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Desulfovibrio alaskensis G20 biofilms were cultivated on 316 steel, 1018 steel, or borosilicate glass under steady-state conditions in electron-acceptor limiting (EAL) and electron-donor limiting (EDL) conditions with lactate and sulfate in a defined medium. Increased corrosion was observed on 1018 steel under EDL conditions compared to 316 steel, and biofilms on 1018 carbon steel under the EDL condition had at least twofold higher corrosion rates compared to the EAL condition. Protecting the 1018 metal coupon from biofilm colonization significantly reduced corrosion, suggesting that the corrosion mechanism was enhanced through attachment between the material and the biofilm. Metabolomic mass spectrometry analyses demonstrated an increase in a flavin-like molecule under the 1018 EDL condition and sulfonates under the 1018 EAL condition. These data indicate the importance of S-cycling under the EAL condition, and that the EDL is associated with increased biocorrosion via indirect extracellular electron transfer mediated by endogenously produced flavin-like molecules.

Localized residual strain develops within the metallurgical texture of 1018 carbon steel from metallurgical processes, such as fabrication, annealing, and shaping. This residual strain results in accelerated localized pitting due to the formation of anodic sites at these locations. Once initiated, micron-sized corrosion pits can coalesce to form sites of potential catastrophic failure. In this contribution, we focus on the localized biocorrosion which initiates and grows in areas of localized strain such as the interfaces between manganese sulfide (MnS) inclusions and ferrite grains in the steel, at grain boundaries between ferrite grains with different crystallographic orientations and at pearlite grains (intergrown cementite (Fe3C) and ferrite), which are readily found in 1018 carbon steel. Here we hypothesize and show experimentally that accelerated biocorrosion in 1018 carbon steel finds its roots in the electrochemical potential difference (micro galvanic cells) generated between the unstrained ferrite iron (α - Fe) and the lattice defects, dislocations and mismatches found at interfaces formed between α - Fe and secondary phases i.e. MnS inclusions, cementite lamellar structures and grain boundaries distributed throughout the 3D network of the carbon steel. This hypothesis is supported by results from multiple micro- and nanoscale imaging and analytical methods obtained from field emission scanning electron microscopy, energy dispersive spectroscopy, electron backscattered diffraction and Auger nanoprobe electron spectroscopy. The morphology and composition of grains in the steel coupons were characterized before and after exposure to suboxic and sulfidogenic environments dominated by aerobic and anaerobic marine organisms. Corrosion processes are demonstrated to initiate in localized areas of high residual strain.

A practical method has been developed for rapidly determining the depth of a corrosion micro-pit from the path lengths of X rays passing through the walls of the pit on their way to an X-ray detector. The method takes advantage of the attenuation of the Bremsstrahlung and characteristic X-ray radiation accompanying each X-ray spectrum, and the results are verified independently using AFM and the special pit geometry surrounding MnS inclusions in 1018 carbon steel. The method has general validity and is especially valuable in those cases where the pit depth-to-width ratio is too steep to measure using the conventional methods.

In a saline anaerobic sulfidogenic environment, pitting on 1018 carbon steel was initiated within a 20–30 nm zone at the MnS inclusion boundary. Nanoscale analysis was performed using scanning electron microscopy and a scanning Auger nanoprobe. The pitting was more pronounced in the presence of a biofilm of sulfate-reducing bacteria than in abiotic sulfide medium. It is proposed that initiation of an anodic reaction leading to dissolution of Fe matrix and subsequent pitting of steel in MnS inclusion boundary regions is due to disorder and strain exerted on the Fe matrix by MnS contamination of the interface from metallurgical processes.

Extended abstract of a paper presented at Microscopy and Microanalysis 2012 in Phoenix, Arizona, USA, July 29 – August 2, 2012.