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. 2025 Apr 12;15(1):12629.
doi: 10.1038/s41598-025-90003-5.

Microbiologically influenced corrosion in uncoated and coated Mild Steel

Sheikh Idrees Ali  1 , Sheikh Nazir Ahmad  2
Affiliations

Microbiologically influenced corrosion in uncoated and coated Mild Steel

Sheikh Idrees Ali et al. Sci Rep. .

Abstract

The study aimed to investigate the corrosion performance of Zn-Ni-Cu and Zn-Ni-Cu-TiB2 coatings in the microbial-induced environment (E-Coli, ATCC 25922, and 3.5%NaCl solution). Zn-Ni-Cu and Zn-Ni-Cu-TiB2 were surfaces coated on an ASTM A-36 Steel substrate utilizing a high-velocity oxy-fuel (HVOF) thermal spray process. Immersion tests following ASTM G-31, and ASTM G1-03, standards were performed in Escherichia Coli (E-Coli, American Type Culture CollectionATCC25922) bacteria medium. The effect of Zn, Ni, and Ti was studied in preventing microbial-induced corrosion.SEM, and XRD analysis before and after helped to understand the morphological and structural changes in coated/uncoated ASTM A-36 steel. Various forms of rust were ascertained in XRD analysis. The inclusion of Zn and Cu inhibited bacterial attachment to the coated surface, hence preventing significant corrosion of the underlying substrate. The coatings performed effectively and inhibited bacterial growth. The uncoated ASTM A-36 Steel specimen showed well-developed bacterial colonies on the surface and in the solution medium. All forms of rust were reported in XRD analysis for uncoated ASTM A-36 steel while few forms of rust were reported in coated ASTM A-36 steel.Electrochemical impedance spectroscopy (EIS) and Tafel polarization in Escherichia coli (E-Coli, ATCC 25922) medium demonstrated that the coated samples had greater corrosion resistance than the uncoated ASTM A-36 Steel specimens. The higher corrosion potential (Ecorr) values of the two coated samples indicated improved anodic protection.

Keywords: Airborne reactive oxygen species; Bacterium Escherichia Coli; Biotic environment; High-velocity oxy-fuel spraying; Microbiologically- Induced Corrosion.

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Conflict of interest statement

Declarations. Competing interests: The authors declare no competing interests. Ethics approval: No plagiarism was incorporated in this research. The literature is cited appropriately. Consent to participate: The corresponding author and co-author agree to participate in any review or discussion process. Consent for publication: The corresponding author and co-author agree to publish this manuscript in your prestigious journal.

Figures

Fig. 1
Fig. 1
Shows the mass loss of uncoated/coated samples in the E Coli medium for 28 days (672 h).
Fig. 2
Fig. 2
Shows the micrographs of specimens before and after the immersion cycle test. (a)uncoated ASTM A-36 Steel before the test, (b) uncoated ASTM A-36 Steel after the test, (c) Zn-Ni-Cu on ASTM A-36 Steel before the test, (d) Zn-Ni-Cu on ASTM A-36 Steel after the test, (e) Zn-Ni-Cu-TiB2 before the test, (f) Zn-Ni-Cu-TiB2 after the test.
Fig. 2
Fig. 2
Shows the micrographs of specimens before and after the immersion cycle test. (a)uncoated ASTM A-36 Steel before the test, (b) uncoated ASTM A-36 Steel after the test, (c) Zn-Ni-Cu on ASTM A-36 Steel before the test, (d) Zn-Ni-Cu on ASTM A-36 Steel after the test, (e) Zn-Ni-Cu-TiB2 before the test, (f) Zn-Ni-Cu-TiB2 after the test.
Fig. 3
Fig. 3
Depicts SEM micrographs of specimens before and after an immersion cycle test. (a) uncoated ASTM A-36 steel before the test; (b) uncoated ASTM A-36 steel after the test; (c) Zn-Ni-Cu on ASTM A-36 steel before the test; (d) Zn-Ni-Cu on ASTM A-36 steel after the test; (e) Zn-Ni-Cu-TiB2 before the test; (f) Zn-Ni-Cu-TiB2 after the test.
Fig. 3
Fig. 3
Depicts SEM micrographs of specimens before and after an immersion cycle test. (a) uncoated ASTM A-36 steel before the test; (b) uncoated ASTM A-36 steel after the test; (c) Zn-Ni-Cu on ASTM A-36 steel before the test; (d) Zn-Ni-Cu on ASTM A-36 steel after the test; (e) Zn-Ni-Cu-TiB2 before the test; (f) Zn-Ni-Cu-TiB2 after the test.
Fig. 4
Fig. 4
(a, b) Shows a higher magnification of uncoated ASTM A-36 Steel specimen following the immersion cycle test.
Fig. 5
Fig. 5
Shows the (a) uncoated ASTM A-36 Steel before and after the test.(b) Zn-Ni-Cu coated ASTM A-36 Steel before and after the test.(c) Zn-Ni-Cu-TiB2 coated ASTM A-36 Steel before and after the test.
Fig. 6
Fig. 6
Shows the optical micrograph of uncoated/coated specimens after 24 h in an E Coli medium.
Fig. 7
Fig. 7
Shows Tafel’s exploration of uncoated/coated samples in E Coli and3.5% NaCl medium.
Fig. 8
Fig. 8
Depicts the Nyquist plot of uncoated/coated samples in E. Coli and 3.5% NaCl media.
Fig. 9
Fig. 9
Depicts the Bode Plot of uncoated/coated samples in E. coli and 3.5% NaCl media.
Fig. 10
Fig. 10
Depicts the Equivalent circuit (EIS) of (a) uncoated ASTM A-36 steel and (b) Zn-Ni-Cu and Zn-Ni-Cu-TiB2 on ASTM A-36 steel.
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