Sustainable Marine Structures

Corrosion-Resistant Materials for Ocean Structures: Innovations, Mechanisms, and Applications

Deepika Sarode

Department of First Year Engineering, Dr. D. Y. Patil Institute of Technology, Sant Tukaram Nagar, Pimpri, Pune 411018, Maharashtra, India;  School of Technology and Research, Dr. D. Y. Patil Dnyan Prasad University, Sant Tukaram Nagar, Pimpri, Pune 411018, Maharashtra, India  

Upendrra Saharkar

Department of Civil Engineering, Dr. D. Y. Patil Institute of Engineering and Technology, Ambi 410506, Pune, SPPU, Maharashtra, India

Hemanshu Hari Ahire

Department of Civil Engineering, D. Y. Patil University, School of Engineering & Technology, Ambi 410507, Pune, Maharashtra, India

Milind Manikrao Darade

Civil Engineering Department, Anantrao Pawar College of Engineering and Research, Parvati, Pune 411009, Maharashtra, India

Sukhadip Mhankali Chougule

Department of Mechanical Engineering, PCET’s Pimpri Chinchwad College of Engineering and Research, Ravet, Pune 412101, Maharashtra, India

Sagar Arjun Dalvi

Department of Mechanical Engineering, Dr. Bapuji Salunkhe Institute of Engineering & Technology (BSIET), Tarabai Park, Kolhapur 416003, Maharashtra, India

Anant Sidhappa Kurhade

School of Technology and Research, Dr. D. Y. Patil Dnyan Prasad University, Sant Tukaram Nagar, Pimpri, Pune 411018, Maharashtra, India; Department of Mechanical Engineering, Dr. D. Y. Patil Institute of Technology (SPPU), Sant Tukaram Nagar, Pimpri, Pune 411018, Maharashtra, India  

DOI: https://doi.org/10.36956/sms.v7i3.2335

Received: 17 June 2025 | Revised: 24 June 2025 | Accepted: 7 July 2025 | Published Online: 23 July 2025

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Abstract

Offshore structures such as platforms, pipelines, the hulls of ships, wind turbine foundations, etc., are constantly subjected to harsh seawater environments with high salinity, changes in temperature, humidity, biological activity, etc. These conditions promote corrosion and jeopardize the service, safety and service life. In this study, recent developments in ocean materials for corrosion resistance are extensively reviewed. It classifies corrosion-resistant materials as metal alloys, nanocomposites, and nanostructured hybrid materials and discusses their performance, mechanisms of protection, and applications in the field. It treats high-performance materials such as stainless steels, Ni-based alloys, and Ti alloys, polymers and composites, ceramics, or even bio-inspired coatings. A comprehensive study including corrosion failure mechanisms, such as pitting, crevice, galvanic, microbiologically influenced, stress corrosion cracking (SCC), is provided to present a comprehensive view of the necessary selection of materials and corrosion control practices. Concurrently, the review presents protective technologies such as cathodic protection systems, anodizing, passivation, thermal spray coatings, as well as emerging ones such as plasma electrolytic oxidation and self-healing smart coatings. Advanced high entropy alloys, graphene barriers and additive manufacturing are stressed as they have the potential to disrupt marine corrosion protection. However, issues such as long-term performance verification, cost-performance ratio for optimal design, compatibility with on-line monitoring systems, and compliance with environmental standard still remain unsolved. The paper highlights significant research gaps and potential future directions in AI-enabled material design, green coatings, and development of digital corrosion management systems. In the end, this book is a great resource for engineers, researchers, and policymakers involved in the development of durable, efficient and ecologically friendly marine infrastructure.

Keywords: Marine Corrosion; Corrosion-resistant Materials; Ocean Structures; Protective Coatings; High-entropy Alloys; Offshore Engineering

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