Aditya Venkatraman, Ryan Michael Katona, Demitri Maestas, Matthew Roop, Philip Noell, David Montes de Oca Zapiain
{"title":"An active learning framework for the rapid assessment of galvanic corrosion","authors":"Aditya Venkatraman, Ryan Michael Katona, Demitri Maestas, Matthew Roop, Philip Noell, David Montes de Oca Zapiain","doi":"10.1038/s41529-024-00476-4","DOIUrl":"10.1038/s41529-024-00476-4","url":null,"abstract":"The current present in a galvanic couple can define its resistance or susceptibility to corrosion. However, as the current is dependent upon environmental, material, and geometrical parameters it is experimentally costly to measure. To reduce these costs, Finite Element (FE) simulations can be used to assess the cathodic current but also require experimental inputs to define boundary conditions. Due to these challenges, it is crucial to accelerate predictions and accurately predict the current output for different environments and geometries representative of in-service conditions. Machine learned surrogate models provides a means to accelerate corrosion predictions. However, a one-time cost is incurred in procuring the simulation and experimental dataset necessary to calibrate the surrogate model. Therefore, an active learning protocol is developed through calibration of a low-cost surrogate model for the cathodic current of an exemplar galvanic couple (AA7075-SS304) as a function of environmental and geometric parameters. The surrogate model is calibrated on a dataset of FE simulations, and calculates an acquisition function that identifies specific additional inputs with the maximum potential to improve the current predictions. This is accomplished through a staggered workflow that not only improves and refines prediction, but identifies the points at which the most information is gained, thus enabling expansion to a larger parameter space. The protocols developed and demonstrated in this work provide a powerful tool for screening various forms of corrosion under in-service conditions.","PeriodicalId":19270,"journal":{"name":"npj Materials Degradation","volume":null,"pages":null},"PeriodicalIF":5.1,"publicationDate":"2024-05-21","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://www.nature.com/articles/s41529-024-00476-4.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"141118022","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
{"title":"Short-time high-temperature oxidation behavior of nanocrystalline Ta coating at 850 °C","authors":"Yunsong Niu, Lingling Xing, Shenglong Zhu, Jinfeng Huang, Minghui Chen, Fuhui Wang, Qiang Chen","doi":"10.1038/s41529-024-00465-7","DOIUrl":"10.1038/s41529-024-00465-7","url":null,"abstract":"Short-time oxidation behavior of nanocrystalline Ta coating is studied at 850 °C in comparison with that of the Ta sheet. Owing to the large PBR value and insufficient expansion space, the oxide scale on Ta sheet is dramatically cracked, delaminated and pulverized, resulting in rapid deterioration. For nanocrystalline Ta coatings with columnar structures and quantitative grain boundaries, a rapid oxygen diffusion rate causes no initial Ta2O5 to form. The gap between columns provides spaces for bulk expansion, resulting in few opening cracks and delamination. Ta oxidation experiences a crystallization course from amorphous Ta oxide, leading to in situ temperature surging and thus pulverization.","PeriodicalId":19270,"journal":{"name":"npj Materials Degradation","volume":null,"pages":null},"PeriodicalIF":5.1,"publicationDate":"2024-05-17","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://www.nature.com/articles/s41529-024-00465-7.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140962311","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Priyanka Adapala, Thomas Avey, Yudie Yuan, Mary Lyn Lim, Ganesh Bhaskaran, Sazol Das, Alan Luo, Gerald S. Frankel
{"title":"Understanding the effect of microstructure and composition on localized corrosion susceptibility of 6xxx aluminum alloys","authors":"Priyanka Adapala, Thomas Avey, Yudie Yuan, Mary Lyn Lim, Ganesh Bhaskaran, Sazol Das, Alan Luo, Gerald S. Frankel","doi":"10.1038/s41529-024-00461-x","DOIUrl":"10.1038/s41529-024-00461-x","url":null,"abstract":"The corrosion performance of 6xxx series Al alloys has been found to depend on small changes in composition and microstructure. The corrosion behaviors of three aluminum alloys, AA6111, AA6451, and AA6016, were investigated. AA6111, containing primarily α (Al15 (Fe,Mn)3Si2) intermetallic particles (IMPs), and AA6016, containing primarily β (Al8Fe2Si) IMPs, exhibited the best and the worst overall corrosion performances, respectively, as indicated by the extent of corrosion in exposure tests. However, this ranking was not predicted by the standard interpretation of potentiodynamic polarization curves measured on the alloys. The corrosion susceptibilities of the three alloys were further investigated by evaluating the electrochemical behavior of the component phases separately. Bulk analogs of the component phases were fabricated using standard alloy casting techniques. The fabricated bulk analogs of α and β IMPs, as well as the three alloy matrix phases, were tested using either macrocell or microcell testing. An explanation for the alloy performances was developed by combining the behavior of the component phases.","PeriodicalId":19270,"journal":{"name":"npj Materials Degradation","volume":null,"pages":null},"PeriodicalIF":5.1,"publicationDate":"2024-05-14","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://www.nature.com/articles/s41529-024-00461-x.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140924940","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Leandro Vaccari, Thomas Scheithauer, Ivan Lendiel, Jan Klett, Thomas Hassel, Hans Jürgen Maier
{"title":"Corrosion behavior of austenitic stainless steel and nickel-based welded joints in underwater wet welding","authors":"Leandro Vaccari, Thomas Scheithauer, Ivan Lendiel, Jan Klett, Thomas Hassel, Hans Jürgen Maier","doi":"10.1038/s41529-024-00471-9","DOIUrl":"10.1038/s41529-024-00471-9","url":null,"abstract":"Marine structures such as ports, bridges, pipelines, vessels, and platforms are an essential part of modern infrastructure, where the use of higher-strength steel provides savings in logistics and construction. However, the repair of higher-strength steels can be challenging, especially underwater. Wet shielded metal arc welding is the most widely used and least expensive method for underwater welding repairs, but is very susceptible to hydrogen-induced cracking. Thus, researchers and welding engineers aim to reduce the amount of hydrogen in the weld material. Recent success has been achieved through the use of austenitic welding consumables, such as austenitic stainless steel and nickel-based electrodes. The use of these consumables drastically reduces the amount of diffusible hydrogen in the weld metal. However, these austenitic materials usually have different corrosion potential as compared to the structural steel the weld beads are applied to. This creates the risk of severe galvanic corrosion. In the presented study, the corrosion behavior of welds created with austenitic stainless steel and nickel-based electrodes were studied. Samples were aged for 1.5 years in the Baltic Sea. Simultaneously, the effectiveness of corrosion protection systems such as coating and Impressed Current Cathodic Protection (ICCP) were evaluated. Localized corrosion occurred in the heat-affected zone when austenitic electrodes were used in the corrosive environment. The localized corrosion depth after 1.5 years in the Baltic Sea and in the salt spray layer was approximately 250 µm and 390 µm, respectively. The ICCP system and the use of a coating were effective in preventing localized corrosion. The low pitting corrosion density of 2.5 × 103 m−2 corresponds to grade A1 according to the standard and was found to be negligible as compared to the localized corrosion in the heat-affect zone.","PeriodicalId":19270,"journal":{"name":"npj Materials Degradation","volume":null,"pages":null},"PeriodicalIF":5.1,"publicationDate":"2024-05-11","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://www.nature.com/articles/s41529-024-00471-9.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140907144","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
{"title":"Localized corrosion in selective laser melted SS316L in CO2 and H2S brines at elevated temperatures","authors":"Deeparekha Narayanan, Alan Martinez, Ulises Martin, Bilal Mansoor, Raymundo Case, Homero Castaneda","doi":"10.1038/s41529-024-00468-4","DOIUrl":"10.1038/s41529-024-00468-4","url":null,"abstract":"In this work, the passivation and localized corrosion of selective laser melted (SLM) stainless steel 316 L when exposed to high pressures of CO2 with the presence of H2S and Cl− at 25 °C and 125 °C were studied. Depletion of Cr/Mo was observed at the cell interiors and melt-pool boundaries (MPBs) compared to the cell boundaries. Volta potential differences obtained from scanning Kelvin probe force microscopy (SKPFM) showed that the MPBs were 8–20 mV lower than the matrix, while the cell interiors were 20–50 mV lower than the cell boundaries. Electrochemical impedance spectroscopy (EIS) and Mott–Schottky tests indicated a more defective passive film at 125 °C, and X-ray photoelectron spectroscopy (XPS) confirmed the formation of a less protective film with an increased S/O ratio at 125 °C than 25 °C. Initiation of localized corrosion was observed at the MPBs and pits formed after a week of immersion were wider by an order of magnitude at 125 °C than 25 °C, with evidence of cell-interior dissolution. While passivity was observed even at elevated temperatures, local chemical heterogeneities compromised the stability of the film and contributed to localized corrosion in SLM SS316L.","PeriodicalId":19270,"journal":{"name":"npj Materials Degradation","volume":null,"pages":null},"PeriodicalIF":5.1,"publicationDate":"2024-05-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://www.nature.com/articles/s41529-024-00468-4.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140902849","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Steffen Wackenrohr, Christof Johannes Jaime Torrent, Sebastian Herbst, Florian Nürnberger, Philipp Krooss, Johanna-Maria Frenck, Christoph Ebbert, Markus Voigt, Guido Grundmeier, Thomas Niendorf, Hans Jürgen Maier
{"title":"Corrosion fatigue behavior of nanoparticle modified iron processed by electron powder bed fusion","authors":"Steffen Wackenrohr, Christof Johannes Jaime Torrent, Sebastian Herbst, Florian Nürnberger, Philipp Krooss, Johanna-Maria Frenck, Christoph Ebbert, Markus Voigt, Guido Grundmeier, Thomas Niendorf, Hans Jürgen Maier","doi":"10.1038/s41529-024-00470-w","DOIUrl":"10.1038/s41529-024-00470-w","url":null,"abstract":"Due to its excellent biocompatibility, pure iron is a very promising implant material, but often features corrosion rates that are too low. Using additive manufacturing and modified powders the microstructure and, thus, the material properties, e.g., the corrosion properties, can be tailored for specific applications. Within the scope of this study, pure iron powder was modified with different amounts of CeO2 or Fe2O3 nanoparticles and subsequently processed by Electron Beam Powder Bed Fusion (PBF-EB/M). The corrosion-fatigue behavior of CeO2 and Fe2O3 modified iron was investigated using rotation bending tests under the influence of simulated body fluid (m-SBF). While the modification using Fe2O3 showed reduced fatigue and corrosion-fatigue strengths, it could be demonstrated that the modification with CeO2 is characterized by improved fatigue properties. The superior fatigue properties in air are attributed to the positive impact of dispersion strengthening. Additionally, an increased degradation rate compared to pure iron could be observed, eventually promoting an earlier failure of the specimens in the corrosion fatigue tests.","PeriodicalId":19270,"journal":{"name":"npj Materials Degradation","volume":null,"pages":null},"PeriodicalIF":5.1,"publicationDate":"2024-05-08","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://www.nature.com/articles/s41529-024-00470-w.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140881230","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Clara Linder, Bharat Mehta, Salil Sainis, Johan B. Lindén, Caterina Zanella, Lars Nyborg
{"title":"Corrosion resistance of additively manufactured aluminium alloys for marine applications","authors":"Clara Linder, Bharat Mehta, Salil Sainis, Johan B. Lindén, Caterina Zanella, Lars Nyborg","doi":"10.1038/s41529-024-00459-5","DOIUrl":"10.1038/s41529-024-00459-5","url":null,"abstract":"Additive manufacturing opens new possibilities for designing light-weight structures using aluminium alloys. The microstructure of two Al alloys and their corrosion resistance in NaCl and natural seawater environments were investigated. The newly designed Al-Mn-Cr-Zr based alloy showed a higher corrosion resistance than reference AlSi10Mg alloy in both environments in as printed and heat-treated conditions. The corrosion initiated in the Al matrix along the precipitates in the alloys where the Volta potential difference was found the highest. The coarser microstructure and precipitate composition of the new Al-alloy led to the formation of a resistant passive film which extended the passivity region of the Al-Mn-Cr-Zr alloy compared to the AlSi10Mg alloy. The effect of heat treatment could be seen in the microstructure as more precipitates were found in between the melt pool boundaries, which affected the corrosion initiation and slightly the pitting resistance. Overall, this study shows that a newly designed Al-alloy for additive manufacturing has a suitable corrosion resistance for applications in marine environments.","PeriodicalId":19270,"journal":{"name":"npj Materials Degradation","volume":null,"pages":null},"PeriodicalIF":5.1,"publicationDate":"2024-05-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://www.nature.com/articles/s41529-024-00459-5.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140834038","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
{"title":"Effect of hydrogen embrittlement on mechanical characteristics of DLC-coating for hydrogen valves of FCEVs","authors":"Dong-Ho Shin, Seong-Jong Kim","doi":"10.1038/s41529-024-00460-y","DOIUrl":"10.1038/s41529-024-00460-y","url":null,"abstract":"Diamond-like carbon (DLC) coating is a surface coating technology with excellent hydrogen permeation resistance and wear resistance. However, it is difficult to completely prevent hydrogen permeation, and when hydrogen penetrates into the coating layer, the DLC coating is adversely affected. Therefore, we investigated the effect of hydrogen embrittlement on the adhesion strength and wear resistance of the DLC coating layer. As the results of the research, the surface roughness of the DLC coating was increased by a maximum of 3.8 times with hydrogen charging, and the delamination ratio of the DLC coating reached about 58%. In addition, the Lc3, which refers to the adhesion strength corresponding to the complete delamination of the DLC coating, was decreased by a maximum of 2.0 N due to hydrogen permeation. In addition, the wear resistance decreased due to hydrogen permeation, and the exposed width of the substrate due to wear increased by more than 4 times. It was also determined that hydrogen blistering or hydrogen-induced cracking occurred at the interface between the DLC coating and the chromium buffer layer due to hydrogen permeation, which decreased the durability of the DLC coating.","PeriodicalId":19270,"journal":{"name":"npj Materials Degradation","volume":null,"pages":null},"PeriodicalIF":5.1,"publicationDate":"2024-05-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://www.nature.com/articles/s41529-024-00460-y.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140834161","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Shuyu Li, Hao Li, Yan Zhang, Wei Yang, Peng Guo, Xiaowei Li, Kazuhito Nishimura, Peiling Ke, Aiying Wang
{"title":"Dense Al2O3 sealing inhibited high hydrostatic pressure corrosion of Cr/GLC coating","authors":"Shuyu Li, Hao Li, Yan Zhang, Wei Yang, Peng Guo, Xiaowei Li, Kazuhito Nishimura, Peiling Ke, Aiying Wang","doi":"10.1038/s41529-024-00469-3","DOIUrl":"10.1038/s41529-024-00469-3","url":null,"abstract":"The corrosion failure of amorphous carbon (a-C) coatings is commonly ascribed to the existence of growth microdefects, which serve as pathways for corrosive fluids to permeate the substrate. Atomic layer deposition (ALD) is renowned for its ability to augment the corrosion resistance of metallic materials. Graphite-like carbon (GLC) is one of the amorphous carbon materials dominated by hybridized sp2-C bonds. In this study, an ALD-deposited Al2O3 layer is specially introduced on the Cr/GLC multilayer coating to solve the aforementioned corrosion risk of a-C by taking the sealing conception for defects. Compared to the as-deposited Cr/GLC coating, the coating encapsulated with Al2O3 layer depicts the reduction of corrosion current density over two orders of magnitude under a wide pressure range of 0.1 ~ 15 MPa. Particularly, the presence of released Crn+ and Fen+ in the corrosion solution is significantly diminished, accompanying with a small quantity of Aln+ generated in sealed coating during corrosion. Microstructural analysis and electrochemical results identified that both the dense Al2O3 layer offered strong safeguard for Cr elements released from multilayers, whilst amorphous carbon network inhibited the likelihood chloride penetration induced by partially infiltrated Al2O3, which made the synergistic contributions to the enhancement of corrosion resistance for Cr/GLC coating for deep-sea applications.","PeriodicalId":19270,"journal":{"name":"npj Materials Degradation","volume":null,"pages":null},"PeriodicalIF":5.1,"publicationDate":"2024-05-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://www.nature.com/articles/s41529-024-00469-3.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140833874","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Evan DelVecchio, Tiffany Liu, Yen-Ting Chang, Yuheng Nie, Maryam Eslami, Marie A. Charpagne
{"title":"Metastable cellular structures govern localized corrosion damage development in additive manufactured stainless steel","authors":"Evan DelVecchio, Tiffany Liu, Yen-Ting Chang, Yuheng Nie, Maryam Eslami, Marie A. Charpagne","doi":"10.1038/s41529-024-00464-8","DOIUrl":"10.1038/s41529-024-00464-8","url":null,"abstract":"The rapid solidification associated with additive manufacturing (AM) leads to complex microstructures with peculiar features amongst which cellular solidification structures are the most remarkable. These metastable structures possess a clear segregation pattern dictated by the solidification pathway of the alloy and are bounded by dislocation walls. While they confer exceptional strength and ductility to AM 316L stainless steel, their effect on localized corrosion in chloride environments remains to be established. Here, we employ correlative electron microscopy to reveal coupled chemical, electrochemical, and crystallographic effects on localized corrosion attack and its development. We show that the Cr and Mo-depleted interior of the cellular solidification structures dissolves selectively, giving rise to an intricate damage morphology, that is directly related to the underlying crystallographic orientation. Whereas surface observations only reveal apparently shallow micrometer-size cavities, 3D tomography via focused ion beam serial-sectioning shows a high degree of connectivity between these features underneath the surface. We reveal this intricate morphology, propose a formation mechanism, and discuss alloy design guidelines to mitigate this phenomenon.","PeriodicalId":19270,"journal":{"name":"npj Materials Degradation","volume":null,"pages":null},"PeriodicalIF":5.1,"publicationDate":"2024-04-30","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://www.nature.com/articles/s41529-024-00464-8.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140817301","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}