Impact of metal corrosion on the process safety of foam fire suppression system

Abstract The long‐term storage of foam extinguishing agent may lead to metal corrosion, which poses substantial risks to the safety and operational reliability of fire suppression systems. This study systematically investigated the performance evolution of foam extinguishing agent interacting with aluminum alloys through accelerated aging tests under elevated temperatures. The results showed that the aluminum alloy surface underwent significant corrosion. Meanwhile, the expansion ratio of the foam decreased by 37.46% and 12.84%, accompanied by precipitation and gelation. Molecular dynamics simulation revealed the mechanism by which aluminum ions coordinate and bridge with xanthan gum through electrostatic interactions, leading to foam concentrate changes. Fire suppression tests demonstrated that prolonged contact between the foam extinguishing agent and metal materials leads to performance deterioration. Moreover, the aged extinguishing agent exhibited poor miscibility with water during discharge, thereby hindering the effective progression of the fire suppression process. The findings highlight the critical importance of compatibility between foam agent and metallic material in process safety management. These results provide a scientific basis for the full life‐cycle management of foam extinguishing agent and the maintenance of system reliability.