Corrosion Science最新文献

{"title":"The evolution process of rust layer formed on the surface of low-alloy steels in simulated marine atmospheric environment","authors":"Qingfeng Hou ,&nbsp;Yuxin Qi ,&nbsp;Rong Chen ,&nbsp;Haitao Wang ,&nbsp;Chao Xiang ,&nbsp;En-Hou Han","doi":"10.1016/j.corsci.2025.113372","DOIUrl":"10.1016/j.corsci.2025.113372","url":null,"abstract":"<div><div>A rust layer formed on the surface of the weathering steel sample after a 288-hour wet/dry cyclic corrosion test simulating a marine atmospheric environment. The results indicate that the degree of crystallization of the rust near the metal is poor, and corrosion products accumulate into a rust layer characterized by good adhesion and a dense structure, as observed through FIB-TEM analysis. The degree of crystallization of the corrosion products is slightly better in the band-like rust and the band-like rust achieves the secondary allocation of elements in the rust layer. Additionally, CuFeO₂ nanocrystalline formed in the band-like rust and phosphate with chromium ions is dispersed in rust near the metal exhibiting a synergistic effect in enhancing rust protection capability. This work analyzes the transformation behavior of corrosion products by characterizing the rust layer of samples subjected to indoor simulated atmospheric corrosion, thereby deepening the understanding of the evolution process of the rust layer.</div></div>","PeriodicalId":290,"journal":{"name":"Corrosion Science","volume":"258 ","pages":"Article 113372"},"PeriodicalIF":7.4,"publicationDate":"2025-09-29","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145189564","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Grain/phase boundary engineering and high Cr contents enhancing oxidation resistance of dual-phase multi-principal component alloys","authors":"Huijie Wei ,&nbsp;Ping Huang ,&nbsp;Fei Wang","doi":"10.1016/j.corsci.2025.113369","DOIUrl":"10.1016/j.corsci.2025.113369","url":null,"abstract":"<div><div>The oxidation behavior of dual-phase FeCrNiAlTi multi-principal component alloys (MCAs) with tailored grain/phase boundaries (GBs/PBs) lengths was systematically investigated by isothermal oxidation at 800℃ in air. Experimental results demonstrate that GBs/PBs engineering, when coupled with chemical composition tuning, yields a significant enhancement of oxidation resistance. The alternating distribution of face-centered cubic (FCC) and body-centered cubic (BCC) grains with short interphase distances facilitates lateral oxide growth along boundaries, promoting the formation of a continuous oxide film. Specifically, prolonged GBs/PBs lengths (up to 320.472 mm⁻¹) and high Cr content in BCC phases (54.20 %) accelerate the diffusion kinetics of protective elements (Al/Cr) during initial oxidation, enabling rapid formation of dense, continuous oxidation scales composed of Al₂O₃ and Cr₂O₃. Notably, the continuous Al₂O₃ layer acts as an effective barrier, suppressing subsequent outward Cr diffusion and inward oxygen ingress, thereby decelerating oxidation kinetics (parabolic rate constant <em>k</em>_<em>p</em> = 0.19 ×10⁻³ mg²·cm⁻⁴·h⁻¹) and outperforming many previously reported MCAs. This work highlights that GBs/PBs engineering, coupled with chemical composition adjustment, offers a viable pathway for developing high-performance MCAs for high-temperature structural applications.</div></div>","PeriodicalId":290,"journal":{"name":"Corrosion Science","volume":"258 ","pages":"Article 113369"},"PeriodicalIF":7.4,"publicationDate":"2025-09-28","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145189565","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Corrosion susceptibility of different microstructural zones in X65 steel weld joints under supercritical CO2 environment","authors":"Xinxin Fan ,&nbsp;Guangyu Liu ,&nbsp;Cailin Wang ,&nbsp;Qihui Hu ,&nbsp;Yuxing Li","doi":"10.1016/j.corsci.2025.113359","DOIUrl":"10.1016/j.corsci.2025.113359","url":null,"abstract":"<div><div>In light of the significant research gap concerning the corrosion behavior of welded joints under supercritical CO₂ pipeline conditions, this study introduces an in-situ monitoring system based on electrochemical noise. A comprehensive investigation was carried out using a supercritical CO₂ corrosion testing platform integrated with multiple characterization techniques, including EBSD, SEM, and 3D profilometry, to evaluate the influence of moisture content and microstructural features on the corrosion susceptibility of X65 steel welded joints. The results indicate that under varying moisture conditions in supercritical CO₂, the heat-affected zone (HAZ) exhibited the highest uniform corrosion rate (0.0946 mm/y) and localized corrosion rate (1.946 mm/y) among the base metal, weld zone, and HAZ. EN analysis revealed the coexistence of both stable and metastable pitting in all specimens. Notably, the HAZ showed the highest electrochemical potential noise (EPN) amplitude (0.24 V) and electrochemical current noise (ECN) amplitude (1.08 × 10⁻⁸ A), along with the shortest fluctuation period (413 s), confirming its pronounced corrosion susceptibility. Microstructural analysis further revealed that the ultrafine-grained structure of the HAZ possessed the highest grain boundary density, with KAM values reaching 1.8°. The combined effects of grain refinement, elevated grain boundary density, and residual stress were identified as the primary contributors to the corrosion mechanisms in the HAZ.</div></div>","PeriodicalId":290,"journal":{"name":"Corrosion Science","volume":"258 ","pages":"Article 113359"},"PeriodicalIF":7.4,"publicationDate":"2025-09-26","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145189566","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"New insights into intergranular corrosion mechanism of high-strength Al-Zn-Mg-Cu alloys","authors":"Hao Liu ,&nbsp;Liankui Wu ,&nbsp;Fahe Cao ,&nbsp;Qingqing Sun","doi":"10.1016/j.corsci.2025.113364","DOIUrl":"10.1016/j.corsci.2025.113364","url":null,"abstract":"<div><div>This study provides new insights into the intergranular corrosion (IGC) mechanism of high-strength Al-Zn-Mg-Cu alloys (i.e., 7000 series Al alloys). Utilizing FIB, SEM, and TEM techniques, the microstructural evolution of 7055, 7150, and 7085 Al alloys during IGC in 3.5 wt% NaCl solution was characterized. Results confirm that IGC preferentially initiates at anodic grain boundary precipitates (GBPs, MgZn₂) and propagates along precipitation-free zones (PFZs) and the adjacent aluminum matrix. Furthermore, nano/submicro-scale Al₂Cu precipitates (50 ∼ 300 nm) and Cu clusters (∼50 nm) distributed along the corroded grain boundaries serve as active cathodic phases, promoting IGC propagation through PFZs while simultaneously accelerating localized dissolution of the adjacent aluminum matrix. This cathodic acceleration contributes to a characteristic corrosion width of 100 ∼ 300 nm within the aluminum matrix. ‌The discovery of Al₂Cu precipitates/Cu clusters and their roles in intergranular corrosion has significantly enhanced the understanding of IGC mechanism in 7000 series Al alloys.</div></div>","PeriodicalId":290,"journal":{"name":"Corrosion Science","volume":"257 ","pages":"Article 113364"},"PeriodicalIF":7.4,"publicationDate":"2025-09-26","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145154251","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Enhanced oxidation resistance of CoNiCrAlY-MoSi2 alloy by oscillating laser-directed energy deposition: Role of (Cr,Mo)3(Co,Ni)5Si2 phase-mediated element-trapping","authors":"Yunzhen Xu ,&nbsp;Pan Ren ,&nbsp;Lei Qin ,&nbsp;Cheng Deng ,&nbsp;Delong Zeng ,&nbsp;Shengfeng Zhou","doi":"10.1016/j.corsci.2025.113334","DOIUrl":"10.1016/j.corsci.2025.113334","url":null,"abstract":"<div><div>To improve the oxidation resistance of CoNiCrAlY alloy, 10 wt% MoSi₂ was introduced into the material using oscillating-laser directed energy deposition (OL-DED). A comparative study of the microstructural evolution and isothermal oxidation behavior between the CoNiCrAlY and CoNiCrAlY-10MoSi₂ alloys was conducted. The results show that adding MoSi₂ with a low coefficient of thermal expansion (CTE) promotes the formation of intermetallic compounds (β and (Cr,Mo)₃(Co,Ni)₅Si₂ phase), reduces the CTE mismatch between oxide scale and CoNiCrAlY-10MoSi₂ alloy, mitigates the risks of oxide scale cracking/spalling, and increases the service temperature of CoNiCrAlY-10MoSi₂ alloy by over 100 °C (to 1100 °C). Furthermore, the (Cr,Mo)₃(Co,Ni)₅Si₂ phase in CoNiCrAlY-10MoSi₂ alloy immobilizes Cr/Mo via high-temperature element-trapping effect, suppressing volatile MoO₃ formation and inhibiting detrimental spinel oxides (e.g., Co(Ni)Cr₂O₄), maintain the oxide scale integrity. This mechanism maintains protective scale integrity and synergistically enhances oxidation resistance.</div></div>","PeriodicalId":290,"journal":{"name":"Corrosion Science","volume":"257 ","pages":"Article 113334"},"PeriodicalIF":7.4,"publicationDate":"2025-09-25","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145154252","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Mitigation of copper corrosion in the presence of an organic oxyanion through microstructural optimization","authors":"Amit Acharjee ,&nbsp;Giorgia Ghiara ,&nbsp;Iwona B. Beech ,&nbsp;Matthew W. Fields ,&nbsp;Roberta Amendola","doi":"10.1016/j.corsci.2025.113358","DOIUrl":"10.1016/j.corsci.2025.113358","url":null,"abstract":"<div><div>This investigation aimed to determine whether altering metal microstructure by introducing special grain boundaries through annealing could reduce the corrosion damage observed in the presence of pyruvate. Oxygen-free pure copper coupons were annealed at 325°C, 475°C and 950°C for varying durations to optimize the formation of ∑3 special boundaries. Samples annealed at 475°C for 30 min had the highest yield of such boundaries, thus, were selected for testing. Annealed and as-received, untreated, copper specimens were exposed under stagnant conditions to an aqueous oxic solution of sodium pyruvate for 30 days. Microscopy, spectroscopy, and electrochemical methods were employed to characterize the specimens prior to and following pyruvate exposure. Pyruvate caused localized corrosion of copper seen as micro pitting, irrespective of the specimen treatment. Reduced pitting severity and a decrease in the corrosion rate by 32 % were recorded for annealed coupons when compared to as-received ones. It is proposed that the difference in thickness and morphology of the oxide layer between annealed and as-received coupons, evidenced through electrochemical techniques, is the likely contributor to the improved corrosion resistance of annealed coupons.</div></div>","PeriodicalId":290,"journal":{"name":"Corrosion Science","volume":"257 ","pages":"Article 113358"},"PeriodicalIF":7.4,"publicationDate":"2025-09-25","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145154255","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Understanding the enhanced corrosion resistance of micro-alloyed SnAg solder based on surface native oxide film evolution","authors":"Weifeng Ma ,&nbsp;Hai Wang ,&nbsp;Chuang Qiao ,&nbsp;Taoyu Zhou ,&nbsp;Chunli Dai ,&nbsp;Mingna Wang ,&nbsp;Long Hao","doi":"10.1016/j.corsci.2025.113356","DOIUrl":"10.1016/j.corsci.2025.113356","url":null,"abstract":"<div><div>The refinement of Ag₃Sn phase is traditionally taken as an important criterion to improve the corrosion resistance of SnAg solder. In this work, the effects of Zn and Ni addition on corrosion resistance of SnAg solder have been investigated. Results indicate that 0.5 wt% Zn addition greatly refines the size of Ag₃Sn but lowers the corrosion resistance of SnAg solder. In contrast, 0.5 wt% Ni addition cannot refine Ag₃Sn grains but can enhance the corrosion resistance of SnAg solder. It has been found that the micro-alloying induced surface native oxide film evolution is responsible for the observed corrosion resistance evolution. Therefore, it has been proposed that the alloying elements that can promote the formation of a stable and compact surface native oxide film are also of interest to corrosion resistance improvement, thus offering another consideration to develop corrosion-resistant SnAg solder.</div></div>","PeriodicalId":290,"journal":{"name":"Corrosion Science","volume":"257 ","pages":"Article 113356"},"PeriodicalIF":7.4,"publicationDate":"2025-09-24","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145154250","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Selective oxidation behavior of Ag-49Cu-xGa precious metal alloys","authors":"Yulai Xu ,&nbsp;Xingyu Wang ,&nbsp;Xiaofei Wu ,&nbsp;Liqin Shen ,&nbsp;Junmei Guo ,&nbsp;Zeyuan Gao ,&nbsp;Tao Peng ,&nbsp;Xianhui Luo ,&nbsp;Zhilong Tan ,&nbsp;Shichen Yan","doi":"10.1016/j.corsci.2025.113350","DOIUrl":"10.1016/j.corsci.2025.113350","url":null,"abstract":"<div><div>Novel Ag-49Cu-xGa (x = 5, 7, 10, wt%) ternary alloys were designed to overcome cost-performance limitations of conventional Ag-28Cu through compositional engineering. By reducing silver content to less than 46 wt% while incorporating 5–10 wt% Ga, we achieve a duplex phase microstructure consisting of Ag and Cu-rich phases with good oxidation resistant property. The outward Cu diffusion and subsequent CuO formation drive the development of porous oxide scale, which creates rapid pathways for enhanced Cu-O interdiffusion, and scattered distribution of Ga₂O₃ under sample surface cannot suppress internal oxidation. Increased Ga content enables the oxidation process to reach a kinetically stable state in a shorter time. Crucially, Ga preferentially dissolves in Cu-rich phase, enabling a unique atomic redistribution mechanism during oxidation. Higher Ga content in Cu-rich phase facilitates outward diffusion of Ga, promoting formation of a continuous Ga₂O₃ barrier with hundreds of nanometers. This nanoscale protective layer, characterized by a favorable Pilling-Bedworth ratio (1.33), effectively suppresses oxygen inward diffusion and maintains integrity of Ga₂O₃ scale. The above results benefit the expanding of new application areas of cost-effective precious metal alloys with low solidus and liquidus temperatures.</div></div>","PeriodicalId":290,"journal":{"name":"Corrosion Science","volume":"257 ","pages":"Article 113350"},"PeriodicalIF":7.4,"publicationDate":"2025-09-23","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145154254","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"In-situ engineered ZrB2-ZrSi2-MoSi2 coatings with self-healing multiphase glass networks for superior oxidation protection at 1973 K","authors":"Yuexing Chen ,&nbsp;Jiaping Chen ,&nbsp;Xiang Ji ,&nbsp;Peipei Wang ,&nbsp;Zhichao Shang ,&nbsp;Chengshan Ji ,&nbsp;Philipp V. Kiryukhantsev-Korneev ,&nbsp;Evgeny A. Levashov ,&nbsp;Xuanru Ren ,&nbsp;Xueqin Kang ,&nbsp;Baojing Zhang ,&nbsp;Ping Zhang ,&nbsp;Xiaohong Wang ,&nbsp;Peizhong Feng ,&nbsp;Junfei Peng ,&nbsp;Junfeng Wang ,&nbsp;Kun Song","doi":"10.1016/j.corsci.2025.113355","DOIUrl":"10.1016/j.corsci.2025.113355","url":null,"abstract":"<div><div>To address the protection failure of ZrB₂-based coatings caused by structural loosening during oxidation, an in-situ alloying strategy with dual-silicide synergistic enhancement via one-step powder-source alloying is presented in this study. The approach successfully produced ZrB₂-ZrSi₂-MoSi₂ composite powders with precisely controllable composition, which were subsequently used to construct high-performance oxidation resistant coatings on graphite substrates. The optimized ZZM40 coating with 40 vol% MoSi₂ demonstrated a remarkable 98.21 % reduction in oxygen permeability and an 84.03 % reduction in carbon loss rate at 1973 K compared to the undoped coating, achieving a protection efficiency of 99.58 %. The performance enhancement is attributed to the in-situ formation of a self-generated glass phase during oxidation, which exhibits high fluidity and self-healing properties. Additionally, the in-situ precipitated nanoscale MoB phase effectively suppresses the volatilization of B₂O₃ through a pinning effect, achieving a synergistic enhancement in thermal stability and oxygen blocking capabilities. Notably, excessive MoSi₂ doping at 50 vol% leads to detrimental effects. Intensified MoO₃ volatilization reduces the viscosity of the glass phase and triggers a chain reaction of defect propagation, consequently increasing the carbon loss rate by 34.43 % compared to ZZM40. The proposed powder-source in-situ alloying strategy validates the defect-repair mechanism driven by dual-silicide oxygen-blocking reinforcement, providing crucial theoretical foundations for the design and application of next-generation high-temperature thermal protection materials.</div></div>","PeriodicalId":290,"journal":{"name":"Corrosion Science","volume":"257 ","pages":"Article 113355"},"PeriodicalIF":7.4,"publicationDate":"2025-09-23","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145154244","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Phase-specific corrosion responses of FeCrNiAl dual-phase HEA to oxygen variations in lead-bismuth eutectic","authors":"Yuxin Lou ,&nbsp;Zhao Shen ,&nbsp;Ziye Dong ,&nbsp;Kun Zhang ,&nbsp;Jiaqi Li ,&nbsp;Yiheng Wu ,&nbsp;Zhenfei Jiang ,&nbsp;Hao Wang ,&nbsp;Yang Ding ,&nbsp;Xintao Zhang ,&nbsp;You Wang ,&nbsp;Kai Chen ,&nbsp;Xiaoqin Zeng","doi":"10.1016/j.corsci.2025.113354","DOIUrl":"10.1016/j.corsci.2025.113354","url":null,"abstract":"<div><div>This study elucidates the phase-specific corrosion mechanisms of a FeCrNiAl dual-phase high-entropy alloy (DP-HEA) in lead-bismuth eutectic (LBE) at 500 °C under two representative oxygen concentrations (10⁻⁴ wt% and 10⁻⁷ wt%). Through systematic multi-scale characterization, we reveal a sharp mechanistic transition from oxidation to selective dissolution governed by the dissolved oxygen content. In oxygen-saturated LBE, the Al-rich BCC matrix phase preferentially oxidizes to form a porous FeAl₂O₄ spinel network, while the FCC matrix phase exhibits superior oxidation resistance owing to the formation of Cr-rich oxides. Conversely, in oxygen-deficient LBE, the FCC phase undergoes rapid Ni depletion, structural destabilization, and phase transformation into BCC, whereas the BCC phase—stabilized by B2-NiAl and Fe–Cr intermetallics—remains largely intact. These findings demonstrate the opposing roles of FCC and BCC matrix phases in resisting oxidation and dissolution, respectively, and highlight the importance of oxygen activity in dictating corrosion pathways. A unified mechanistic framework is proposed to describe the corrosion evolution under varying oxygen conditions, providing critical insights for the design of LBE-compatible structural materials for lead-cooled fast reactors.</div></div>","PeriodicalId":290,"journal":{"name":"Corrosion Science","volume":"257 ","pages":"Article 113354"},"PeriodicalIF":7.4,"publicationDate":"2025-09-22","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145154246","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}