Corrosion Science最新文献

{"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}

{"title":"Electropolishing-enhanced corrosion resistance mechanisms of 316L stainless steel in semiconductor applications: Inclusion regulation, passive film optimization and aggressive microdroplet suppression","authors":"Chaoran Ma ,&nbsp;Zhice Yang ,&nbsp;Xi Zhuo Jiang ,&nbsp;Peng Zhou ,&nbsp;Yang Zhao ,&nbsp;Yong Hua ,&nbsp;Cheng Su ,&nbsp;Tao Zhang ,&nbsp;Fuhui Wang","doi":"10.1016/j.corsci.2025.113347","DOIUrl":"10.1016/j.corsci.2025.113347","url":null,"abstract":"<div><div>316L stainless steel is exclusively utilized in manufacturing delivery pipelines of electronic special gas (ESG). Long-term exposure to corrosive ESG poses severe corrosion threats to stainless steel components. Particle contamination arising from corrosion products has emerged as a critical challenge impeding the advancement of semiconductor microchips. Electropolishing, a pivotal anti-corrosion techniques in semiconductor applications, enhances the corrosion resistance of 316L stainless steel through three primary mechanisms: 1) surface purification through significant removal of inclusions, 2) passive film optimization by improving structural integrity and flatness at matrix/inclusion interfaces and metal/film interfaces, accompanied by a 277 % increase in the CrOx/FeOx ratio, 3) Effective suppression of aggressive microdroplets formation through surface energy modification.</div></div>","PeriodicalId":290,"journal":{"name":"Corrosion Science","volume":"257 ","pages":"Article 113347"},"PeriodicalIF":7.4,"publicationDate":"2025-09-22","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145154415","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":"Thermo-mechanical coupling effects on the high-temperature oxidation behavior of a NiCrAlY-coated single-crystal superalloy","authors":"Peng Deng ,&nbsp;Bin Yin ,&nbsp;Lijun Zhang ,&nbsp;Min Liu ,&nbsp;Chunming Deng","doi":"10.1016/j.corsci.2025.113349","DOIUrl":"10.1016/j.corsci.2025.113349","url":null,"abstract":"<div><div>MCrAlY coatings provide effective high-temperature protection against oxidation and corrosion for turbine blades. However, the inevitable thermo-mechanical coupling during service has a significant impact on the oxidation resistance of the coating, and the internal mechanism remains unclear. This study investigated the oxidation behavior of the NiCrAlY coating/nickel-based single-crystal superalloy system under conditions with/without applied thermo-mechanical coupling. The results indicate that the specimens with/without stress developed markedly different oxide scales. Thermo-mechanical coupling promoted the formation of thicker, poorly protective spinel oxides and a thinner protective alumina layer. Notably, W-Y-rich Y₂WO₆ oxides were exclusively detected on the surface of thermo-mechanical coupling specimens. The thermo-mechanical coupling effect aggravated the internal oxidation/nitridation of the NiCrAlY coating and weakened the protective capability of the oxide scale.</div></div>","PeriodicalId":290,"journal":{"name":"Corrosion Science","volume":"257 ","pages":"Article 113349"},"PeriodicalIF":7.4,"publicationDate":"2025-09-22","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145154243","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 deformation and high-temperature concentrated alkaline solution on intergranular oxidation behavior and cracking resistance of Alloy 690 plugs","authors":"Xinhe Xu ,&nbsp;Baoliang Cheng ,&nbsp;Songhan Nie ,&nbsp;Zhihao Yu ,&nbsp;Zhanpeng Lu ,&nbsp;Li Baojun ,&nbsp;Junjie Chen ,&nbsp;Tongming Cui ,&nbsp;Sergio Lozano-Perez ,&nbsp;Hannu Hänninen","doi":"10.1016/j.corsci.2025.113346","DOIUrl":"10.1016/j.corsci.2025.113346","url":null,"abstract":"<div><div>In this study, the long-term service reliability of Alloy 690 plug mock-ups for nuclear power plant steam generators was assessed via an accelerated stress corrosion cracking (SCC) test in 10 wt% NaOH at 350 °C. After 1000 h exposure, eight intergranular cracks initiated in highly deformed zones on the plug’s inner surface, induced by expansion joining and friction. Microstructural analysis revealed a few micrometers thick, three-layer oxide at the crack initiation sites: an outer Fe-rich spinel layer, a Ni-enriched solid-solution middle layer, and an inner mixed layer of localized Cr-rich oxides within the unoxidized Ni matrix. High-resolution characterization results showed that the alkaline environment promoted oxidation along deformation–induced dislocations and grain boundaries (GBs), forming fibrous inner and intergranular oxidation zones. Cr-rich oxides appeared only at coherent Σ3 GBs fronts, and no continuous Cr₂O₃ film formed on cracked high-angle grain boundaries. These findings indicate that the alkaline solution accelerates Cr-rich oxide dissolution at GBs while inhibiting protective Cr₂O₃ formation and that deformation-induced stress/strain facilitates oxidation and intergranular crack growth. This work quantitatively elucidates the coupled effects of oxidation and plastic deformation, validates high-temperature alkaline solution testing as a degradation–screening method and offers critical insights for service-life assessment and expansion–process optimization of Alloy 690 plugs.</div></div>","PeriodicalId":290,"journal":{"name":"Corrosion Science","volume":"257 ","pages":"Article 113346"},"PeriodicalIF":7.4,"publicationDate":"2025-09-22","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145118244","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":"An area-tailored (Hf, Ta)B2-SiC coating for ultra-high thermal protection: Design and evolution of microstructure","authors":"Jiaqi Hou,&nbsp;Jiaping Zhang,&nbsp;Ruicong Chen,&nbsp;Chenglong Tan,&nbsp;Binghong Li,&nbsp;Xianghui Hou,&nbsp;Qiangang Fu","doi":"10.1016/j.corsci.2025.113353","DOIUrl":"10.1016/j.corsci.2025.113353","url":null,"abstract":"<div><div>In the service environments of advanced aircrafts, thermal and aerodynamic loads on different areas of carbon/carbon composites thermal-structural components exhibit significant variation, often leading to cracking or failure of the protective coatings due to mismatched thermal expansion and stress accumulation. To address the problem, an innovative area-tailored protective coating strategy is proposed in this paper. An area-tailored (Hf, Ta)B₂-SiC coating was designed and prepared, featuring enriched (Hf, Ta)B₂ in the central area and SiC in the edge area, and was evaluated under oxyacetylene flame. After ablation, the area-tailored coating showed good cyclic ablation resistance due to the alleviated thermal stress mismatch across different coating regions, whose thickness and mass loss rates decreased by 104 % and 103 % after ablation for 30 s, respectively, compared to the uniform (Hf, Ta)B₂-SiC coating. The ablation resistance is manifested in the thermostability of Hf-based oxides, sintering densification, and grain boundary pinning, which reduce oxygen diffusion and improve the stability of the oxide layer. This work provides a new strategy and inspiration for the design and preparation of coatings for thermal structural components.</div></div>","PeriodicalId":290,"journal":{"name":"Corrosion Science","volume":"257 ","pages":"Article 113353"},"PeriodicalIF":7.4,"publicationDate":"2025-09-22","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145154242","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}