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Ultrasonic guided waves cut corrosion rate on coated steel pipes
A novel active anti-corrosion technique uses ultrasonic guided waves as an “acoustic coating” to protect metal surfaces against salt-spray corrosion. Experimental results show that the method reduces the corrosion rate of unprotected steel pipes by 33.5 % and further enhances the performance of conventional epoxy, acrylic and polyurethane coatings.
Marine atmospheric environments present a persistent challenge for the corrosion protection of metal structures, particularly pipe systems exposed to salt spray. In this study, researchers propose a novel active anti-corrosion technique based on ultrasonic guided waves (UGWs). The approach generates a tiny but rapid vibration on the material surface, functioning as an “acoustic coating” that actively protects the substrate against salt-spray attack.
A typical pipe structure was numerically modelled using finite element analysis to investigate the interaction between the UGWs, the material surface and the salt-spray particles. By tracking the motion of the particles, the researchers identified two key mechanisms: salt sprays on the surface can be removed by the shear stress produced by UGWs, and the high-frequency vibration of the surface slows down the deposition of salt-spray particles.
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Synergy with conventional anti-corrosive coatings
Four experimental groups were tested to compare the effect of UGWs on unprotected steel pipes and on steel pipes coated with three different anti-corrosive paints. The results show that the corrosion rate decreased by 33.5 % on unprotected pipes, by 45.8 % on epoxy-coated pipes, by 32.7 % on acrylic-coated pipes, and by 29.5 % on polyurethane-coated pipes. The epoxy system demonstrated the strongest synergistic effect when combined with the acoustic coating technique.
The findings indicate that the UGW-based “acoustic coating” can effectively prevent salt-spray corrosion of metals and extend the service life of conventional anti-corrosion coatings in aggressive marine atmospheric environments. The approach provides both a theoretical basis and a practical route for the physical anti-corrosion protection of metal pipes, with potential applications in offshore infrastructure, marine engineering and industrial pipeline systems.
Source: Qu, Z. et al., Acoustic coating – an active anti-corrosion technique using ultrasonic guided waves in marine atmospheric environment. Progress in Organic Coatings, 110187 (2026).
