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High-performance corrosion resistance of plasma-deposited thin C:H:N films onto carbon steel alloys in an acidic medium

  • Alaa Fahmy ORCID logo EMAIL logo , Safwat Hassaballa , Abdullah A. Moustafa ORCID logo EMAIL logo and Mahmoud A. Bedair
Published/Copyright: September 23, 2025
Zeitschrift für Physikalische Chemie
From the journal Zeitschrift für Physikalische Chemie Volume 239 Issue 11-12

Abstract

Nitrogen-doped hydrogenated amorphous carbon (a-C:H:N) films were synthesized via plasma-activated chemical vapor deposition (PACVD) using a capacitively coupled RF plasma (RF-CCP) source to address the critical challenge of carbon steel corrosion in acidic environments. This study is motivated by the urgent need to replace toxic corrosion inhibitors and improve upon conventional nitriding methods that typically offer <80 % protection in hydrochloric acid. We systematically investigated the effects of plasma power (400–700 W), treatment time (5–20 min), and N2/C2H2 gas ratios (0–100 % N2) on film properties and corrosion resistance in 1.0 M HCl. Electrochemical measurements revealed exceptional corrosion inhibition efficiencies (IE %) of 99.3 % for C2H2-derived films and 99.1 % for N2/C2H2 (75/25 %) mixtures – the highest reported values for plasma-treated steel in acidic media. Tafel analysis showed these films preferentially inhibit anodic reactions, reducing corrosion current density from 400 μA/cm2 (untreated steel) to just 2.7 μA/cm2. Surface characterization demonstrated that optimal films combine a hydrophobic carbon matrix (30.23 at.% C by EDX) with nitrogen functionalities (0.68 at.% N), forming a nanostructured barrier that resists acid penetration (SEM). The 700 W, 20 min N2 treatment achieved 97.7 % IE %, while shorter 10 min treatments maintained 97.6 % efficiency, suggesting energy-saving potential. These results establish that a-C:H:N films deposited at room temperature can provide near-complete corrosion protection through two mechanisms: (1) C–H network formation at high power and (2) synergistic N-doping that enhances passivation. The study provides a scalable, environmentally friendly alternative to conventional coatings for industrial applications involving acid exposure, with quantified performance benchmarks that surpass existing plasma-based methods.

Keywords: plasma deposition; surface treatments; carbon steel; corrosion resistance; acetylene; N2 gas
Corresponding authors: Alaa Fahmy, Petrochemicals Department, Faculty of Engineering, Pharos University in Alexandria, Alexandria, Egypt; and Bundesanstalt für Materialforschung und -prüfung (BAM), Unter den Eichen 87, 12205 Berlin, Germany, E-mail: ; and Abdullah A. Moustafa, General Manager of Technical Management and Technical Consultant for General Force Battery Manufacturing Company, El Salhiya, Al Sharqia, Egypt, E-mail:

Acknowledgement

The authors are thankful to the Deanship of Graduate Studies and Scientific Research at the University of Bisha for supporting this work through the Fast-Track Research Support Program.

  1. Research ethics: Not applicable.

  2. Informed consent: Not applicable.

  3. Author contributions: The authors have accepted responsibility for the entire content of this manuscript and approved its submission.

  4. Use of Large Language Models, AI and Machine Learning Tools: None declared.

  5. Conflict of interest: The authors declare that they have no known competing financial interests or personal relationships that could have appeared to influence the work reported in this paper.

  6. Research funding: None declared.

  7. Data availability: The data supporting this article have been included in the publication.

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Received: 2024-10-13
Accepted: 2025-08-11
Published Online: 2025-09-23
Published in Print: 2025-12-17

© 2025 Walter de Gruyter GmbH, Berlin/Boston

Articles in the same Issue

  1. Frontmatter
  2. Review Article
  3. A review on synthesis and studies on CoMn2O4/ nanocomposite (metal oxide/metal sulphide/carbon material) based electrodes in view of supercapacitor applications
  4. Original Papers
  5. High-performance corrosion resistance of plasma-deposited thin C:H:N films onto carbon steel alloys in an acidic medium
  6. Zur Physikalischen Chemie des Treibhaus-Effekts
  7. Chemical potential of iron in systems of low dimensionality
  8. Optimized triplex nanomaterial all-around gate tunnel field-effect transistors for high-precision biomolecule detection
https://doi.org/10.1515/zpch-2024-1009
Keywords for this article
plasma deposition; surface treatments; carbon steel; corrosion resistance; acetylene; N2 gas

Articles in the same Issue

  1. Frontmatter
  2. Review Article
  3. A review on synthesis and studies on CoMn2O4/ nanocomposite (metal oxide/metal sulphide/carbon material) based electrodes in view of supercapacitor applications
  4. Original Papers
  5. High-performance corrosion resistance of plasma-deposited thin C:H:N films onto carbon steel alloys in an acidic medium
  6. Zur Physikalischen Chemie des Treibhaus-Effekts
  7. Chemical potential of iron in systems of low dimensionality
  8. Optimized triplex nanomaterial all-around gate tunnel field-effect transistors for high-precision biomolecule detection
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