Corrosion Science最新文献

{"title":"Unraveling the role of tensile stress in corrosion and the formation of oxide films on sensitized Al-Mg alloys","authors":"Yuanyuan Ji ,&nbsp;Chengcheng Pan ,&nbsp;Mingyang Wang ,&nbsp;Yashar Behnamian ,&nbsp;Dongdong Zhao ,&nbsp;Wenbin Hu ,&nbsp;Da-Hai Xia ,&nbsp;Bernard Tribollet","doi":"10.1016/j.corsci.2025.113306","DOIUrl":"10.1016/j.corsci.2025.113306","url":null,"abstract":"<div><div>Intergranular corrosion (IGC) significantly damages the strength of Al-Mg alloys with a Mg content &gt; 3 wt% when these alloys are serviced in marine environments. Although a dense oxide film can prevent the degradation of Al alloys, the influence of tensile stress on the properties of the oxide film is unclear. Here, the oxide films formed on a sensitized 5083 Al-Mg alloy under constant elastic and plastic tensile stresses are investigated. Pitting corrosion and intergranular corrosion occurred on the alloy surface. Tensile stress accelerated the anodic dissolution on the alloy surface and promoted intergranular corrosion, weakening the corrosion resistance of the oxide film. A heterogeneous oxide film was found on sensitized Al-Mg alloy, with the oxide film formed on the IGC region was thicker than that on the alloy matrix due to local alkalization. Tensile stress caused dislocations near the grain boundaries, but did not change the composition of the oxide film in the region subjected to intergranular corrosion. Density-functional theory calculations suggest that tensile stress destroyed the oxide film and weakened the electronic interactions between the oxide film and the alloy matrix, fostering the propagation of intergranular corrosion. Our findings clarify the mechanisms of oxide film formation on Al-Mg alloys under constant tensile stress in aqueous solution.</div></div>","PeriodicalId":290,"journal":{"name":"Corrosion Science","volume":"257 ","pages":"Article 113306"},"PeriodicalIF":7.4,"publicationDate":"2025-09-07","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145026698","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 and nodule oxide formation mechanism of Alloy 625 in high temperature CO2 environment with impurities","authors":"Shanmugam Mannan Muthu,&nbsp;Taejeong An,&nbsp;Chaewon Jeong,&nbsp;Changheui Jang","doi":"10.1016/j.corsci.2025.113307","DOIUrl":"10.1016/j.corsci.2025.113307","url":null,"abstract":"<div><div>The effect of impurities on the corrosion behavior of Alloy 625 was investigated in CO₂ (0.1 MPa) with a mixture of O₂ and CO impurities at 600 °C for 500 h. A very thin and dense chromia scale was developed on the surface without any significant oxide layer failure. In addition, Nb-rich nodule oxides were developed on the surface after exposure to all the environmental conditions. The crack formation was seen on the nodule oxides due to the oxide growth stress. The XRD results showed the predominant Cr-rich oxides and other phases Ni₃Mo and γ-Ni₃Al on the corroded alloy surface. A specimen exposed to CO₂+O₂ condition shows less oxidation due to the development of dense and compact Cr₂O₃. The carbon deposits were not observed at the oxide-metal interface. However, carbide formation was noticed in the subsurface below the nodule oxide for the specimen corroded in CO₂+CO condition. This may be attributed to the diffusion of C from the CO impurity through the non-protective Nb-rich nodule oxide and grain boundaries. The mechanism of nodule oxide formation and the corrosion behavior of Alloy 625 were discussed focusing on the role of impurities.</div></div>","PeriodicalId":290,"journal":{"name":"Corrosion Science","volume":"257 ","pages":"Article 113307"},"PeriodicalIF":7.4,"publicationDate":"2025-09-06","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145019393","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 and carburization behavior of high-chromium alloys in high-temperature supercritical CO₂ with 3.1% H₂O addition","authors":"Ho Jung Lee ,&nbsp;Gokul Obulan Subramanian ,&nbsp;Changheui Jang","doi":"10.1016/j.corsci.2025.113305","DOIUrl":"10.1016/j.corsci.2025.113305","url":null,"abstract":"<div><div>The corrosion and carburization behavior of four high-chromium (∼20 wt%) Fe- and Ni-based alloys (Alloy X, Alloy 230, Alloy 800HT and Alloy 282) were evaluated in supercritical CO₂ containing 3.1 vol% H₂O at 750 °C and 25 MPa for up to 1000 h. All alloys formed thin, continuous chromia (Cr₂O₃) layers and the corrosion rates followed the sequence of Alloy 282 &gt; Alloy 800HT &gt; Alloy 230 ≈ Alloy X. Parabolic kinetics were observed and were governed by the type and concentration of minor alloying elements such as Mn, Ti, Si, and Al. MnCr₂O₄ and TiO₂ were formed at the outermost oxide layer, whereas SiO₂ was observed at the oxide/matrix interface as either discrete particles or a continuous amorphous layer, depending on the alloying element content. Subscale internal oxides, mostly Al-rich alumina with traces of TiO₂, extended to depths that matched the bulk Al and Ti levels. The presence of 3.1 vol % H₂O accelerated oxide growth, yet carbon enrichment at the oxide/matrix interface was not detected. TEM-EELS mapping and SIMS depth profiling revealed only trace carbon confined to voids within the scale. The absence of interfacial carburization was attributed to the combined barrier effect of a thicker chromia scale formed by H₂O addition at high temperature and the structural modification of chromia through the incorporation of minor alloying elements.</div></div>","PeriodicalId":290,"journal":{"name":"Corrosion Science","volume":"257 ","pages":"Article 113305"},"PeriodicalIF":7.4,"publicationDate":"2025-09-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145010652","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":"Microstructure evolution under thermal cycling and water-oxygen corrosion behavior of Yb2Si2O7-Yb2SiO5 gradient structural environmental barrier coating","authors":"Zhaolu Xue ,&nbsp;Jiao Mei ,&nbsp;Yue Lin ,&nbsp;Xin Wang ,&nbsp;Chun Li ,&nbsp;Zhenya Zhang ,&nbsp;Gobinda Gyawali ,&nbsp;Eungsun Byon ,&nbsp;Shihong Zhang","doi":"10.1016/j.corsci.2025.113304","DOIUrl":"10.1016/j.corsci.2025.113304","url":null,"abstract":"<div><div>Si/Yb₂Si₂O₇/Yb₂Si₂O₇-Yb₂SiO₅ gradient structural environmental barrier coating (EBC) was designed and fabricated with stoichiometric Yb₂Si₂O₇ as the intermediate transition coat to mitigate the thermal expansion mismatch between the layers and thus improve the service life. Subsequently, the thermal cycling and water-oxygen corrosion behavior of this gradient structural EBC and a traditional Si/Mullite/Yb₂SiO₅ EBC were comparatively investigated at 1350 °C. The results showed that the plasma-sprayed 0.5Yb₂Si₂O₇-0.5Yb₂SiO₅ coating exhibited a dense microstructure composed of 52.96 mol% Yb₂SiO₅ and 47.04 mol% Yb₂Si₂O₇. The thermal cycling life of gradient structural EBC reached 672 times at 1350 °C, approximately 160 % higher than that of traditional EBC. The overall structure of the gradient structural coating remained stable during the thermal cycling. However, with an increasing number of cycles, the Si bond coat underwent continuous oxidation, leading to the thickening and cracking of the thermally grown SiO₂ layer, ultimately resulting in the spalling failure of the Yb₂Si₂O₇/Yb₂Si₂O₇-Yb₂SiO₅ coating. The water-oxygen corrosion resistance of the gradient structural EBC at 1350 °C was comparable to that of the traditional EBC. After 200 h of water-oxygen corrosion, the content of the Yb₂Si₂O₇ phase in the topcoat decreased due to its reaction with high-temperature water vapor. Nevertheless, the coating structure remained stable and dense, without peeling. Furthermore, the failure mechanism after thermal cycling and kinetics of water-oxygen corrosion were also discussed in detail.</div></div>","PeriodicalId":290,"journal":{"name":"Corrosion Science","volume":"257 ","pages":"Article 113304"},"PeriodicalIF":7.4,"publicationDate":"2025-09-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145010562","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":"Unveiling the role of irradiation in stress corrosion cracking of alloy 690","authors":"Donghai Du ,&nbsp;Tenghong Lin ,&nbsp;Mi Wang ,&nbsp;Miao Song ,&nbsp;Hefei Huang ,&nbsp;Gary S. Was","doi":"10.1016/j.corsci.2025.113303","DOIUrl":"10.1016/j.corsci.2025.113303","url":null,"abstract":"<div><div>Oxidized grain boundaries (GBs) in Alloy 690 samples from both unirradiated and irradiated regions were systematically characterized following constant extension rate tensile testing in a simulated pressurized water reactor primary water environment. Comparative analysis revealed distinct degradation mechanisms: significant chromium depletion occurred at carbide-free GBs, while crack initiation predominated at carbide-decorated GBs in irradiated specimens. Notably, irradiated regions exhibited substantially higher strain localization at both GBs and carbide/matrix interfaces compared to unirradiated GBs. These observations demonstrate that irradiation enhances stress corrosion cracking susceptibility through two synergistic mechanisms: radiation-enhanced diffusion along GBs and intensified strain localization at carbide/matrix interfaces.</div></div>","PeriodicalId":290,"journal":{"name":"Corrosion Science","volume":"257 ","pages":"Article 113303"},"PeriodicalIF":7.4,"publicationDate":"2025-09-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145004366","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 behaviour of novel Al-Fe-Zr alloy developed for additive manufacturing","authors":"Reynier I. Revilla ,&nbsp;Rubén del Olmo ,&nbsp;Kitty Baert ,&nbsp;Ilya Ostrovsky ,&nbsp;Loïc Malet ,&nbsp;Stéphane Godet ,&nbsp;Iris De Graeve","doi":"10.1016/j.corsci.2025.113292","DOIUrl":"10.1016/j.corsci.2025.113292","url":null,"abstract":"<div><div>This study investigates the corrosion behaviour of an additively manufactured (AM) Al-Fe-Zr alloy produced by laser-based powder bed fusion (PBF-LB). The alloy was developed to target high strength and conductivity applications and as a substitute for conventional 6xxx series alloys, which suffer from hot cracking during PBF-LB processing. Multiscale characterization (SEM, EBSD, SKPFM, XPS, and electrochemical testing) revealed that the rapid solidification during PBF-LB produces a highly refined microstructure with nanoscale Fe-Al intermetallic particles (IMPs), resulting in a narrow surface Volta potential range. These features contribute to enhanced electrochemical homogeneity and reduced susceptibility to localized corrosion compared with conventional AA6060. Potentiodynamic polarization tests in NaCl solution indicated comparable overall performance between the AM Al-Fe-Zr alloy and AA6060, while immersion tests demonstrated that the AM alloy exhibited lower pitting susceptibility, attributed to microstructural refinement and the modified composition of the native oxide film. XPS analysis confirmed the incorporation of Fe- and Zr-based oxides into the native film, potentially improving stability and supporting the enhanced corrosion resistance of the AM alloy. Nonetheless, heterogeneities were observed at the level of the melt pools, with the melt pool boundaries (MPBs) presenting coarser IMPs and inclusion-free zones (IFZs). These regions acted as preferential sites for localized attack, occasionally aligning corrosion along MPBs.</div></div>","PeriodicalId":290,"journal":{"name":"Corrosion Science","volume":"257 ","pages":"Article 113292"},"PeriodicalIF":7.4,"publicationDate":"2025-09-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145019395","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":"High temperature oxidation of Ni-based superalloy 247 produced by electron beam powder bed fusion additive manufacturing","authors":"Karthikeyan Hariharan ,&nbsp;Michael Landes ,&nbsp;Markus Ramsperger ,&nbsp;Oswaldo Luengas ,&nbsp;Taiwu Yu ,&nbsp;Erdmann Spiecker ,&nbsp;Christopher H. Zenk ,&nbsp;Yunzhi Wang ,&nbsp;Sannakaisa Virtanen","doi":"10.1016/j.corsci.2025.113301","DOIUrl":"10.1016/j.corsci.2025.113301","url":null,"abstract":"<div><div>This study investigates high temperature oxidation of Ni-base superalloy 247 processed by electron beam powder bed fusion (PBF-EB) compared with a conventionally cast (CC) counterpart. In terms of mass-gain during isothermal thermogravimetry at 1100 °C, the CC alloy outperformed the PBF-EB alloy. However, the PBF-EB alloy suffers from deeper internal oxidation due to its fine grain structure while shortening the transient oxidation stage. On the other hand, the CC alloy forms a non-homogeneous scale due to inhomogeneous distribution of bulky carbides and takes longer time to transition towards a steady-stage oxidation. The findings are analyzed and rationalized in the context of prior literature and thermodynamic-kinetic modeling.</div></div>","PeriodicalId":290,"journal":{"name":"Corrosion Science","volume":"257 ","pages":"Article 113301"},"PeriodicalIF":7.4,"publicationDate":"2025-09-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145010653","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":"Enhancing high-temperature oxidation resistance in directed energy deposition-processed Ni-based superalloys via heat treatment","authors":"Hao Yu ,&nbsp;Quan Zhao ,&nbsp;David san Martín ,&nbsp;Jinguo Li ,&nbsp;Wei Xu","doi":"10.1016/j.corsci.2025.113281","DOIUrl":"10.1016/j.corsci.2025.113281","url":null,"abstract":"<div><div>Ni-based superalloys produced via additive manufacturing (AM) face challenges in achieving optimal oxidation resistance due to elemental segregation and microstructural anisotropy inherent to the process. In this work, the oxidation resistance of additively manufactured Ni-based superalloys AMS-OR was remarkedly improved by heat treatment, reducing mass gain by 35 %, and oxide layer thickness by 38 % compared to the as-printed condition. This enhancement arises from microstructural optimization during heat treatment: Dendritic W segregation is eliminated through heat treatment, which redistributes aluminum into the γ matrix. This redistribution, combined with a lower oxygen partial pressure resulting from the coarser spinel grains in the oxide layer, enhances Al availability and promotes the formation of a continuous, protective Al₂O₃ layer. In addition, the localized W enrichment in dendritic cores in the as-printed alloy led to the formation of volatile WO₃, causing porous oxide morphologies and transient mass loss. Heat treatment suppresses WO₃ evolution by homogenizing W distribution, while partial dissolution of interdendritic (Nb,Ta)C carbides further stabilizes the oxide structure. By prioritizing microstructural homogenization over compositional changes, this work demonstrates that post-build heat treatment effectively addresses oxidation challenges in additive manufacturing, offering a scalable strategy to enhance high-temperature durability for aerospace and energy applications.</div></div>","PeriodicalId":290,"journal":{"name":"Corrosion Science","volume":"257 ","pages":"Article 113281"},"PeriodicalIF":7.4,"publicationDate":"2025-09-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145004365","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":"Effects of hydrogen charging on the corrosion behavior and hydrogen embrittlement of 7xxx Al Alloys: An integrated experimental and multiscale simulation study","authors":"Yue Hou ,&nbsp;Liting Dong ,&nbsp;Shougang Chen ,&nbsp;Zihao Guo ,&nbsp;Shushuai Liu ,&nbsp;Yanan Pu ,&nbsp;Wen Li ,&nbsp;Huimeng Feng","doi":"10.1016/j.corsci.2025.113291","DOIUrl":"10.1016/j.corsci.2025.113291","url":null,"abstract":"<div><div>This work presents a novel integrated approach combining in-situ and pre-charging electrochemical hydrogen charging (EHC) methods with multiscale simulations to unravel the synergistic effects of hydrogen on the corrosion and mechanical degradation of 7xxx Al alloys. The in-situ EHC coupon exhibited enhanced mechanical performance and reduced HE susceptibility (10.3 %) compared to the EHC 4 h and EHC 12 h coupons. A coupled mechanical-hydrogen diffusion finite element model (FEM) and density functional theory (DFT) calculations were developed to predict hydrogen distribution and its interaction with microstructural defects. Fractography and simulations identified a synergistic HE mechanism where hydrogen-enhanced localized plasticity (HELP) dominated at low hydrogen concentrations, facilitating dislocation mobility, while hydrogen-enhanced decohesion (HEDE) prevailed at higher concentrations, promoting intergranular fracture. This study establishes a framework for the coexistence and transition between HELP and HEDE mechanisms, governed by hydrogen concentration and local stress states, offering actionable insights for designing hydrogen-resistant Al alloys in marine and energy storage applications.</div></div>","PeriodicalId":290,"journal":{"name":"Corrosion Science","volume":"257 ","pages":"Article 113291"},"PeriodicalIF":7.4,"publicationDate":"2025-09-03","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145010560","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":"Decoding the corrosion inhibition mechanism of a new cinnamaldehyde derivative for mild steel in HCl medium by ToF-SIMS and AIMD","authors":"Z.N. Jiang ,&nbsp;J.M. Duan ,&nbsp;S.Y. Tian ,&nbsp;R.Y. Xue ,&nbsp;C.F. Dong ,&nbsp;G.A. Zhang","doi":"10.1016/j.corsci.2025.113289","DOIUrl":"10.1016/j.corsci.2025.113289","url":null,"abstract":"<div><div>A green corrosion inhibitor, (2<em>E</em>, 4<em>E</em>)-2-cyano-5-phenyl-2,4-pentadienoic acid (CPPA), was synthesized via one-step modification of cinnamaldehyde. CPPA exhibits outstanding inhibition effect for mild steel (MS) in HCl medium with an inhibition efficiency of 98.83 % at a concentration of 0.6 mM with good inhibition stability. The inhibition mechanism of CPPA was elucidated by combining surface characterization techniques with ab initio molecular dynamics (AIMD) simulations. XPS and ToF-SIMS analyses indicate that CPPA molecules could adsorb on MS surface by covalent bonding through N, C, and O atoms. AIMD simulations reveal that CPPA approaches to steel surface motivated by van der Waals force, i.e., physisorption occurs. Subsequently, the physisorption of CPPA is transformed into a strong and stable chemisorption, which was demonstrated by IGMH, CPPA-Fe bond length, electron density difference and PDOS characteristics. The adsorbed CPPA film significantly improves the hydrophobicity of MS surface, and acts as a shield to effectively hinder the diffusion and access of corrosive particles to steel surface, thus exhibiting outstanding and stable corrosion inhibition performance.</div></div>","PeriodicalId":290,"journal":{"name":"Corrosion Science","volume":"257 ","pages":"Article 113289"},"PeriodicalIF":7.4,"publicationDate":"2025-09-03","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145019448","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}