Abstract

The synergistic effect of sediment impact and corrosive media-such as CO2, H2S, Cl -during oil and gas exploitation have caused significant pipeline damage. Sediment impact diminishes the protective efficacy of coatings by inducing cracks, which accelerate the penetration of corrosive medium. The extrusion of the coating by the corrosion products at the film/substrate interface caused the coating to fall off due to stress concentration. To mitigate the influence of impact on the corrosion resistance, inspired by the exceptional impact resistance of coconut shells, a multilayer Si/HDLC coating with enhanced corrosion and impact performance was developed. The multilayer design of high-Si-doped DLC and low-Si-doped DLC reduces the internal stress of the coating. Furthermore, the deposition of a thick Si support layer improves the adhesion and impact resistance. This combination enables the coating to maintain excellent corrosion resistance even after impact. This work elucidates the synergistic interaction between impact and corrosion, offering a novel design idea for protective coatings in impact-prone environments. The protective coating with excellent corrosion and impact resistance for pipelines during oil and gas exploitation was provided.

Keywords Plus: DIAMOND-LIKE CARBON，A-C-H，MECHANICAL-PROPERTIES，IMPEDANCE MODELS，STAINLESS-STEEL，NACL SOLUTION，DLC FILM，BEHAVIOR，H2S，SI

Published in CHEMICAL ENGINEERING JOURNAL，Volume526；10.1016/j.cej.2025.171065，DEC 15 2025