We are pleased to announce that Dr. R. Vaira Vignesh, Assistant Professor (Selection Grade) – Research Track at Amrita School of Engineering, Coimbatore, has secured a three-year research grant from the Science and Engineering Research Board (SERB), under the Department of Science and Technology (DST), Government of India. The project titled “Development of Surface Composites of Magnesium-Rare Earth Alloy with Controlled Corrosion Kinetics by Friction Stir Processing for Sacrificial Anodic Applications” is a collaborative effort with the National Institute of Technology (NIT), Tiruchirappall

Project Overview and Outcomes

The primary aim of this research is to develop magnesium-rare earth (Mg-RE) alloy-based surface composites using Friction Stir Processing (FSP), specifically for sacrificial anode applications in marine environments. This project will focus on optimizing the corrosion kinetics of sacrificial anodes, which will ultimately help in reducing the frequency of their replacement in marine structures, ships, and offshore platforms. The outcome is expected to substantially lower maintenance costs and improve the longevity of these structures. The research also aims to test application-oriented studies at the component level, generating a comprehensive database for future studies on rare-earth-based magnesium alloys.

Key Emerging Areas and Contributions

1. Advanced Surface Composites: Development of Mg-RE alloy-based composites through FSP, optimizing properties for sacrificial anode applications.
2. Cathodic Protection Systems: Enhancing corrosion resistance in marine structures with sacrificial anodes that have controlled corrosion kinetics.
3. Sustainable Marine Solutions: Promoting eco-friendly materials for long-term protection in seawater environments.
4. High-Performance Alloys: Improving the durability of rare earth-based alloys in challenging marine conditions.

Applicability and Impact

The results of this project are poised to make a significant impact across various industries:

• Marine Industry: The project will help reduce the frequent replacement of sacrificial anodes, lowering the maintenance costs for ships, pipelines, and offshore structures.
• Defense & Shipping: The research will be crucial for the protection of naval ships and submarines.
• Renewable Energy: This work will contribute to the protection of offshore wind turbines from corrosion.
• Oil & Gas: The outcomes will provide enhanced corrosion protection for pipelines and offshore platforms exposed to seawater.

Moreover, this research has the potential for broader applications:

• Aerospace: Developing lightweight sacrificial anodes for aerospace components exposed to corrosive environments.
• Automotive: Offering corrosion protection solutions for vehicles, particularly in coastal regions.
• Infrastructure: Enhancing the durability of infrastructure like bridges and pipelines exposed to harsh environmental conditions.
• Medical Implants: Investigating biodegradable Mg-RE alloys for medical implants with controlled corrosion behavior.

Key Publications

The research team has already produced notable publications:

1. Venkata Sai Krishna Teja, P. Durga Karthik, Anem Lakshmi Manohar, P.G.S.S.S. Manogjna, R. Vaira Vignesh, A. Shanmugasundaram, P. Sathiya, N. Jeyaprakash, “Influence of Heat Treatments on the Corrosion, Electrochemical, and Sacrificial Anodic Performance of Mg-Er-Yb Alloy”, Journal of Solid State Electrochemistry (2025). DOI: 10.1007/s10008-024-06171-3.
2. Vaira Vignesh, P. Sathiya, “Sacrificial Anode Materials to Protect Marine Grade Steel Structures: A Review”, Corrosion Reviews (2024). DOI: 10.1515/corrrev-2023-0099.
3. S P Hariesh, Dhanyanth P V, S A Kughan, Dhanush K Babu, R. Vaira Vignesh, P. Sathiya, “Influence of Temperature and Thermal Cycles on the Corrosion Mechanism of Wrought AZ91D Magnesium Alloy in Simulated Sea Water Solution”, Koroze a Ochrana Materialu, vol. 66, no. 1, pp. 66-77 (2023). DOI: 10.2478/kom-2023-0009

Project Scaling and Future Vision

The innovative methods and findings from this project have the potential to be scaled to other areas, including aerospace, automotive, infrastructure, and medical implants. The research will provide a solid foundation for expanding the use of rare earth-based magnesium alloys beyond marine applications, opening up opportunities for diverse industries to benefit from enhanced corrosion protection.
This exciting project promises to make significant contributions to the development of sustainable, high-performance materials for critical applications across multiple sectors.