Corrosion SciencePub Date : 2025-09-15DOI: 10.1016/j.corsci.2025.113318
Xiaoyang Zhang , Jinchen Yang , Pengya Lei , Ruifeng Dong , Hua Hou , Yuhong Zhao
{"title":"Corrosion behaviors of Fe50Mn30Co10Cr10 high-entropy alloy wires with different processing states in various aqueous environments","authors":"Xiaoyang Zhang , Jinchen Yang , Pengya Lei , Ruifeng Dong , Hua Hou , Yuhong Zhao","doi":"10.1016/j.corsci.2025.113318","DOIUrl":"10.1016/j.corsci.2025.113318","url":null,"abstract":"<div><div>The electrochemical corrosion behavior and passive film characteristics of a low-stacking-fault-energy high-entropy alloy (HEA) cold-drawn wire with the composition of Fe<sub>50</sub>Mn<sub>30</sub>Co<sub>10</sub>Cr<sub>10</sub> were studied in acidic, alkaline, and saline solutions with three different processing states: deformation, recovery, and recrystallization. In NaCl solutions, the cold-drawn sample exhibits the best corrosion resistance, attributed to its high dislocation density and the formation of stable Mn-rich passive films. In contrast, the recrystallized sample shows the highest corrosion susceptibility. In low concentration H<sub>2</sub>SO<sub>4</sub> solution, the cold-drawn sample demonstrates the best corrosion resistance, with high dislocation density enhancing passive film stability. However, as the H<sub>2</sub>SO<sub>4</sub> concentration increases to 1 M, corrosion resistance deteriorates, with the recrystallized sample showing the best performance. At 2 M H<sub>2</sub>SO<sub>4</sub>, the recovered sample performs relatively better. X-ray photoelectron spectroscopy (XPS) analysis reveals that the Cr<sub>2</sub>O<sub>3</sub> content on the alloy surface is influenced by both the microstructure and acid concentration, which together regulate the competition between oxidation and dissolution kinetics. In alkaline solutions, corrosion resistance improves with increasing NaOH concentration, with the cold-drawn sample exhibiting the best performance due to enhanced passivation stability. This study establishes a framework for tailoring HEA wire processing strategies to achieve enhanced durability in diverse corrosive environments by elucidating the critical relationships between microstructure, processing history, and corrosion resistance.</div></div>","PeriodicalId":290,"journal":{"name":"Corrosion Science","volume":"257 ","pages":"Article 113318"},"PeriodicalIF":7.4,"publicationDate":"2025-09-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145099694","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}
Corrosion SciencePub Date : 2025-09-13DOI: 10.1016/j.corsci.2025.113317
Ting Xu, Min Du, Gengxin Li
{"title":"The performance and mechanisms of imidazoline phosphonate inhibitors in mitigating sulfate-reducing bacteria-induced under deposit corrosion","authors":"Ting Xu, Min Du, Gengxin Li","doi":"10.1016/j.corsci.2025.113317","DOIUrl":"10.1016/j.corsci.2025.113317","url":null,"abstract":"<div><div>The inhibition performance of an imidazoline phosphonate corrosion inhibitor (IPI) on X65 steel beneath corrosion products film formed by sulfate-reducing bacteria (SRB) at different growth stages in simulated CO₂-saturated oilfield produced water was investigated. 300 mg/L IPI effectively mitigated corrosion under varying conditions of the corrosion products film. IPI demonstrated over 80 % inhibition efficiency against SRB-induced corrosion and significantly reduces pitting corrosion. IPI can adsorb onto X65 steel and reorganize the initially disordered and detached corrosion products film. Molecular dynamics (MD) simulations elucidated IPI's inhibition mechanism, revealing its preferential adsorption on the Fe (1 1 0) compared to the FeS (0 0 1).</div></div>","PeriodicalId":290,"journal":{"name":"Corrosion Science","volume":"257 ","pages":"Article 113317"},"PeriodicalIF":7.4,"publicationDate":"2025-09-13","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145099695","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}
Corrosion SciencePub Date : 2025-09-12DOI: 10.1016/j.corsci.2025.113316
Yunlong Bai , Jin Xu , Kaihui Dong , Guanlun Guo , Feng Tian , Boxin Wei , Changkun Yu , Cheng Sun
{"title":"Synergistic acceleration of galvanic corrosion by selective D. vulgaris colonization on the heat-affected zone of steel welds","authors":"Yunlong Bai , Jin Xu , Kaihui Dong , Guanlun Guo , Feng Tian , Boxin Wei , Changkun Yu , Cheng Sun","doi":"10.1016/j.corsci.2025.113316","DOIUrl":"10.1016/j.corsci.2025.113316","url":null,"abstract":"<div><div>The study reveals that <em>D. vulgaris</em> (sulfate-reducing bacteria, SRB) selectively accelerate galvanic corrosion in the heat-affected zone (HAZ) of X80 steel under thin liquid films, using electrochemical tests, scanning vibrating electrode technology (SVET), ultraviolet photoelectron spectroscopy (UPS), and finite element simulation (FES). UPS confirmed that the HAZ exhibits a lower work function, which not only enhances its anodic activity but also promotes the adsorption of <em>D. vulgaris</em>. Furthermore, galvanic coupling between the HAZ and other regions intensifies this selective bacterial colonization. The concentrated metabolic activities of the adsorbed <em>D. vulgaris</em> further amplify the driving force for galvanic corrosion. Collectively, these synergistic effects result in a significantly increased anodic current density of 14.38 μA·cm<sup>−2</sup> in the HAZ, which is 3.94 times higher than the control group, thereby enhancing the susceptibility to localized corrosion.</div></div>","PeriodicalId":290,"journal":{"name":"Corrosion Science","volume":"257 ","pages":"Article 113316"},"PeriodicalIF":7.4,"publicationDate":"2025-09-12","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145099691","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}
Corrosion SciencePub Date : 2025-09-12DOI: 10.1016/j.corsci.2025.113315
Zhe Yang , Boxuan Cao , Zhenbao Liu , Yilu Zhao , Jun Wei
{"title":"Superior hydrogen embrittlement resistance of 1.9 GPa-grade precipitation hardening stainless steel achieved by multi-phase precipitation engineering","authors":"Zhe Yang , Boxuan Cao , Zhenbao Liu , Yilu Zhao , Jun Wei","doi":"10.1016/j.corsci.2025.113315","DOIUrl":"10.1016/j.corsci.2025.113315","url":null,"abstract":"<div><div>Overcoming the inherent high susceptibility of hydrogen embrittlement (HE) remains an enduring objective in the development of precipitation hardening stainless steels. This study demonstrates how multi-phase precipitation engineering synergistically enhances hydrogen resistance in duplex-aged Ferrium S53 steel through coupled experiments and simulations. TDS analysis identifies three distinct hydrogen desorption peaks corresponding to trapping at martensitic substructures, austenite interfaces, and nanoprecipitates, with the secondary-aged condition showing enhanced trapping capacity. Microstructural engineering through optimized aging generates high-density <em>M</em>₂C/α'<sub>Cr</sub> nanoprecipitates and stabilized austenite, shifting hydrogen desorption peaks to higher altitudes and reducing mobile hydrogen populations. Fracture analysis demonstrates the competing roles of plasticity-mediated and decohesion mechanisms, with their relative dominance evidenced by hybrid fracture features combining intergranular cracking with localized plasticity markers. First-principles calculations reveal Mo-modified carbides exhibit reduced vacancy formation barriers while increased hydrogen binding energy. The coordinated microstructure design achieves superior embrittlement resistance through: (i) TDS-verified hydrogen capture at engineered reversible traps, (ii) dislocation pinning that impedes hydrogen transport, and (iii) suppression of critical hydrogen accumulation at vulnerable interfaces. These findings establish a microstructure-property framework for developing hydrogen-resistant alloys via precipitation engineering.</div></div>","PeriodicalId":290,"journal":{"name":"Corrosion Science","volume":"257 ","pages":"Article 113315"},"PeriodicalIF":7.4,"publicationDate":"2025-09-12","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145099690","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}
Corrosion SciencePub Date : 2025-09-11DOI: 10.1016/j.corsci.2025.113314
Weijie Wu , Chenwei Xia , Zhicheng Fang , Xuewei Zhang , Xiaowei Wang , Jianming Gong , Jinxu Li
{"title":"Hydrogen microprinting revealing role of strain-induced defects on hydrogen distribution near austenite crack tip","authors":"Weijie Wu , Chenwei Xia , Zhicheng Fang , Xuewei Zhang , Xiaowei Wang , Jianming Gong , Jinxu Li","doi":"10.1016/j.corsci.2025.113314","DOIUrl":"10.1016/j.corsci.2025.113314","url":null,"abstract":"<div><div>In this study, we combined hydrogen micro‑printing test with finite‑element (FE) analysis to investigate the microscale origins of crack‑tip hydrogen enrichment in 2101 duplex stainless steel during in situ hydrogen-charging slow strain rate tensile loading. Results show that hydrogen concentrates mainly on either side of austenitic hydrogen‑induced cracks and within the very narrow region immediately ahead of the tip, with no direct correlation to strain‑induced martensite or dislocation density. FE models incorporating hydrogen‑lowered vacancy‑formation energy demonstrate that hydrogen‑promoted vacancy generation via dislocation jog drag produces high local vacancy densities that trap hydrogen, accounting for the observed enrichment. These findings can help to gain a deeper understanding of the interactions and respective roles of various hydrogen embrittlement mechanisms.</div></div>","PeriodicalId":290,"journal":{"name":"Corrosion Science","volume":"257 ","pages":"Article 113314"},"PeriodicalIF":7.4,"publicationDate":"2025-09-11","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145045179","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}
Corrosion SciencePub Date : 2025-09-10DOI: 10.1016/j.corsci.2025.113312
Ye Tian , Zhihao Yang , Junsheng Wang , Chi Zhang , Chengpeng Xue , Hui Su , Yisheng Miao , Zhongyao Li , Wenbo Wu , Xinghai Yang
{"title":"Designing ultra-high corrosion resistance Mg alloys by passivating cathodic activity and promoting RE oxide films","authors":"Ye Tian , Zhihao Yang , Junsheng Wang , Chi Zhang , Chengpeng Xue , Hui Su , Yisheng Miao , Zhongyao Li , Wenbo Wu , Xinghai Yang","doi":"10.1016/j.corsci.2025.113312","DOIUrl":"10.1016/j.corsci.2025.113312","url":null,"abstract":"<div><div>Many studies on improving the corrosion resistance of Mg alloys have been focusing on identifying certain elements which can reduce the corrosion rate of Mg alloys. However, without quantitative analysis of individual contributions of alloying elements and their combined effects, the corrosion resistance alloy design is always performed by trial-and-error process. In this study, we have quantified the effects of binary, ternary and quaternary additions of Y, Ce, and Mn to Mg alloys and found that their electrochemical performances are not only a function of simple dissolution but also their existing states by microstructure quantification before and after immersion tests. Using first-principles calculations, we have found that the beneficial effects of Rare Earth (RE) elements, such as Ce, and Y, can only be effective when they form secondary phases and act as the anode to form oxide films in front of Mg matrix; while dissolution of Mn can actually passivate the cathodic activity and improve the work function of the matrix (from 3.66 eV to 3.80 eV). Measurements of as-cast Mg-2Y-0.5Ce-0.5Mn alloy exhibit the best corrosion resistance (0.395 mm/y), due to both reduction of galvanic corrosion sites and protection of RE-containing oxides. Therefore, ultra-high corrosion-resistant Mg alloys have been successfully developed by passivating cathodic activity and promoting RE oxide films, further illuminating a new route for stainless Mg alloy development.</div></div>","PeriodicalId":290,"journal":{"name":"Corrosion Science","volume":"257 ","pages":"Article 113312"},"PeriodicalIF":7.4,"publicationDate":"2025-09-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145045075","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":"Effect of CaO/MgO bilayer film formation on nonflammability and oxidation resistance of Mg–Al–Ca alloys determined by high-temperature in situ residual stress measurement","authors":"Shin-ichi Inoue , Loku Singgappulige Rosantha Kumara , Yoshihito Kawamura","doi":"10.1016/j.corsci.2025.113311","DOIUrl":"10.1016/j.corsci.2025.113311","url":null,"abstract":"<div><div>In this study, the relationship between the oxide film structure and the protective properties of the oxide film of Mg–Al–Ca–Mn alloys was investigated by TEM observation and high-temperature in situ residual stress measurements. At 773 K, a CaO monolayer film formed on the surface. Then, a CaO/MgO bilayer film formed above 823 K. On the CaO monolayer film, tensile stress acted owing to the thermal expansion of the alloy substrate. Nevertheless, once the inner MgO layer formed, the tensile stress was relaxed, and compressive stress acted on the outer CaO layer. Additionally, the inner MgO layer acted as a scaffold for the outer CaO layer after the alloy melted, and strong compressive stress continued acting on the outer CaO layer. This suggests that the CaO/MgO bilayer can easily maintain its soundness and protectivity after melting because of the strong compressive stress.</div></div>","PeriodicalId":290,"journal":{"name":"Corrosion Science","volume":"257 ","pages":"Article 113311"},"PeriodicalIF":7.4,"publicationDate":"2025-09-09","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145045181","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}
Corrosion SciencePub Date : 2025-09-09DOI: 10.1016/j.corsci.2025.113293
Zihao Liu , Shidong Wang , Baojie Wang , Daokui Xu , Wanqing Chang , Chuanqiang Li , Shuo Wang , Hongzhi Cui , Bolv Xiao , Zongyi Ma
{"title":"Enhanced corrosion resistance and mechanism of a novel Mg-4Li-6Zn-1Y-0.2Ca alloy through cross-rolling and Ca microalloying","authors":"Zihao Liu , Shidong Wang , Baojie Wang , Daokui Xu , Wanqing Chang , Chuanqiang Li , Shuo Wang , Hongzhi Cui , Bolv Xiao , Zongyi Ma","doi":"10.1016/j.corsci.2025.113293","DOIUrl":"10.1016/j.corsci.2025.113293","url":null,"abstract":"<div><div>In this study, a novel Ca-microalloyed Mg-4Li-6Zn-1Y-0.2Ca alloy was developed to address corrosion issues associated with the fragmentation of icosahedral quasicrystalline phase (I-phase) eutectic pockets and the non-uniform distribution of precipitates in conventionally processed Mg-Li-Zn-Y alloys. The effects of cross-rolling (CR) at reduction ratios of 20 %, 40 %, and 80 % on the microstructural evolution and corrosion behavior were systematically investigated. Cross-rolling significantly promoted dynamic recrystallization, reducing the average grain size from 59.6 μm in the annealed state to 2.4 μm at 80 % reduction. It also fragmented and dispersed coarse secondary phases (I-Mg<sub>3</sub>Zn<sub>6</sub>Y, W-Mg<sub>3</sub>Zn<sub>3</sub>Y<sub>2</sub>, and Ca<sub>2</sub>Mg<sub>6</sub>Zn<sub>3</sub>), while promoting the uniform precipitation of nanoscale LiMgZn particles. As the reduction ratio increased, corrosion behavior shifted from severe localized attack to more uniform degradation. Annealed samples formed loose and discontinuous Mg(OH)<sub>2</sub>/CaCO<sub>3</sub> corrosion layers that provided limited protection, whereas the CR80 % samples developed compact and continuous Mg(OH)<sub>2</sub>-based layers incorporating CaCO<sub>3</sub> and Li<sub>2</sub>CO<sub>3</sub>. Consequently, the corrosion rate of the CR80 % sample decreased to 1.34 mm/y, representing a 77 % reduction compared to the annealed state (5.71 mm/y). This improvement is attributed to the refined microstructure and uniform distribution of LiMgZn precipitates, which enhanced the compactness and integrity of the corrosion product layer, thereby improving corrosion resistance.</div></div>","PeriodicalId":290,"journal":{"name":"Corrosion Science","volume":"257 ","pages":"Article 113293"},"PeriodicalIF":7.4,"publicationDate":"2025-09-09","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145060027","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}
Corrosion SciencePub Date : 2025-09-08DOI: 10.1016/j.corsci.2025.113308
Xing Qi , Zihan Zhuo , Yafeng He , Xiang Su , Cheng Yang , Bo Jiang , Renguo Song
{"title":"Effect of an MAO/PMTMS composite coating on the electrochemical corrosion and stress corrosion cracking behavior of an AZ80 magnesium alloy","authors":"Xing Qi , Zihan Zhuo , Yafeng He , Xiang Su , Cheng Yang , Bo Jiang , Renguo Song","doi":"10.1016/j.corsci.2025.113308","DOIUrl":"10.1016/j.corsci.2025.113308","url":null,"abstract":"<div><div>Various micro arc oxidation (MAO)/polymethyltrimethoxysilane (PMTMS) composite coatings are prepared on an AZ80 magnesium alloy by MAO treatment combined with a hydrolysis reaction. The outer PMTMS layer seals the micropores and cracks in the MAO coating and cross-links with the MAO coating, contributing to a compact double-layer coating. The test results show that the MAO/PMTMS coating can significantly improve the corrosion resistance of the Mg alloy, especially for the MAO/PMTMS3 coating. Compared with that of the substrate, the corrosion potential of the AZ80 magnesium alloy with this coating is more positive, the corrosion current density is three orders of magnitude lower, and its susceptibility to stress corrosion cracking (SCC, IUTS) decreases by 45.9 %. The change in OCP values during the SSRT indicates that the MAO/PMTMS coating retards crack initiation and propagation.</div></div>","PeriodicalId":290,"journal":{"name":"Corrosion Science","volume":"257 ","pages":"Article 113308"},"PeriodicalIF":7.4,"publicationDate":"2025-09-08","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145019394","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}
Corrosion SciencePub Date : 2025-09-08DOI: 10.1016/j.corsci.2025.113309
Jing Liu , Yabin Jing , Ran Wei , Jingjing Peng , Xian Zhang , Lin Cheng , Tao Zhang
{"title":"Mechanism modeling and prediction of Ag electrochemical migration failure in ultra-thin liquid film","authors":"Jing Liu , Yabin Jing , Ran Wei , Jingjing Peng , Xian Zhang , Lin Cheng , Tao Zhang","doi":"10.1016/j.corsci.2025.113309","DOIUrl":"10.1016/j.corsci.2025.113309","url":null,"abstract":"<div><div>This study established a mechanistic model for the prediction of electrochemical migration (ECM) failure time of Ag electrode in a thin liquid film, based on electrode kinetics and diffusion dynamics. The dendrite growth processes of Ag under various bias voltages, liquid film thicknesses and Cl<sup>-</sup> concentrations were investigated. The ECM model was validated against experimental data, demonstrating the reliability of this model. Under actual packaging technology where experimental precision is insufficient (film thickness lower than 10 μm), model-based extrapolation reveals that migration resistance becomes the dominant determinant instead of volume effect, leading to a pronounced extension of ECM failure time.</div></div>","PeriodicalId":290,"journal":{"name":"Corrosion Science","volume":"257 ","pages":"Article 113309"},"PeriodicalIF":7.4,"publicationDate":"2025-09-08","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145045180","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}