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At least 253 records · Page 14

Corrosion of Commercial Mg–Al Alloys: AZ31B, AM60, and AZ91D

Aqueous corrosion, atmospheric corrosion, and ionic liquid dissolution studies were performed on commercial alloys AZ31B, AM60, and AZ91D and compared with previously reported results for single-phase binary Mg–Al alloys containing similar Al concentrations (αMg-2 at% Al, αMg-5 at% Al, and Mg-8 at% Al). Polarization studies in 0.6 M NaCl were used to characterize the aqueous free corrosion behavior during 20-h free immersion. Accelerated corrosion testing was performed using a rotating-disk electrode which revealed the evolution of an Al-rich mud-cracking and platelet morphology. Atmospheric droplet testing showed rapid pH increases that depended on the Al concentration in the alloy. Time-dependent contact angle measurements showed that the degree of droplet wetting increased during free corrosion by ~50° over 20 h in 0.6 M NaCl. Ionic liquid dissolution studies in 1:2 M choline chloride:urea deep eutectic solvent were performed in order to examine the current-voltage behavior of these alloys in the absence of water and hydrogen reduction. The results of these studies revealed the formation of nanowire corrosion morphologies within a honeycomb lattice structure which we attribute to selective dissolution of Mg via a two-dimensional stepflow process

25 ENERGY STORAGE↗

Corrosion Electrochemistry of Chromium in Molten FLiNaK Salt at 600 °C

The manuscript revisits the corrosion behavior of pure Cr in molten FLiNaK salt at 600 °C from the perspective of corrosion electrochemistry. In this work, the potential-dependent, rate-limiting charge-transfer, and salt film-mediated mass-transport controlled regimes of Cr corrosion in FLiNaK at 600 °C are investigated. The kinetic and thermodynamic parameters that limit electrodissolution and the consideration of grain orientation on these regimes are elucidated. At low Cr(III) concentrations, the corrosion process is governed by charge transfer control at low overpotentials and is crystal orientation dependent. However, when Cr(III) concentrations are high or when there is a high overpotential, the formation of a metal fluoride salt film on the Cr surface shifts the kinetic behavior to be governed by mass transport control at all anodic potentials with a surface morphology controlled by salt film deposition location and identity. Evan’s diagrams were developed to consolidate and elucidate these observations. These findings were supported by an examination of the post-corrosion microstructure, X-ray diffraction of solidified salts, and thermo-kinetics analysis in each corrosion regime.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

Understanding the Effect of Electrochemical Properties and Microstructure on the Microgalvanic Corrosion of Mg Alloys via Phase-Field Simulations

In this work, we apply a phase-field model to gain insights into the corrosion behavior of Mg alloys. Specifically, we study the effect of electrochemical properties of the materials and their environment and the spatial distribution of second phases in a magnesium alloy. To this end, we perform sensitivity analyses in which we separately vary the exchange current density and corrosion potential of the second phase, as well as the electrolyte conductivity. We describe the effects of these parameters on the corrosion current and the resulting corrosion-front morphology. We also confirm that the ratio between the Wagner length, calculated for the anodic phase, and the initial width of the anodic domain is a good predictor of the morphological characteristic of the corroding surface. In addition, we examine the effect of the microstructure on the corrosion behavior in both 2D and 3D systems by varying the shape, size, and distribution of the second-phase regions. Our findings provide insights into the influence of the two-phase microstructure on the corrosion behavior in a magnesium alloy.

Electrochemistry↗

The impact of temperature, chlorides and sulfate-reducing bacteria on the corrosion of steel in soil

Here, this investigation aimed to study the corrosion performance of low-carbon steel in a soil environment at different temperatures. The steel specimens in the soil were treated at three temperatures: 5, 25 and 60°C. The specimens were embedded in chloride-free soil for 21 days, and then 3.5% (by weight) sodium chloride (NaCl) was added to the soil. The specimens were then kept in the chloride-contaminated soil for 54 days. The results of electrochemical experiments showed superior corrosion performance of the specimens at 60°C, which had the lowest corrosion activity, followed by the specimens at 5 and 25°C. The slow nature of the kinetics of the corrosion reactions at 5°C compared with that at ambient temperature was the reason for this improvement at 5°C. The lower number of microorganisms, including sulfate-reducing bacteria, in the soil at 60°C compared with that at the other temperatures was attributed to the lower corrosion activity of steel in the soil at 60°C compared with the corrosion activity of steel in the soil at other temperatures.

99 - GENERAL AND MISCELLANEOUS↗

Corrosion Studies of Pine-Derived Bio-Oil and Heavy Fuel Oil Blends

To reduce the amount of greenhouse gas produced from the combustion of petroleum fuels, renewable liquid fuels are needed. Pyrolysis of biomass provides a means to produce liquid fuels to displace current petroleum products. However, common ferrous alloys are susceptible to high corrosion rates when exposed to bio-oil. This study analyzes the effects of blending bio-oil derived from loblolly pine with heavy fuel oil added to reduce corrosion of common structural alloys. Laboratory corrosion studies of six different blends of bio-oil/heavy fuel oil were performed for 1,000 hours at 50°C. Chemical characterization was also performed to determine the total acid content of each blend. Post-exposure characterizations such as changes in weight, X-ray diffraction, dye penetrant testing, and metallography were performed to provide more insight into the corrosion mechanism of bio-oil/heavy fuel oil blends. We hypothesized that the corrosion rates of ferrous alloys would increase with an increase in bio-oil concentration. The results of these characterization and corrosion studies confirmed this hypothesis and will be reported.

09 BIOMASS FUELS↗

K-3 Refractory Corrosion Test Results, HAL24M2

This report summarizes the refractory corrosion data of the high-Al matrix of Direct Feed High-Level Waste (DFHLW) glasses generated to expand glass compositional ranges. Design of a 20 high-Al glass matrix, HAL24M2, was reported in Russell et al. (2025, in progress). The HAL24M2 glasses were tested for K-3 corrosion and the results are presented in this report. Corrosion of Monofrax K-3 refractory materials in the HAL24M2 glass melts was measured using a crucible-scale method. Two test conditions, 1150 °C/7days and 1200 °C/7days were applied. The melt-line neck corrosion depth of the test coupons was measured by micro-computed tomography (micro-CT). The measured K-3 neck corrosion values were compared to predicted values using the model in Vienna et al. (2024). The model slightly over-predicted the neck corrosion depth of these glasses.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

Impact of Laboratory-Accelerated Aging Methods to Study Alkali–Silica Reaction and Reinforcement Corrosion on the Properties of Concrete

This study focuses on two separate investigations of the main aging mechanisms: alkali–silica reactivity (ASR) and the corrosion of reinforcing steel (rebar) concrete, both of which may result in a premature failure to meet the serviceability or strength requirements of a concrete structure. However, these processes occur very slowly, spanning decades. The impact of direct chemical additives to fresh concrete to accelerate ASR and the corrosion of reinforcing steel on the fresh and hardened properties of the ensuing material are investigated to inform the potential use of chemicals in large-scale studies. The deterioration of reinforced concrete (RC) is determined by means of expansion, cracking, bulk diffusivity and surface resistivity measurements, and compressive, split tensile and flexural strength tests. The results indicate that the addition of sodium hydroxide and calcium chloride can effectively accelerate the crack formation and propagation in concrete due to ASR and the corrosion of rebar, respectively. The ASR-induced cracks maintained a constant crack width from 0.05 mm to 0.1 mm over the measurement period regardless of the intensity of aging acceleration. Adding 4% chloride by weight of cement for accelerating rebar corrosion resulted in an average crack that was 82% larger than in the case of ASR accelerated with the addition of sodium hydroxide. The addition of alkali resulted in an increase in early-age (7-day) strength. At a total alkali loading of 2.98 kg/m3, 3.84 kg/m3 and 5.57 kg/m3, the 28-day compressive strength of concrete decreased by 3%, 10% and 24%, respectively. Similarly, a higher early-age strength and a lower later-age strength was observed for the concrete in the presence of corrosive calcium chloride. The results from this research are expected to inform future studies on the long-term performance of RC structures under accelerated ASR and corrosion.

36 MATERIALS SCIENCE↗

A Laboratory Corrosion Inhibition Study of Carbon Steel Using 2-Mercaptobenzothiazole (MBT) Under Post-Combustion CO2 Capture Conditions

Corrosion mitigation is an important aspect of amine-based post-combustion carbon dioxide (CO2) capture operations due to the desire to use less expensive but corrosion-vulnerable materials such as low carbon steels in the construction of a capture system. In this study, the corrosion behavior of A106 (grade B) carbon steel with an in-house proprietary amine-based solvent was investigated in a laboratory environment at 80°C using an organic corrosion inhibitor, 2-mercaptobenzothiazole (MBT). The corrosion inhibition mechanism was interpreted by electrochemical methods and surface analyses. The results revealed that the corrosion rates of carbon steel were significantly retarded using MBT. The critical inhibitor concentration was determined to be lie between 10 ppm and 50 ppm under the tested conditions.

Materials Science↗

Fuel Matrix Degradation Model Development Update: Alloy Corrosion Rates and Hydrogen Generation

This work is being performed as part of the DOE NE Spent Fuel and Waste Science and Technology Campaign, Argillite and Crystalline Rock R&D work packages: SF-19AN01030101 and SF-19AN01030201. This document meets the milestone M4SF-19AN010301013 for Argillite R&D and the milestone M4SF-19AN010302013 for Crystalline R&D. The fuel matrix degradation (FMD) model calculates the degradation rate of spent UO2 fuel based on fundamental electrochemical theory and thermodynamics. The model provides the quantitative basis for radionuclide source term predictions in the generic disposal system analysis (GDSA) performance assessment (PA) model. The FMD model has been implemented in a manner that facilitates its integration with the GDSA-PA code and a preliminary, integrated FMD-GDSA model has been successfully tested (Jerden et al., 2017). The specific focus of on-going work is to accurately and quantitatively represent the generation of H2 in a breached waste package and its effect on the spent fuel degradation rate so that this key process can be accurately represented in PA models. It has been shown experimentally that millimolar concentrations of dissolved H2 in contact with spent fuel will inhibit oxidative dissolution and decrease the fuel degradation rates by as much as three orders of magnitude (e.g., Röllin et al., 2001, Ollila, 2008). This will lead to a significant decrease in the radionuclide source term values used in repository PA models. Sensitivity studies using the FMD model have shown that the dissolved H2 concentration is the dominant environmental variable affecting the UO2 spent fuel dissolution rate as long as a source of H2 persists in the breached waste package (Jerden et al., 2015). Therefore, on-going experimental and modeling efforts focus on H2 production, accumulation and interfacial reactions within a breached waste package. The anoxic corrosion of metallic engineering materials within a breached waste package will be the main source of H2 in crystalline and argillite rock repository systems. The most important H2-producing alloys present within a waste package include stainless steel, carbon steel, and aluminum alloys and the Zircaloy fuel cladding. A steel corrosion module was added to the FMD model to account for these H2 sources and couple the H2 generation rate with fuel degradation processes (Jerden et al., 2017). As discussed below, there is a need for experimental data from electrochemical corrosion tests to quantify the H2 generation rates due to the corrosion of these waste package alloys as a function of key environmental variables (Eh, pH, groundwater chemistry). This report presents results from series of electrochemical corrosion tests with materials present in waste packages that provide information needed to parameterize and validate the FMD model. The alloys tested include 316L stainless steel (316SS), AISI 4320 carbon steel (C-steel) and Zircaloy-4 fuel cladding (unirradiated). Potentiodynamic polarization and potentiostatic polarization tests were performed in buffer solutions at pH 4, 7 and 10 with NaCl concentrations of 0, 4 and 100 millimolar (mM). The potentiostatic tests were performed at voltages varying from 0.5 volts down to -0.66 volts, vs the standard hydrogen electrode (SHE), and all tests were performed at laboratory ambient temperatures (~22 °C). The corrosion rates measured during the electrochemical tests were used as direct input to a new FMD/in-package chemistry model that is being developed to provide accurate long-term spent fuel degradation rates as chemical conditions (Eh, pH, speciation) evolve within a breached waste package. This new model was developed by coupling the FMD model with the reactive transport code X1t, which is a module within the Geochemist’s Workbench (GWB) reaction path modeling code (Jerden et al., 2019). The reactive transport model consists of a 1D domain discretized with 21 reaction diffusion cells and includes a single waste packag

Jerden, James↗

Corrosion evaluation of metal foams in eutectic molten salts for high temperature latent heat energy storage application

High-temperature Thermal Energy Storage (TES) has drawn great attention as a technology that can increase the role and profitability of micro nuclear reactors in the decentralized clean energy market. Various research needs have been proposed by Idaho National Laboratory (INL) in "the Integrated Energy Systems: 2020 Roadmap" with the goal of utilizing the high temperature of 550 degrees or more generated in the 4th generation reactor to industrial purposes from the standpoint of integrated energy systems [1]. With the recent development of the 4th generation nuclear power plant, including micro nuclear reactor, there is a great deal of interest in researching how to efficiently couple a heat source to an industrial process through thermal processing. Texas A&M University (TAMU) and INL are currently collaborating to develop a novel latent heat storage design called HITB (Heat pipe-Integrated Thermal Battery). As part of the small-scale experimental demonstration research for HITB, a study for storage medium selection was conducted at TAMU. Eutectic salts have attracted interest as high-temperature heat storage medium for HITB. Especially, chloride molten salts and fluoride molten salts are considered promising candidates due to their high melting temperature, thermal stability, and high latent heat of fusion. Since eutectic salts have poor thermal conductivity in general, it is critical to distribute materials with high thermal conductivity evenly to facilitate the charging and discharging of heat. In this study, metal foam was considered in the HITB system to overcome the poor heat transfer characteristics of eutectic salts. In order to improve heat transfer, it is necessary to study materials with high thermal conductivity, corrosion resistant to molten salts, such as fins, extended surfaces, particles, microcapsulation, or foam structure. Porous structure of copper or aluminum can increase heat transfer area, form a thermal transfer network, and increase the effective thermal conductivity of thermal storage medium [2]. Since the melting temperature is required to be at least 450? in the current HITB design, various eutectic salts are being considered. FLiNaK and FLiBe, which are famous for fluoride salts, are good candidates, but due to the sharp rise in the price of LiF recently, they are excluded for economic reasons to be applied to large-capacity thermal energy storage. On the other hand, chloride salts are very cheap and easy to obtain, have a high melting temperature, and have a high latent heat of fusion, so they are recently in the spotlight as a phase change material. However, because of the hygroscopic nature of chloride salts, HCl gas due to impurity is easy to be released and is particularly vulnerable to corrosion. Chloride eutectic salts have been tested and suggested for metal alloys that are particularly resistant to corrosion, such as SS304, SS316, Hastelloy, Inconel 625, Incoloy 800H, which has low thermal conductivity, and is very expensive [3-6]. Porous materials with high thermal conductivity such as copper and aluminum have been tested for stability in fluids such as paraffin or water as metal foam or metal fin structures, but high temperature corrosion tests were not performed on various eutectic salts yet. Therefore, this study investigated the high temperature corrosion characteristics of metal alloys, such as C10100 foam, C10100 plate, 6101 alloy foam, and SS316 plate, while immersed in the candidate eutectic salts. A total of 20 tests for SS316 coupons and 10 tests for C10100 coupons were performed to ensure the repeatability of the present measurements. Since it is difficult to completely remove the salt inside metal foam due to the complex inner structure of the metal foam, only the surface condition was observed with a microscopy and scanning electron microscopy (SEM) image, except for measuring the corrosion rate and average mass loss.

25 ENERGY STORAGE↗

Effect of Minor Ce Additions on Corrosion Behavior of Experimental Pipeline Steel

Minor additions of rare earth elements (REEs) have been shown to improve various steel properties. In particular, Cerium (Ce), as a relatively abundant and inexpensive element, has received attention as a potentially beneficial minor alloying addition for a variety of steel applications, including pipelines materials. The objective of this work is to investigate the effect of Ce on corrosion performance of experimental high-strength pipeline steel. Electrochemical corrosion experiments were carried out on steel without and with 0.006, 0.018, and 0.03 wt.% of Ce in 3.5 wt.% NaCl saturated with CO2 at 20 oC. For comparison purposes, X100 carbon steel specimens machined from an experimental pipe with a yield strength of 731 MPa were tested under the same conditions. The electrochemical techniques employed included: potentiodynamic polarization (PDP), linear polarization resistance (LPR), and electrochemical impedance spectroscopy (EIS). In addition, post-corrosion surface characterization was performed using scanning electron microscopy (SEM) equipped with energy dispersive X-ray spectroscopy (EDS), while crystalline phases were determined by X-ray diffraction (XRD). The corrosion of base metal without Ce was lower (0.15 mm/y) compared to carbon steel X100 (0.9 mm/yr). The electrochemical results showed that adding Ce accelerates corrosion rates compared to base metal without Ce. No pitting corrosion of tested steel was detected.

Belarbi, Zineb↗

Effectiveness of Vapor Corrosion Inhibitors Under Elevated Chloride Conditions for Aboveground Storage Tank Application

The sand quality used to construct the tank pad is an important contributing factor to the rate of corrosion that occurs on the soil-side of the aboveground storage tanks (ASTs) floor plates. Clean sand that meets specific criteria provides the first line of defense for mitigation of tank floor corrosion. However, it has been observed that the sand quality used for some existing tanks differ greatly from the specifications provided in the API 651 standard; this could be partially due to initial sand quality not meeting the specification, and partially due to the environmental effects over time. For example, rain-water intrusion could lead to higher than the specified contents of corrosive species such as chloride. Tank operators are increasingly using vapor corrosion inhibitors (VCIs) either as a stand alone or in combination with cathodic protection (CP) for ASTs to mitigate soil-side corrosion. VCIs are delivered either through-thefloor or injected through the ports in the ring wall. Experimental studies were conducted to evaluate VCIs’ performance at elevated chloride concentrations and to study the effectiveness of the delivery methods under extreme chloride conditions. The experimental work found that VCI performance is robust and not compromised due to high chloride levels, such as 300 ppm or more. The work also showed that the through-the-floor VCI delivery method is more beneficial compared to the through-the-sand-pad method when tank pad corrosivity is elevated.

Shukla, Pavan K.↗

Effectiveness of Vapor Corrosion Inhibitors Under Bacterial Activity for Aboveground Storage Tank Application

Bacterial activity is known to influence corrosion and can result in increasing soil-side corrosion of the aboveground storage tanks (ASTs) floor plates. Association for Materials Protection and Performance (AMPP) defines this phenomenon as Microbiologically Influenced Corrosion (MIC). It has been hypothesized that vapor corrosion inhibitors (VCIs) can not only function in presence of bacterial activity but can also function as biocides. Experiments were conducted to study the effect of bacterial activity on corrosion in the sand pad conditions and effect of VCIs in mitigating MIC. Various bacteria cultures were grown using commercially available culture media, and coupon exposure tests were performed with field sand mixed with the culture media. To this end, control and VCI-dosed electrolytes were prepared using the field sand plus bacteria cultures. Pre- and post-test bacteria concentration estimation and measurements, respectively, in the VCI-dosed electrolytes indicated that VCIs do not function as biocides, however, VCIs are highly effective for mitigating corrosion in presence of bacterial activity.

Shukla, Pavan K.↗

Characterization of wellbore casing corrosion product as a permeable porous medium

Leakage along wellbores is of concern for a variety of applications, including sub-surface fluid storage facilities, geothermal wells, and CO 2 storage wells. We have investigated whether corroded casing is permeable to gas and can serve as a leakage pathway along wellbores. Three specimens were prepared from laboratory steel plates corroded using different mechanisms to reflect different possible field conditions and produce a variety of corrosion rates. Single-phase gas flow measurements were made under a range of gas pressures to investigate flow in both the viscous and visco-inertial flow regimes. Tests were conducted at different confining stresses (range from 3.45 to 13.79 MPa) following both loading and unloading paths. The gas flow test results imply corroded casing can serve as a significant leakage path along the axis of a wellbore. Transmissivity was discovered to be sensitive to the variation in confining stress suggesting that the corrosion product is deformable. Gas slip factors and the coefficients of inertial resistance of the corrosion product were comparable to those available in the literature for other porous media. Post-test examination of the corrosion product revealed it to be a heterogeneous, mesoporous material with mostly non-uniform slit type porosity. There was no discernable difference in the composition of corrosion product from specimens corroded by different mechanisms.

02 PETROLEUM↗

Time-Dependent Corrosion Behavior of Aluminum Using Advanced Electrochemical and Characterization Techniques

The time-dependent corrosion behavior of pure aluminum (Al) in a chloride-containing environment was investigated using various electrochemical and characterization techniques for up to 336 h. Transmission electron microscopic and secondary ion mass spectroscopic analysis revealed the continuous dissolution of the surface film over the immersion time. In the meantime, the increasing passive oxide thickness resulted in the surface film resistance enhancement over the immersion time, as indicated by the electrochemical impedance spectroscopic analysis. The electrochemical noise measurements showed an increase in the corrosion kinetics with immersion time until 60 h because of the accelerated localized corrosion in the early stage of immersion. However, an inhibition in corrosion kinetics occurred after longer immersion times due to corrosion product deposition inside the pit.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

Corrosivity Screening of Pyrolysis Bio-Oils by Short-Term Alloy Exposures. Laboratory Analytical Procedure (LAP), Issue Date: May 12, 2022

Bio-oils contain organic acids and oxygenated compounds that can lead to corrosion issues during bio-oil processing and storage. This Laboratory Analytical Procedure (LAP) allows for rapid screening of a bio-oil's corrosivity without the need for complex equipment and long-term exposures. A robust and repeatable method for assessing the corrosivity of bio-oils is necessary in order to remove materials degradation as an obstacle to research, upgrading, use and storage of bio-oils. This LAP involves the incubation of a representative alloy, 410 stainless steel (410 SS), specimen in bio-oil over a period of 48 hours at 50 degrees C in a sealed container. The corrosive species in the bio-oil react with and deplete alloy elements such as iron (Fe) and/or chromium (Cr) from the specimen into the bio-oil solution. The depletion of Fe and Cr from the specimen results in a significant mass loss that can be recorded. The mass loss is directly correlated to the corrosivity of a bio-oil. Examples of bio-oils in scope include the ones produced by fast pyrolysis and catalytic fast pyrolysis, as well as liquids produced from hydrothermal liquefaction.

09 BIOMASS FUELS↗

Effect of Carboxylic Acids on Corrosion of Type 410 Stainless Steel in Pyrolysis Bio-Oil

Biomass-derived oils are renewable fuel sources and commodity products and are proposed to partially or entirely replace fossil fuels in sectors generally considered difficult to decarbonize such as aviation and maritime propulsion. Bio-oils contain a range of organic compounds with varying functional groups which can lead to polarity-driven phase separation and corrosion of containment materials during processing and storage. Polar compounds, such as organic acids and other oxygenates, are abundant in bio-oils and are considered corrosive to structural alloys, particularly to those with a low-Cr content. To study the corrosion effects of small carboxylic acids present in pyrolysis bio-oils, type 410 stainless steel (SS410) specimens were exposed in bio-oils with varying formic, acetic, propionic and hexanoic acid contents at 50 °C during 48 h exposures. The specific mass change data show a linear increase in mass loss with increasing formic acid concentration. Interestingly, a mild corrosion inhibition effect on the corrosion of SS410 specimens was observed with the addition of acetic, propionic and hexanoic acids in the bio-oil.

09 BIOMASS FUELS↗

Laser Surface Processing of Alloys for Corrosion Protection (Final Project Report of Marine Energy Seedling Project)

This is the final project report for the MHK Seedling project. The report describes use of laser surface processing (LSP) to modify the surface of test materials (Al, steel) and the corrosion testing performed on the resulting samples in different corrosion environments. Data shows that LSP improved the corrosion resistance of Al and steel used in this work relative to respective non-LSP samples. The data also showed that each material had a specific range of laser processing conditions where the beneficial effects of LSP (i.e. improvement in corrosion protection) were observed. Application of LSP to enable low-cost materials in marine environments, additional microstructural analysis and long-term testing are proposed to further develop this technology for marine renewable energy and systems.

36 MATERIALS SCIENCE↗