Sonochemical technologies in corrosion science and engineering: from laboratory studies to industrial perspectives

Corrosion causes substantial economic, safety, and environmental losses globally, motivating the development of advanced mitigation strategies. Recently, sonochemical technologies have emerged as versatile and powerful tools for actively controlling corrosion processes and understanding corrosion mechanisms. This review critically evaluates sonochemical principles and their role in corrosion and engineering. This review examines mechanisms of acoustic cavitation and their effects on metallic corrosion. Particular emphasis is placed on the interplay between sonophysical effects (microjet impregnation, shock waves, surface deformation, acoustic steaming) and sonochemical effects governing electrochemistry. The effect of ultrasound (US) parameters, such as power, reactor desing, exposure time, and frequency, is systematically presented in relation to diffusion-layer modulation, electrochemical performance, cavitation intensity, and coating densification. Beyond traditional effects, US is highlighted as a versatile tool that enhances interfacial adhesion, promotes surface activation, refines grain boundaries, and encourages uniform passivation-repassivation cycles, ultimately resulting in superior corrosion resistance. This review covers US-assisted corrosion protection strategies, with particular emphasis on efficient nanoparticle deagglomeration, intensified electrodeposition, enhanced corrosion-inhibitor adsorption, and improved coating integrity. Emerging US-enabled strategies, such as encapsulated corrosion inhibitors, US-grafted polymers, and self-healing coatings, are critically assessed. US is presented as a transformative technology in corrosion engineering, enabling controlled manipulation of surface phenomena despite potential cavitation damage. The work discusses potential pathways for industrial implementation, offers insights into emerging high-performance corrosion-mitigation strategies, and explores their potential for more resource-efficient processing. Despite significant advances, the competing effects of cavitation-induced degradation and corrosion mitigation remain poorly understood across material systems and operating conditions.