-02751-9.
[62]   Gao Z, Li J. Fuzzy Analytic Hierarchy Process Evaluation Method in Assessing Corrosion Damage of Reinforced Concrete Bridges. Civ Eng J 2018;4:843. https://doi.org/10.28991/cej-0309138.
[63]   Mukhopadhyay A, Duari S, Barman TK, Sahoo P. Optimization of Friction and Wear Properties of Electroless Ni–P Coatings Under Lubrication Using Grey Fuzzy Logic. J Inst Eng Ser D 2017;98:255–68. https://doi.org/10.1007/s40033-016-0133-9.
[64]   Roy S, Sahoo P. Potentiodynamic Polarization Behaviour of Electroless Ni-P-W Coatings. ISRN Corros 2012;2012:1–11. https://doi.org/10.5402/2012/914867.
[65]   Roy S, Sahoo P. Parametric optimization of corrosion and wear of electroless Ni-P-Cu coating using grey relational coefficient coupled with weighted principal component analysis. Int J Mech Mater Eng 2014;9:10. https://doi.org/10.1186/s40712-014-0010-y.
[66]   Balaraju JN, Kalavati, Rajam KS. Surface morphology and structure of electroless ternary NiWP deposits with various W and P contents. J Alloys Compd 2009;486:468–73. https://doi.org/10.1016/j.jallcom.2009.06.173.
[67]   Liu J, Wang X, Tian Z, Yuan M, Ma X. Effect of copper content on the properties of electroless Ni–Cu–P coatings prepared on magnesium alloys. Appl Surf Sci 2015;356:289–93. https://doi.org/10.1016/j.apsusc.2015.08.072.

Files

Cited by

History

  • Receive Date: 28 January 2022
  • Revise Date: 29 April 2022
  • Accept Date: 02 June 2022

Share

How to cite

Statistics