Tuning transition metals layered-electroplated on bimetallic MxCu1-x crystallites (M = Fe, Co, Ni, and Zn) to boost ammonia yield in electrocatalytic reduction of nitrate wastewaters.

Nitrate-containing wastewaters have been recognized as an important source for recovering valuable ammonia. This work targets integrating a series of transition metals (M = Fe, Co, Ni, and Zn) onto Cu crystallites through a layered-plating method. The strategy to promote the nitrate reduction reaction (NO3-RR) involves tuning M surfaces in specific ratios for the hydrogenation of nitrogenous species on MxCu1-x electrodes. Electrochemical analysis and operando Raman spectra identified that a solid-state Cu2O-to-Cu0 transition acted as the primary mediator, while its high corrosion resistance protected the M metals or metal oxides from inactivation in nitrate-to-ammonia pathways. Among bimetals, FeCu was the best combination, with the order of performance in constant potential electrolysis, Fe0.36Cu0.64 > Ni0.73Cu0.27 > Co0.34Cu0.66 > Zn0.64Cu0.36. The collaboration of Cu and M in deoxygenating nitrate and subsequently hydrogenating NOx at respective overpotentials is key to enhancing ammonia yield. Nitrate removal (96 %), NH3 selectivity (93 %), and Faradaic efficiency (92 %) were optimized on Fe0.36Cu0.64 electrode at -0.6 V (vs. RHE). A steady yield as high as 14,080 µg h-1 mg-1 was achieved at 30 mA cm-2 using a real water sample (NO3- ∼ 500 mg-N L-1, pH 4) as the input stream, continuously operated for 96 h.

Magnesium-promoted rapid self-reconstruction of NiFe-based electrocatalysts toward efficient oxygen evolution.

The acceleration of active sites formation through surface reconstruction is widely acknowledged as the crucial factor in developing high-performance oxygen evolution reaction (OER) catalysts for water splitting. Herein, a simple one-step corrosion method and magnesium (Mg)-promoted strategy are reported to develop the NiFe-based catalyst with enhanced OER performance. The Mg is introduced in NiFe materials to preparate a "pre-catalyst" Mg-Ni/Fe2O3. In-situ Raman shows that Mg doping would accelerate the self-reconstruction of Ni/Fe2O3 to form active NiOOH species during OER. In-situ infrared indicates that Mg doping benefits the formation of *OOH intermediate. Theoretical analysis further confirms that Mg doping can optimize the adsorption of oxygen intermediates, accelerating the OER kinetics. Accordingly, the Mg-Ni/Fe2O3 catalyst exhibits excellent OER performance with overpotential of 168 mV at 10 mA cm-2. The anion exchange membrane water electrolyzer achieved 200 mA cm-2 at voltage of 1.53 V, showing excellent stability over 500 h as well. This work demonstrates the potential of Mg-promoted strategy in regulating the activity of transition metal-based OER electrocatalysts.

The Fatigue Behavior of Narrow Single-body Titanium Implants in Saline and Acidic Media.

PURPOSE: The objective of this study was to examine how the saline and acidic environment affects the mechanical integrity of narrow single-body titanium implants for oral rehabilitation. MATERIALS AND METHODS: Thirty titanium-base alloy implants with 2.5 mm diameter were placed into a polyacetal holder and coupled to a stainless-steel prosthetic cap for fatigue testing in three different environments, as follows: dry air; saline solution (pH at 7.6); and lactic acid solution (pH at 3.4). The fracture surfaces were analyzed using a Scanning Electron Microscope (SEM). Also, finite element analysis was carried out to estimate the maximum von Mises stresses. RESULTS: The fatigue resistance was higher in the group tested in dry air (60%), followed by saline solution (30%) and lactic acid (10%). Regardless of the environment, fracture occurred at the same region of the failed specimens in line with the highest stress concentration spots, according to the finite element analysis. SEM analyses revealed two distinct failure regions, both with the presence of fatigue streaks: fatigue and overload. A high incidence of secondary cracks was also noticed on the specimens exposed to the solutions. CONCLUSIONS: The present study revealed that both saline and acidic solutions significantly affect the fatigue resistance of narrow dental implants. Critical regions of the narrow implants were also susceptible to cracks and plastic deformation that should be taken into consideration in planning for oral rehabilitation.

No signs of microbial-influenced corrosion of cast iron and copper in bentonite microcosms after 400 days.

High-level radioactive waste needs to be safely stored for a long time in a deep geological repository by using a multi-barrier system. In this system, suitable barrier materials are selected that ideally show long-term stability to prevent early radionuclide release into the biosphere. In this study, different container matals (copper and cast iron) and pore water compositions (Opalinus Clay pore water and saline cap rock solution) were combined with Bavarian bentonite in static batch experiments to investigate microbial-influenced corrosion. The increasing concentration of iron and copper in the solution as well as detected corrosion products on the metal surface are indicative of anaerobic corrosion of the respective metals during an incubation of 400 days at 37 °C. However, although the intrinsic microbial bentonite community was stimulated with either lactate or H2, an acceleration of cast iron- and copper corrosion did not occur. Furthermore, neither corrosive bacteria nor conventional bacterial corrosion products, such as metal sulfides, were detected in any of the analyzed samples. The analyses of geochemical parameters (e.g. ferrous iron-, iron-, copper- and potassium concentrations as well as redox potentials) showed significant changes in some cast iron- and copper-containing setups, but these changes did not correlate with the microbial community structure in the respective microcosms, as confirmed by statistical analyses. Hence, the analyzed Bavarian bentonite (type B25) showed no significant contribution to cast iron and copper corrosion under the applied conditions after 400 days of incubation. From this perspective, bentonite B25 could be a suitable candidate as a geotechnical barrier in future repositories.

Machine learning-based corrosion rate prediction of steel embedded in soil.

Predicting the corrosion rate for soil-buried steel is significant for assessing the service-life performance of structures in soil environments. However, due to the large amount of variables involved, existing corrosion prediction models have limited accuracy for complex soil environment. The present study employs three machine learning (ML) algorithms, i.e., random forest, support vector regression, and multilayer perception, to predict the corrosion current density of soil-buried steel. Steel specimens were embedded in soil samples collected from different regions of the Wisconsin state. Variables including exposure time, moisture content, pH, electrical resistivity, chloride, sulfate content, and mean total organic carbon were measured through laboratory tests and were used as input variables for the model. The current density of steel was measured through polarization technique, and was employed as the output of the model. Of the various ML algorithms, the random forest (RF) model demonstrates the highest predictability (with an RMSE value of 0.01095 A/m2 and an R2 value of 0.987). In light of the feature selection method, the electrical resistivity is identified as the most significant feature. The combination of three features (resistivity, exposure time, and mean total organic carbon) is the optimal scenario for predicting the corrosion current density of soil-buried steel.

Analysis of the Ag M4,5 EELS edge to study silver nanoparticle corrosion.

Electron energy loss spectra collected from fresh and corroded silver nanoparticles are compared with those from a number of reference materials, focusing on the M4,5 edge. Chemical shifts and changes in the energy loss near edge structure (ELNES) are described and found to be sufficient to distinguish metallic silver from chemically oxidised silver. The measurements, in conjunction with electron energy loss spectrum imaging, are used to assess the mechanisms for atmospheric corrosion of silver nanoparticles. We unambiguously assign the corrosion product under atmospheric conditions to be silver sulphide, but show the reaction process to be distinctly inhomogeneous, producing a variety of types of corroded particles. LAY DESCRIPTION: >Here, we use analytical electron microscopy to track the corrosion of silver nanoparticles and present chemical maps of the corrosion products. We show clear spectroscopic differences between metallic and corroded silver using the M4,5 electron energy loss spectral feature, which is not commonly studied. Our study shows that corrosion is due to interactions with sulphur in the atmosphere; and the corrosion is not uniform, but appears to develop from specific points on the surface of the nanoparticles.

Upcycling of Spent LiFePO4 Cathodes to Heterostructured Electrocatalysts for Stable Direct Seawater Splitting.

The pursuit of carbon-neutral energy has intensified the interest in green hydrogen production from direct seawater electrolysis, given the scarcity of freshwater resources. While Ni-based catalysts are known for their robust activity in alkaline water oxidation, their catalytic sites are prone to rapid degradation in the chlorine-rich environments of seawater, leading to limited operation time. Herein, we report a Ni(OH)2 catalyst interfaced with laser-ablated LiFePO4 (Ni(OH)2/L-LFP), derived from spent Li-ion batteries (LIBs), as an effective and stable electrocatalyst for direct seawater oxidation. Our comprehensive analyses reveal that the PO43- species, formed around L-LFP, effectively repels Cl- ions during seawater oxidation, mitigating corrosion. Simultaneously, the interface between in situ generated NiOOH and Fe3(PO4)2 enhances OH- adsorption and electron transfer during the oxygen evolution reaction. This synergistic effect leads to a low overpotential of 237 mV to attain a current density of 10 mA cm-2 and remarkable durability, with only a 3.3 % activity loss after 600 h at 100 mA cm-2 in alkaline seawater. Our findings present a viable strategy for repurposing spent LIBs into high-performance catalysts for sustainable seawater electrolysis, contributing to the advancement of green hydrogen production technologies.

Corrosion behavior of Ti-Pt-coated stainless steel for bipolar plates in polymer electrolyte membranes under water electrolysis conditions.

In this study, the corrosion behavior and degradation mechanism of Ti-Pt-coated stainless steel bipolar plates were investigated through electrochemical tests and surface analysis in a polymer electrolyte membrane water electrolysis (PEMWE) operating environment. The coated bipolar plate has a corrosion current density of only 1.68 × 10-8 A/cm2, which is an order of magnitude lower than that of the bare SS316L substrate (1.94 × 10-7 A/cm2), indicating that its corrosion resistance is superior to that of bare SS316L substrate. However, in the PEMWE operating environment, the protection efficiency of the coating and the corrosion resistance of the coated bipolar plate decreased. The degradation of the coated bipolar plate can be attributed to electrolyte penetration into the blistering areas of the coating layer with micro voids. Defects in the coating layer occur because of the pressure of oxygen gas generated within the coating layer under high-potential conditions, thereby exposing the substrate to the electrolyte and corrosion.

Research on a Method for Classifying Bolt Corrosion Based on an Acoustic Emission Sensor System.

High-strength bolts play a crucial role in ultra-high-pressure equipment such as bridges and railway tracks. Effective monitoring of bolt conditions is of paramount importance for common fault repair and accident prevention. This paper aims to detect and classify bolt corrosion levels accurately. We design and implement a bolt corrosion classification system based on a Wireless Acoustic Emission Sensor Network (WASN). Initially, WASN nodes collect high-speed acoustic emission (AE) signals from bolts. Then, the ReliefF feature selection algorithm is applied to identify the optimal feature combination. Subsequently, the Extreme Learning Machine (ELM) model is utilized for bolt corrosion classification. Additionally, to achieve high prediction accuracy, an improved goose algorithm (GOOSE) is employed to ensure the most suitable parameter combination for the ELM model. Experimental measurements were conducted on five classes of bolt corrosion levels: 0%, 25%, 50%, 75%, and 100%. The classification accuracy obtained using the proposed method was at least 98.04%. Compared to state-of-the-art classification diagnostic models, our approach exhibits superior AE signal recognition performance and stronger generalization ability to adapt to variations in working conditions.

An MeV Proton Irradiation Facility: DICE.

Materials applied in nuclear environments such as fission or fusion power-plants face severe conditions. The irradiation by neutrons induces thermal loads and irradiation damage. Furthermore, coolants in contact with the materials induce corrosion, which is particularly challenging for liquid salts intended for the next generation of fission reactors. A new device (DICE) is installed at the 3.5 MV accelerator at DIFFER for the accelerated testing of such materials under combined irradiation and corrosion conditions. The DICE enables irradiation of samples at temperatures of up to 1050 K and in contact with liquid salts. An integrated shielding and a low power temperature control concept based on radiation cooling enables high-duty cycle application in a standard accelerator laboratory. Ion currents of up to 30 µA are possible with continuous irradiation. This work outlines the technical concept of the device and presents the first data.

The Mechanical and Electrochemical Stability of Trimethysilane Plasma Nanocoatings Deposited onto Cobalt Chromium Cardiovascular Stents.

The objective of this study was to evaluate the coating integrity performance and corrosion protection property of trimethylsilane (TMS) plasma nanocoatings that were directly deposited onto cobalt chromium (CoCr) L605 cardiovascular stents. Hydrophilic surfaces were achieved for the TMS plasma nanocoatings that were deposited onto the coronary stents through NH3/O2 (2:1 molar ratio) plasma post-treatment. With a coating thickness of approximately 20-25 nm, the TMS plasma nanocoatings were highly durable and able to resist delamination and cracking from crimping and expansion by a Model CX with a J-Crimp Station. The stent surface that was evaluated by Scanning Electron Microscopy (SEM) and Energy-Dispersive X-ray Spectroscopy (EDS) showed no indications of pitting, corrosion, or adsorption products on either the luminal or abluminal surfaces of the stents, in contrast to the uncoated stent surface. The TMS plasma nanocoatings significantly enhanced the stent's corrosion resistance in immersion experiments that followed the ASTM F2129-15 corrosion protocol, evident in the increase of the open circuit potential (OCP) from 0.01 V for the uncoated L605 stent to 0.18 V for the plasma-nanocoated L605 stent, reducing potential cytotoxic metal ion release. Cyclic polarization (CP) curves show that the corrosion rate (density level) observed in plasma-nanocoated L605 stents was approximately half an order of magnitude lower than that of the uncoated stents, indicating improved corrosion protection of the stents. CP curves of the TMS plasma-nanocoated stents with different coating thicknesses show that, in the range of 20-65 nm, the coating thickness does not result in any difference in the corrosion resistance of the stents.

Phosphonic Acids as Corrosion Inhibitors and Adhesion Promoters for Organic Coatings and Bronze.

Currently used organic coatings for the protection of bronze sculptures have a relatively short lifespan as a consequence of strict requirements of conservation ethics, which limit the selection of coatings. For that reason, enhancement of the corrosion protection level and durability of appropriate coatings is needed. The aim of this work was to examine if corrosion protection of bronze by selected acrylic and polyurethane coatings could be improved by using two phosphonic acids, 16-phosphonohexadecanoic acid (COOH-PA) and 12-aminododecylphosphonic acid (NH2-PA). Electrochemical measurements (linear polarization and electrochemical impedance spectroscopy, EIS) were performed to gain an insight into the influence of these phosphonic acids on the performance of the coatings during a two-week exposure to artificial acid rain and a three-month outdoor exposure. Besides the influence on the corrosion protection level, the influence on the coating adhesion was examined as well. A pull-off test clearly confirmed that the studied phosphonic acids act as adhesion promoters of both polyurethane and acrylic coatings, while electrochemical studies revealed improvements in corrosion protection levels, especially in the case of the acrylic coating Paraloid B72.

Preparation and Characterization of Oxide Nanotubes on Titanium Surface for Use in Controlled Drug Release Systems.

Preventing or treating infections at implantation sites where the risk of bacterial contamination is high requires the development of intelligent drug delivery systems. The objective of this work was to develop a production method and characterization of fourth-generation oxide nanotubes on titanium grade 4 surface as a potential drug carrier. This study focused on the anodizing process; physico-chemical characterization using FE-SEM, EDS, and FTIR; in vitro corrosion resistance in an artificial saliva solution; and determining the drug release kinetics of gentamicin sulfate using UV-VIS. The anodizing process was optimized to produce fourth-generation oxide nanotubes in a fluoride-free electrolyte, ensuring rapid growth and lack of order. Results showed that the length of the oxide nanotubes was inversely proportional to the anodizing voltage, with longer nanotubes formed at lower voltages. The nanotubes were shown to have a honeycomb structure with silver particles co-deposited on the surface for antibacterial properties and were capable of carrying and releasing the antibiotic gentamicin sulfate in a controlled manner, following Fick's first law of diffusion. The corrosion resistance study demonstrates that the oxide nanotubes enhance the corrosion resistance of the titanium surface. The oxide nanotubes show promise in enhancing osseointegration and reducing post-implantation complications.

Turning Waste into Treasure: Invasive Plant Ambrosia trifida L Leaves as a High-Efficiency Inhibitor for Steel in Simulated Pickling Solutions.

High toxicity is the main reason for the limited application of traditional corrosion inhibitors. Herein, it is critical to find a green, efficient, and long-term stable alternative substitute for the hazardous and conventional corrosion inhibitor. Ambrosia trifida L is widely distributed in fields and riverside wetlands as an invasive plant in China. According to the concept of turning waste into treasure, the extract of Ambrosia trifida L leaves (ATL) has the potential to address this issue due to its natural origin and abundant presence of heterocyclic organics. Therefore, ATL, as a green corrosion inhibitor, is prepared for the first time via a simple water-based extraction method. FT-IR (Fourier transform infrared spectroscopy) and UV-Vis (UV-visible) indicate that ATL extract contains abundant heterocyclic organics with conjugated structures, which exhibit the potential to become a high-efficiency inhibitor. Notably, the active sites of ATL molecules and their interaction with Q235 steel at the molecular/atomic level are revealed via theoretical calculations. The highest Ebinding value observed for the major components in the ATL extract is 259.66 kcal/mol, implying a significant adsorption capacity. The electrochemical results verify that microdose ATL extract can prominently inhibit steel corrosion, and the highest inhibition efficiency (η) is 97.5% (1000 mg/L). Following immersion for 24 h, the η value is enhanced to 99.0%, indicating a reliable and long-term ATL extract protection film is formed on the steel surface in harsh acidic solutions. The results of the weight loss, SEM (scanning electron microscope), and LSCM (laser scanning confocal microscopy) are consistent with the above conclusions. Finally, this study anticipates providing theoretical support for developing novel green plant extract inhibitors and aiding in their application in industrial pickling environments.

Comparative Analysis of Coatings Applied for Anti-Corrosion Protection of Public Transport Vehicles' Structural Parts.

The conducted research focused on anti-corrosion systems applied for the protection of structural parts used in public transport vehicles. Detailed tests were carried out on samples taken from the brackets supporting the doors of a public transport bus. This work includes the results of the chemical analysis of the composition of snow-mud samples taken from the selected bus route and the results of laboratory tests performed on samples with various anti-corrosion coatings. Four types of samples made of S235JR steel with a zinc coating deposited by thermo-diffusion, electroplating, hot-dip zinc galvanization, and the cataphoresis method were tested. Both non-destructive tests-NDTs (the measurement of coating thickness and roughness, microscopic observations)-and destructive tests-DTs (scratch tests, salt chamber tests)-were performed. The conducted tests proved that the most effective method is the use of anti-corrosive hot-dip zinc coating.

Numerical Investigation of Fatigue Behavior in Ti-6Al-4V Orthopedic Hip Implants Subjected to Different Environments.

In this paper, hip implants made of Ti-6Al-4V titanium alloy are analyzed numerically using Extended Finite Element Method XFEM. The combined effect of corrosion and fatigue was considered here since this is a common cause of failure of hip implants. Experimental testing of Ti-6Al-4V alloy was performed to determine its mechanical properties under different working environments, including normal, salty, and humid conditions. The integrity and life of the hip implant were assessed using the Linear Elastic Fracture Mechanics (LEFM) approach. For this purpose, the conditional fracture toughness Kq using CT specimens from all three groups (normal, humid, salty conditions) were determined. This provided insight into how different aggressive environments affect the behavior of Ti-6Al-4V alloy; i.e., how much its resistance to crack growth would degrade depending on conditions corresponding to the real exploitation of hip implants. Next, analytical and XFEM analyses of fatigue behavior in terms of the number of cycles were performed for all three groups, and the obtained results showed good agreement, confirming the validity of the integrity assessment approach shown in this work, which also represented a novel approach since fatigue and corrosion effects were investigated simultaneously.

Numerical Simulation Study on the Corrosion Behaviour of Q345 Steel in a Simulated Marine Thermocline.

Changes in temperature, pH, dissolved oxygen content, and nutrients, which are key factors that cause metal corrosion, are common in marine thermoclines. To study the corrosion behaviours and reveal the corrosion mechanisms of metals in a marine thermocline, COMSOL 6.2 software is used in this paper. With this software, the corrosion behaviour of Q345 steel in a thermocline is numerically simulated, and a simulated marine thermocline is built indoors for experimental research purposes. The corrosion behaviour and mechanism of Q345 steel in a marine thermocline were investigated through numerical simulation, electrochemical testing, and corrosion morphology observation. After 21 days of immersion in the simulated marine thermocline, Q345 steel specimens at different depths are shown to have undergone vertical galvanic corrosion, with two anodes and two cathodes. At depths of 70 m and 150 m, the Q345 steel becomes the anode in the galvanic corrosion reaction, while at depths of 110 m and 190 m, the Q345 steel becomes the cathode in the galvanic corrosion reaction. The cathode is protected by the anode and has a relatively low corrosion rate. The main reason underlying these phenomena is that there are large differences in the dissolved oxygen contents and temperatures at different depths in a thermocline. The different dissolved oxygen contents lead to differences in the oxygen concentrations of Q345 steel specimens at various depths. These variations trigger galvanic coupling corrosion. Moreover, the difference in temperature further aggravates the degree of galvanic corrosion.

Advances in Nickel-Containing High-Entropy Alloys: From Fundamentals to Additive Manufacturing.

High-entropy alloys (HEAs) are recognized as a class of advanced materials with outstanding mechanical properties and corrosion resistance. Among these, nickel-based HEAs stand out for their impressive strength, ductility, and oxidation resistance. This review delves into the latest advancements in nickel-containing HEAs, covering their fundamental principles, alloy design strategies, and additive manufacturing techniques. We start by introducing HEAs and their unique properties, emphasizing the crucial role of nickel. This review examines the complex relationships between alloy composition, valence electron concentration (VEC), and the resulting crystal structures. This provides insights into design principles for achieving desired microstructures and mechanical properties. Additive manufacturing (AM) techniques like selective laser melting (SLM), electron beam melting (EBM), and laser metal deposition (LMD) are highlighted as powerful methods for fabricating intricate HEA components. The review addresses the challenges of AM processes, such as porosity, fusion defects, and anisotropic mechanical properties, and discusses strategies to mitigate these issues through process optimization and improved powder quality. The mechanical behavior of AM-processed nickel-based HEAs is thoroughly analyzed, focusing on compressive strength, hardness, and ductility. This review underscores the importance of microstructural features, including grain size, phase composition, and deformation mechanisms, in determining the mechanical performance of these alloys. Additionally, the influence of post-processing techniques, such as heat treatment and hot isostatic pressing (HIP) on enhancing mechanical properties is explored. This review also examines the oxidation behavior of nickel-containing HEAs, particularly the formation of protective oxide scales and their dependence on aluminum content. The interplay between composition, VEC, and oxidation resistance is discussed, offering valuable insights for designing corrosion resistant HEAs. Finally, this review outlines the potential applications of nickel-based HEAs in industries such as aerospace, automotive, and energy, and identifies future research directions to address challenges and fully realize the potential of these advanced materials.

Facilitating Oriented Dense Deposition: Utilizing Crystal Plane End-Capping Reagent to Construct Dendrite-Free and Highly Corrosion-Resistant (100) Crystal Plane Zinc Anode.

Dendrite growth and corrosion issues have significantly hindered the usability of Zn anodes, which further restricts the development of aqueous zinc-ion batteries (AZIBs). In this study, a zinc-philic and hydrophobic Zn (100) crystal plane end-capping reagent (ECR) is introduced into the electrolyte to address these challenges in AZIBs. Specifically, under the mediation of 100-ECR, the electroplated Zn configures oriented dense deposition of (100) crystal plane texture, which slows down the formation of dendrites. Furthermore, owing to the high corrosion resistance of the (100) crystal plane and the hydrophobic protective interface formed by the adsorbed ECR on the electrode surface, the Zn anode demonstrates enhanced reversibility and higher Coulombic efficiency in the modified electrolyte. Consequently, superior electrochemical performance is achieved through this novel crystal plane control strategy and interface protection technology. The Zn//VO2 cells based on the modified electrolyte maintained a high-capacity retention of ≈80.6% after 1350 cycles, corresponding to a low-capacity loss rate of only 0.014% per cycle. This study underscores the importance of deposition uniformity and corrosion resistance of crystal planes over their type. And through crystal plane engineering, a high-quality (100) crystal plane is constructed, thereby expanding the range of options for viable Zn anodes.

Study of microstructure and corrosion behavior of nano-Al2O3 coating layers on TiO2 substrate via polymeric method and microwave combustion.

The study describes the successful development of a TiO2 ceramic substrate with a protective nano-Al2O3 coating using two different coating techniques: microwave combustion and polymeric methods. The coated ceramics demonstrate enhanced corrosion resistance compared to the uncoated substrate. The optimal TiO2 substrate was prepared by firing it at 1000 °C. This was done to give the desired physical properties of the TiO2 substrate for the coating procedures. Nano-Al2O3 powder was coated onto the surface of the TiO2 substrates. The TiO2 substrates with the Al2O3 coating were then calcined (heat-treated) at 800 and 1000 °C. The structures, morphology, phase composition, apparent porosity, bulk density, and compressive strength of the substrate and coated substrate were characterized. Upon firing at 1000 °C, it was discovered that the two phases of TiO2-rutile and anatase-combine in the substrate. Once the substrate has been coated with nano Al2O3 at 1000 °C, the anatase is transferred into rutile. When compared to the substrate, the coated substrate resulted in a decrease in porosity and an increase in strength. The efficiency of the ceramic metal nanoparticles Al2O3 as a good coating material to protect the TiO2 substrates against the effect of the corrosive medium 0.5 M solution of H2SO4 was measured by two methods: potentio-dynamic polarization (PDP) and the electrochemical impedance spectroscopy (EIS). The results indicated that the corrosion rate was decreased after the substrate coated with alumina from (67.71 to 16.30 C.R. mm/year) and the percentage of the inhibition efficiency recorded a high value reaching (78.56%). The surface morphology and composition after electrochemical measurements are investigated using SEM and EDX analysis. After conducting the corrosion tests and all the characterization, the results indicated that the coated TiO2 substrate prepared by the polymeric method at 800 °C displayed the best physical, mechanical, and corrosion-resistant behavior.