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At least 397 records · Page 22
All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

MECHANICAL AND CORROSION ASSESSMENT OF FRICTION SELF-PIERCING RIVET JOINT OF CARBON FIBER-REINFORCED POLYMER AND MAGNESIUM ALLOY AZ31B

In the present work, thermoset carbon fiber–reinforced polymer (CFRP) was spot joined to magnesium alloy AZ31B by a friction self-piercing riveting (F-SPR) process. Lap shear tensile and cross-tension testing were used to evaluate the mechanical joint performance. An average lap shear tensile load of 5.18 kN was achieved, while an average of 2.81 kN was found from cross-tension testing. All F-SPR samples showed pull-out of AZ31B after mechanical testing, indicating good mechanical interlocking between the steel rivet and AZ31B. Corrosion potential was measured for each material to establish the galvanic corrosion characteristics. As expected, AZ31B was found to be the most active, while thermoset CFRP was the most noble. The steel rivet fell between the AZ31B (active) and the thermoset CFRP (noble). Salt fog corrosion testing (ASTM B-117) was performed to evaluate the corrosion performance of the uncoated F-SPR joint. With up to 200 h of exposure, the post-corroded F-SPR joint integrity retained 81.2% of the pre-exposure F-SPR joint strength with AZ31B pull-out failure mode. From cross-sectional analysis of the F-SPR joint, extensive corrosion of AZ31B was observed at the joint and other exposure areas. However, steel rivet was not significantly corroded potentially due to sacrificial anode effect by which AZ31B corroded first in the galvanic couple.

Lim, Yong Chae↗
DOE OSTI2024

Potential–Dependent BDAC Adsorption on Zinc Enabling Selective Suppression of Zinc Corrosion for Energy Storage Applications

Utility-scale zinc (Zn) batteries are a promising solution to address the problem of intermittency of renewable energy sources; however, Zn-metal anodes in these batteries suffer from capacity loss due to spontaneous corrosion of the Zn especially when high-surface area anode configurations are employed. Additionally, Zn dendrites are known to form during battery charging limiting the cycle-life of these batteries. Electrolyte additives have been explored that prevent aforementioned issues, but these too come at a cost, i.e., surface-blocking additives polarize the electrode surface leading to loss in the voltaic and energy efficiencies of the battery. In this contribution, a novel electrolyte additive, benzyldimethylhexadecylammonium chloride (BDAC), is investigated for its ability to suppresses corrosion of Zn in an acidic (pH = 3) electrolyte. An attribute of BDAC distinct from previously studied additives is that it selectively suppresses electrochemical activity when the Zn electrode is at its corrosion potential; however, during high-rate Zn deposition (charging) or stripping (discharging), BDAC is essentially deactivated and thus it does not appreciably polarize the electrode surface, thus minimizing voltaic efficiency losses. This selective corrosion suppression behavior is explored using slow-scan voltammetry, which reveals hysteresis implying a potential- or current-dependent BDAC adsorption mechanism in which BDAC reaches higher surface coverages when the partial currents at the Zn surface are low (e.g., at or near the corrosion potential), but BDAC coverage is reduced considerably when the Zn deposition or stripping rates are increased. Numerical simulations of the BDAC diffusion-adsorption process corroborate this mechanism. Ramifications of our approach to the selective suppression of Zn dendrites are discussed.

25 ENERGY STORAGE↗
DOE OSTI2022

Stainless and carbon steel corrosion in aqueous piperazine at absorber and water wash conditions

Corrosion of carbon steel (C1010) and stainless steels (304, 316L, 430) was measured at absorber and water wash conditions at the bench scale. Corrosion rate decreases with increasing concentration of piperazine (PZ). With more than 0.003 m PZ in solution, carbon steel has acceptable corrosion performance. Corrosion of carbon steel increases with increasing partial pressure of CO2, suggesting loading is another dominant parameter. The effect is more significant for dilute PZ; therefore, untreated flue gas with high CO2 content should be avoided in the water wash. Temperature has a less significant effect than PZ concentration and loading. Carbon steel corrosion increases with increasing flow velocity at both absorber and water wash conditions

Liu, Ching-Ting↗
DOE OSTI2021

Analysis of Microbial Communities as Indicators of Microbially Induced Corrosion Potential in Stainless Steel Piping

The 200 West Area Pump-and-Treat (200W P&T) facility is part of the final remedy decision for the 200 ZP-1 Operable Unit (OU) and is the interim remedial action for 200-UP-1 OU at the Hanford Site. The facility also treats water from other sources across the site, including 200-DV-1 OU perched water, groundwater from the 200-BP-5 OU, and leachate from the Environmental Restoration Disposal Facility. The facility originally operated a biological treatment process for nitrate that resulted in systemic biofouling and loss of injection well capacity, requiring frequent and costly well rehabilitation. Biofouling has also contributed to corrosion of welds and pitting of stainless-steel piping at the facility. The biological treatment for nitrate was suspended at the end of 2019 calendar year to eliminate negative impacts from biological treatments which improve facility operations and treatment of carbon tetrachloride. Evaluation of the 200W P&T facility’s response to operational improvements, specifically the suspension of the biological treatment, provides information on the potential for continued microbially induced corrosion (MIC). To this end, historical data sets (2015-2017) were compared with molecular biological analyses of 200W P&T water samples from 2018-2020 to quantify trends in total microbial biomass and specific microbial indicator species (iron, sulfate, nitrate, and manganese reducing bacteria) known to cause and enhance metal corrosion. Results showed unequivocal reductions (in excess of 90%) in all microbiological indicators measured following the suspension of the biological treatment. Although abundance measurements for all corrosive MIC populations initially declined after removal of the treatment system, nitrate-reducing bacteria (nirK) and sulfate-reducing bacteria remain highly abundant in the system, an order of magnitude higher than the number of cells present prior to the removal of the biological treatment system [5.14e (1.4) cells/L, vs. 1.14e (0.07) cells/L, reported as average (±SD) for n=3]. In addition, there was an unexpected inflection point in 2019 where all microbial indicators increased unexpectedly in abundance in 2020 by as much as two orders of magnitude compared to 2019 samples. Given the limited number of water samples available for this analysis, the cause of the increase in microbial indicators post-biological treatment has not yet been determined. Systematic sampling of the facility for continued monitoring is recommended so that the responses of MIC populations can be evaluated to ensure that further corrosion is avoided, allowing the 200W P&T facility to operate safely and efficiently at design capacity.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2024

Corrosion Analysis of 121103072 (SAVY-4000)

A surveillance feedlist for fiscal year (FY) 2022 was developed with the intent to target containers with contents known to generate corrosive gasses. One SAVY-4000 (hereafter “SAVY”) container with a serial number 121103072 was selected due to the reasonable wattage and known molten salt extraction (MSE) material corrosive behavior. The material was measured at 3.08 W with approximately 200 g of material placed inside of the SAVY for 6.07 years. The inner packaging configuration included a ¼ Qt stainless steel slip top inner container and a sPVC bag-out bag enclosing the inner container. Visual observations of the container during retrieval revealed several concerning features on the exterior of the container, notably on the lid. Fig. 1 shows the container lid along with an inset image further magnifying the features of interest. The corroded tamper indicating device (TID) wire and the corroded radioactive material tag wire indicated that corrosive gas species for steel were produced during storage. Although the TID wire and rad tag wire are not the same composition as the SAVY body and lid, these are often used as an indicator of potential corrosion inside of the SAVY container. The oxide residing inside of the filter holes and significant buildup around one hole provided further evidence supporting the presence of corrosive species inside of the container.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Multi-Parameter Optical Fiber for Distributed Sensing of Humidity, CH4, CO2, and Corrosion

This work describes the use of the optical fiber sensor (OFS) for successful monitoring of humidity, CH4, and CO2 based on the strain produced along the single-mode fiber (SMF) sensor. This is enabled by absorption of H2O/gases onto the commercially available polyacrylate coated jacketed portion of the fiber resulting in a change in strain. Under equilibrium, a differential microstrain was observed along the jacketed portion of the SMF with N2, CH4, and CO2 at different relative humidity (RH) conditions. The strain response of the SMF under various mixed gas composition and different RH conditions were also measured and made calibration curves accordingly. Linear regression and principal component analysis of the strain datasets provided deconvolution of the impact of strain from H2O, N2, CH4, and CO2. Additionally, modified OFS comprised of the Fe coated fiber section was employed to monitor corrosion based on the increase in backscattered intensity amplitude of the light being passed once corrosion of Fe occurs. Also, corrosion of Fe was studied under soil by installing the fiber in soil with protective measures which would prevent the sensor being mechanically disturbed or broken during installation. The corrosion rates were studied by monitoring the rate at which the intensity of backscattered light amplitude attains a steady state value when complete corrosion of Fe with a specific coating thickness occurs.

Mainali, Badri↗
DOE OSTI2025

Applied Research and Development to Support Open Water Testing at PacWave – Task 5: Development of additively manufactured, functionally graded, corrosion resistant clads for wave energy applications

In this task, we focused on developing corrosion-resistant claddings for wave energy applications. Wave energy systems are exposed to saline conditions, which are corrosive to many metallic structural materials (e.g., carbon steel). Corrosion-resistant (stainless) steels are typically alloyed with >18% chromium (Cr) and >8% nickel (Ni), which dramatically raises material costs and can hinder the development of wave energy systems; thus, coatings are a necessary corrosion protection method for most. Non-metallic coatings (paint, epoxy) have shorter service lives, limited resistance to mechanical stress and wear, plus additional costs of inspection and eventual replacement. Therefore, overlay stainless steel (SS) claddings have a cost-effective use case for protecting components from corrosion, particularly for those that may be subject to mechanical stress / wear and with long service lives.

16 TIDAL AND WAVE POWER↗
DOE OSTI2026

Degradation science: Integrating modeling and experiments to predict localized corrosion processes (Annual Progress Report)

Additively manufactured (AM) eutectic high-entropy alloys (EHEAs), such as nano-lamellar AlCoCrFeNi 2.1 , have excellent strength, ductility, and wear resistance even at elevated temperatures, but their corrosion behavior in aggressive acids at different length scales remain poorly understood. This work investigates the corrosion behavior of laser powder bed–fused (L-PBF) AlCoCrFeNi 2.1 as a function of annealing temperatures, probing degradation mechanisms from nanoscopic to macroscopic length scales. The alloy is dual phase consisting of a ductile FCC L1 2 phase and a high-strength BCC B2 phase. Rapid solidification during L-PBF produces a far-from-equilibrium nano-lamellar structure with nearly homogeneous elemental distribution, which tends to evolve upon annealing toward Cr/Co/Fe-enriched FCC and Al/Ni-enriched B2. Three conditions were studied: as-printed, 600 °C/5 h, and 1000 °C/1 h, over which B2 lamellae coarsen, lamellar spacing increases, and elemental segregation becomes more prominent. Microstructure and chemistry were characterized by scanning electron microscopy (SEM) and energy-dispersive spectroscopy (EDS), while in-situ electrochemical atomic force microscopy (EC-AFM) was used to link early (<5 h) local dissolution to microstructure after exposure in sulfuric acid. EC-AFM highlights preferential dissolution of the BCC/B2 phase where the surrounding matrix is Cr-depleted and directly quantifies the dissolution rates within individual phases, tracks the transition from early nano-scale attack to partial repassivation, to correlate height differences with current and impedance responses. To monitor longer-term behavior (up to 96 h), ex-situ AFM, SEM, and confocal imaging were combined with conventional bulk electrochemical tests, bridging nanoscale observations to micro/meso-scale damage morphologies. At the meso-scale, the deepest dissolution channels align with the build-direction lamellae and melt-pool boundaries, indicating that printing directionality guides the propagation of these localized corrosion sites. Annealing modifies corrosion by restructuring BCC/FCC phase fractions, lamellar spacing, and Cr/Al segregation, thereby changing the cathode/anode ratio and passive film stability. The results clarify how as-printed and annealed nano-lamellar architectures differ in their susceptibility to selective dissolution; how elemental segregation competes with residual stresses along the build direction. With these insights, future work will use CALPHAD-guided alloy modification to stabilize higher Cr contents in the B2 phase while retaining a dominant FCC+B2/BCC microstructure, with the goal of designing mechanically robust, corrosion-resistant EHEAs for safety-critical applications to leverage the LLNL’s broader national and global security mission.

36 MATERIALS SCIENCE↗
NASA NTRS1972

ZM-21 magnesium alloy corrosion properties and cryogenic to elevated temperature mechanical properties

The mechanical properties of bare ZM-21 magnesium alloy flat tensile specimens were determined for test temperatures of +400 F, +300 F, +200 F, +80 F, 0 F, -100 F, -200 F, and -320 F. The ultimate tensile and yield strengths of the material increased with decreasing temperature with a corresponding reduction in elongation values. Stress corrosion tests performed under: (1) MSFC atmospheric conditions; (2) 95% relative humidity; and (3) submerged in 100 ppm chloride solution for 8 weeks indicated that the alloy is not susceptible to stress corrosion. The corrosion tests indicated that the material is susceptible to attack by crevice corrosion in high humidity and chemical type attack by chloride solution. Atmospheric conditions at MSFC did not produce any adverse effects on the material, probably due to the rapid formation of a protective oxide coating. In both the mechanical properties and the stress corrosion evaluations the test specimens which were cut transverse to the rolling direction had superior properties when compared to the longitudinal properties.

Montana, J. W.↗
NASA NTRS1973

Apollo experience report: The problem of stress-corrosion cracking

Stress-corrosion cracking has been the most common cause of structural-material failures in the Apollo Program. The frequency of stress-corrosion cracking has been high and the magnitude of the problem, in terms of hardware lost and time and money expended, has been significant. In this report, the significant Apollo Program experiences with stress-corrosion cracking are discussed. The causes of stress-corrosion cracking and the corrective actions are discussed, in terminology familiar to design engineers and management personnel, to show how stress-corrosion cracking can be prevented.

Johnson, R. E.↗
NASA NTRS1978

Effect of a chromium-containing fuel additive on hot corrosion

Four cast superalloys (one cobalt-base and three nickel-base) were tested at 900 C for 100 h in Mach 0.3 combustion gases. 5 ppm of synthetic sea salt were added to the gases in the combustion chamber. Several types of thermal cycle and washing procedures were employed. Similar tests were made with the addition of 300 ppm of a chromium-containing fuel additive. In both sets of tests the extent of hot corrosion was evaluated by specific weight change and metal recession. In general, the chromium additive in the fuel reduced the extent of hot (salt) corrosion but did not eliminate it. The percentage reduction of hot corrosion attack was similar for all four alloys. As great a reduction of hot corrosion was achieved by reducing the number of thermal cycles during the test from 100 to 5 or 6. The effect of washing the alloys every ten cycles as opposed to the end of the test was erratic; some alloys were attacked slightly more, others somewhat less. A NiCrAlY coating was found to be more effective in reducing hot corrosion than either the fuel additive or the washing schedule.

Lowell, C. E.↗
NASA NTRS1979

Chemical processes involved in the initiation of hot corrosion of B-1900 and NASA-TRW VIA

Sodium surface-induced hot corrosion of B-1900 and NASA-TRW VIA alloys at 900 C has been studied, with special attention to the chemical reactions during and immediately after the induction period. Thermogravimetric tests were run and data were obtained by chemical analysis of water soluble metal salts and of residual sulfate. Surface analyses of hot corroded samples were obtained by spectroscopic techniques (ESCA). A chemical mechanism for elucidating Na2SO4-induced hot corrosion is proposed indicating that hot corrosion is initiated by basic fluxing of the protective Al2O3 scale. The sequential, catastrophic corrosion results from molybdenum content. The self-sustaining feature is a consequence of the cyclic nature of the acidic fluxing. It is believed that the mechanism is applicable not only to laboratory results, but also to the practical problem of hot corrosion encountered in gas turbine engines.

Fryburg, G. C.↗
NASA NTRS1981

Corrosion of 310 stainless steel in H2-H2O-H2S gas mixtures: Studies at constant temperature and fixed oxygen potential

Corrosion of SAE 310 stainless steel in H2-H2O-H2S gas mixtures was studied at a constant temperature of 1150 K. Reactive gas mixtures were chosen to yield a constant oxygen potential of approximately 6 x 10 to the minus 13th power/cu Nm and sulfur potentials ranging from 0.19 x 10 to the minus 2nd power/cu Nm to 33 x 10 to the minus 2nd power/cu Nm. The kinetics of corrosion were determined using a thermobalance, and the scales were analyzed using metallography, scanning electron microscopy, and energy dispersive X-ray analysis. Two corrosion regimes, which were dependent on sulfur potential, were identified. At high sulfur potentials (p sub S sub 2 less than or equal to 2.7 x 10 to the minus 2nd power/cu Nm) the corrosion rates were high, the kinetics obeyed a linear rate equation, and the scales consisted mainly of sulfide phases similar to those observed from pure sulfication. At low sulfur potentials (P sub S sub 2 less than or equal to 0.19 x 10 to the minus 2nd power/cu Nm) the corrosion rates were low, the kinetics obeyed a parabolic rate equation, and scales consisted mainly of oxide phases.

Rao, D. B.↗
NASA NTRS1981

High temperature alkali corrosion in high velocity gases

The effects of potential impurities in coal derived liquids such as Na, K, Mg, Ca and Cl on the accelerated corrosion of IN-100, U-700, IN-792 and Mar-M509 were investigated using a Mach 0.3 burner rig for times to 1000 hours in one hour cycles. These impurities were injected in combination as aqueous solutions into the combustor of the burner rig. The experimental matrix utilized was designed statistically. The extent of corrosion was determined by metal recession. The metal recession data were fitted by linear regression to a polynomial expression which allows both interpolation and extrapolation of the data. As anticipated, corrosion increased rapidly with Na and K, and a marked maximum in the temperature response was noted for many conditions. In contrast, corrosion decreased somewhat as the Ca, Mg and Cl contents increased. Extensive corrosion was observed at concentrations of Na and K as low as 0.1 PPM at long times.

Lowell, C. E.↗
NASA NTRS1982

Corrosion inhibitors for water-base slurry in multiblade sawing

The use of a water-base slurry instead of the standard PC oil vehicle was proposed for multiblade sawing (MBS) silicon wafering technology. Potential cost savings were considerable; however, significant failures of high-carbon steel blades were observed in limited tests using a water-based slurry during silicon wafering. Failures were attributed to stress corrosion. A specially designed fatigue test of 1095 steel blades in distilled water with various corrosion inhibitor solutions was used to determine the feasibility of using corrosion inhibitors in water-base MBS wafering. Fatigue tests indicate that several corrosion inhibitors have significant potential for use in a water-base MBS operation. Blade samples tested in these specific corrosion-inhibitor solutions exhibited considerably greater lifetime than those blades tested in PC oil.

Chen, C. P.↗
NASA NTRS1982

The relative stress-corrosion-cracking susceptibility of candidate aluminum-lithium alloys for aerospace applications

Stress corrosion tests of Al-Li-Cu powder metallurgy alloys are described. Alloys investigated were Al-2.6% Li-1.4% and Al-2.6% Li-1.4% Cu-1.6% Mg. The base properties of the alloys were characterized. Process, heat treatment, and size/orientational effects on the tensile and fracture behavior were investigated. Metallurgical and electrochemical conditions are identified which provide reproducible and controlled parameters for stress corrosion evaluation. Preliminary stress corrosion test results are reported. Both Al-Li-Cu alloys appear more susceptible to stress corrosion crack initiation than 7075-T6 aluminum, with the magnesium bearing alloy being the most susceptible. Tests to determine the threshold stress intensity for the base and magnesium bearing alloys are underway. Twelve each, bolt loaded DCB type specimens are under test (120 days) and limited crack growth in these precracked specimens has been observed. General corrosion in the aqueous sodium chloride environment is thought to be obscuring results through crack tip blunting.

Pizzo, P. P.↗
NASA NTRS1983

Mechanism of corrosion of Ni base superalloys by molten Na2MoO4 at elevated temperatures

The corrosion of nickel base superalloy, U-700, by molten Na2MoO4 was studied in the temperature range of 750 deg to 950 deg C. After an induction period, the rate of corrosion is linear and catastrophic corrosion is observed. It is shown that the induction period is associated with the attainment of a minimum MoO3 activity in the melt, which corresponds to the equilibrium MoO3 activity for the reaction, 2MoO3(l) + Mo = 3MoO2(s). A mechanism is proposed to describe the catastrophic nature of corrosion, which involves transport of Ni++ through the melt resulting in formulation of NiO at the melt gas interface and basic fluxing of Cr2O3. The effect of the amount of Na2MoO4 on the corrosion kinetics was also studied. It is found that evaporation and the thermodynamic calculations for the Na2MoO4 - MoO3 system the activity of MoO3 is reduced considerably when dissolved in Na2MoO4, which causes a sharp decrease in the rate of evaporation of MoO3 from a Na2MoO4 - MoO3 melt.

Misra, A. K.↗