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At least 397 records · Page 22

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DOE OSTI2019

The Anodic Role of Ni-Containing LPSO Phases During the Microgalvanic Corrosion of Mg{sub 98}Gd{sub 1.5}Ni{sub 0.5} Alloy

In the present study, the corrosion characteristics of cast Mg{sub 98}Gd{sub 1.5}Ni{sub 0.5} alloy with Ni-containing long-period stacking ordered (LPSO) structures were investigated. The results reveal that the Ni-containing LPSO phases were more active than the Mg matrix and preferentially eroded during the immersion process. This behavior indicates that the Ni-containing LPSO phases could have acted as microanodes, in contrast to the cathodic role of the Ni-free LPSO phases in other Mg alloys. Furthermore, the potential difference of approximately 600 mV between the phases accelerated the dissolution rate of the LPSO phase. Corrosion of the Mg matrix also occurred due to the inhomogeneous microstructure of the matrix. The synergetic corrosion between the Ni-containing LPSO phases and the enrichment of Cl{sup −} in the thick corrosion product films dominated the propagation of corrosion, which substantially deteriorated the corrosion resistance and accelerated the corrosion process of the Mg{sub 98}Gd{sub 1.5}Ni{sub 0.5} alloy.

36 MATERIALS SCIENCE↗

DOE OSTI2019

Corrosion and Electrochemical Behavior of Sn-2Ag-0.5Cu Lead-Free Solders Solidified with Magnet Stirring

In this study, permanent magnet stirring (PMS) was applied to modify the crystallographic texture and corrosion resistance of Sn-2Ag-0.5Cu (SAC205) solders. The results indicate that PMS transforms the lamellar structure into equiaxed grains. Following the initiation corrosion process, the crystallographic texture shows a new class of grains that consists of single-crystal morphology with {111}{sub Sn} facets before applying PMS. This could result in severe corrosion of β-Sn crystals with non-uniform corrosion rate caused by the orientation effect of (111). The corrosion rate for SAC205 solder, measured by immersion tests in 3.5% NaCl solution at 25 °C, was significantly decreased from 31 to 8 mpy after applying PMS. This change in corrosion resistance of SAC205 solder can be attributed to the improved anodic and cathodic reaction activities caused by the modification of microstructure and crystallographic texture. The mechanism of pitting and sequential corrosion events is fully explained and discussed.

36 MATERIALS SCIENCE↗

DOE OSTI2021

A review on molten sulfate salts induced hot corrosion

Hot corrosion has been extensively observed in various high temperature applications, which might cause large economic losses. Here, to deepen the insight and understanding of hot corrosion, we provide a detailed discussion on hot corrosion induced by molten sulfate salt, in which Na 2 SO 4 is the main chemical reactant. The hot corrosion is triggered and sustained by the negative solubility gradient of protective oxide from the oxide/salt interface to salt/gas interface. In this work, we reviewed several key factors, including temperature, gas composition, molten salt composition, alloy element and external stress, influencing the hot corrosion of alloy beneath the molten salt. The application of anti-corrosion coating seems to be the most effective and commercial mothed to mitigate hot corrosion. Therefore, the progress of the development of effective coatings, e.g., Ni-Cr coatings, aluminide coatings, silicide coatings and MCrAlY(X) coatings, has also been summarized.

36 MATERIALS SCIENCE↗

DOE OSTI2023

Development of hydrothermal corrosion model and BWR metal coating for CVD SiC in light water reactors

SiC/SiC fiber composites with CVD SiC overcoats are potential candidates for light water reactor advanced accident tolerant cladding materials. Understanding its corrosion kinetics in Light Water Reactor (LWR) conditions is essential to evaluate the concept's viability. Existing models only account for the temperature and oxygen concentration effect on the hydrothermal corrosion behavior applicable to LWR operating conditions. However, the development of a general corrosion rate for CVD SiC that accounts for the impact of irradiated microstructure, flow rate, electrical resistivity, pH, and surface roughness is critical for the practical realization of SiC/SiC-based cladding concepts. After a rigorous experimental campaign, this work updates the existing hydrothermal corrosion model to predict hydrothermal corrosion in LWRs. Numerical radiation and coolant chemistry analysis for LWRs conducted based on the updated corrosion kinetic models suggests that CVD SiC is likely a viable environmental barrier coating for Pressurized Water Reactors while questionable for Boiling Water Reactors (BWR) when the effect of irradiation damage on SiC corrosion is considered. An effective mitigation strategy for the double-layer metal coating is proposed for BWR applications. The double-layer metal coating comprising a FeCrAl overcoat with an intermediate Cr bond coating was observed to provide a stable protective barrier against SiC dissolution in BWR conditions. Finally, the proposed metal coating was also fully adherent following quench and burst tests.

36 MATERIALS SCIENCE↗

DOE OSTI2018

Intergranular corrosion resistance of Zn modified 5××× series Al alloy during retrogression and re-aging treatment

Highlights: • Increase the strength due to precipitation hardening of T-Mg{sub 32}(AlZn){sub 49} phase in the Zn modified Al-Mg alloy. • Both high corrosion resistance and high strength are achieved by retrogression and re-aging treatment in Al-5Mg-3Zn alloy. • Large Mg and Zn content difference between GBP and PFZ results in relatively high IGC susceptibility. • The intergranular corrosion mechanism of Zn modified Al-Mg alloy during retrogression and re-aging treatment is clarified. - Abstract: The effects of retrogression and re-aging treatment on the intergranular corrosion behavior of Al-5.0Mg-3.0Zn alloys are systematically studied. The alloy's strength increases when retrogression temperature increases from 390 °C to 420 °C. Samples retrogressed at 390 °C then re-aged are very susceptible to intergranular corrosion and those retrogressed at 405 °C and 420 °C express good corrosion resistance. Then the alloy's corrosion susceptibility rises with increasing retrogression temperature. Grain boundary precipitates are coarsened and distributed discontinuously with decreasing retrogression temperature. Higher retrogression temperature results in higher Mg and Zn content difference and intergranular corrosion susceptibility.

36 MATERIALS SCIENCE↗

DOE OSTI2026

Atomistic Mechanisms of Stress-Dependent Molten Salt Corrosion in NiCr Alloys

Ni-based structural alloys in molten salt environments often experience simultaneous mechanical loading and corrosive attack, yet the mechanisms governing stress-corrosion interactions remain unclear. Prior studies largely emphasize tensile stress, while the role of compressive stress has received limited attention. Here, reactive molecular dynamics simulations are used to investigate the coupled effects of applied strain and corrosion in Ni 0.75 Cr 0.25 exposed to molten FLiNaK at 800 °C. A Σ5(210) grain boundary model is subjected to tensile (+4%) to compressive (−4%) uniaxial strains, and corrosion behavior is evaluated through fluorine adsorption, charge redistribution, and grain boundary evolution. Tensile strain accelerates intergranular corrosion susceptibility by reducing local atomic packing through elastic dilation and increasing excess free volume at the grain boundary, which enhances atomic mobility and salt infiltration. In contrast, compressive strain can suppress corrosion by promoting the formation of a ridge-like surface layer along the grain boundary, limiting salt access to the underlying alloy. These results provide atomistic insight into how stress states influence grain boundary corrosion in molten salts.

36 - MATERIALS SCIENCE↗

DOE OSTI2019

Quantitative Nanoscale 3D Imaging of Intergranular Corrosion of 304 Stainless Steel Using Hard X-Ray Nanoprobe

Multi-modal imaging, which visualizes changes in the structure and chemistry of the same region of interest in materials by combining various techniques, is becoming attractive to material scientists. Here, we describe a multi-modal approach to investigate intergranular (IG) corrosion of sensitized stainless steels using synchrotron-based nanoscale X-ray imaging with sensitivity to microstructure and chemical composition. Three-dimensional tomography of 304 stainless steel samples deteriorated by IG corrosion, was carried out using X-ray fluorescence and differential phase contrast imaging. These findings were further supported with surface imaging and chemical analysis using scanning electron microscopy and energy dispersive X-ray spectroscopy. The combined quantitative structural and chemical analysis indicates that chromium segregates along grain boundaries, cracking is due to IG corrosion, and Cr-enrichment occurs on the cracked surfaces. Such quantitative 3D imaging of Cr 23 C 6 nucleation at grain boundaries and Cr enriched oxides at cracked surfaces is a powerful tool to correlate IG corrosion mechanisms at nanoscale with buried grain boundary structure and alloy composition. Such understanding of IG corrosion mechanisms is critical for both the development of predictive multiscale corrosion models, and the engineering of corrosion resistant materials.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2024

Enhancing corrosion resistance of lightweight metal alloys through laser shock peening

In this study, we investigated the effects of laser shock peening (LSP) on the corrosion resistance of lightweight metal alloys, specifically AA6061 and AZ31. LSP was performed underwater, using a nanosecond pulse laser and without using a protective coating or layer on the workpiece. The corrosion behaviors of these alloys were analyzed through electrochemical tests, including open circuit potential, electrochemical impedance spectroscopy, and potentiodynamic polarization measurements. The results demonstrated that LSP significantly improved the polarization resistance, and higher laser power intensities led to increased corrosion resistance and reduced corrosion rates. This enhancement in anti-corrosion performance is attributed to the formation of a protective oxide layer on the surface, acting as a barrier against corrosion. In conclusion, the findings underscore the potential of laser surface treatment as a viable technique for enhancing the corrosion resistance of lightweight metal alloys.

36 MATERIALS SCIENCE↗

NASA NTRS2015

Smart Multifunctional Coatings for Corrosion Detection and Control in the Aerospace Industry

Nearly all metals and their alloys are subject to corrosion that causes them to lose their structural integrity or other critical functionality. It is essential to detect corrosion when it occurs, and preferably at its early stage, so that action can be taken to avoid structural damage or loss of function. Protective coatings are the most commonly used method of corrosion control. However, progressively stricter environmental regulations have resulted in the ban of many commercially available corrosion protective coatings due to the harmful effects of their solvents or corrosion inhibitors. This work concerns the development of a multifunctional, smart coating for the autonomous control of corrosion. This coating is being developed to have the inherent ability to detect the chemical changes associated with the onset of corrosion and respond autonomously to indicate it and control it.

Corrosion↗

NASA NTRS2016

Corrosion Control in the Aerospace Industry

Corrosion Control↗

NASA NTRS2016

Smart Coatings for Corrosion Protection

Coatings↗

DOE OSTI2016

Corrosion test of LWR cladding tubes in high temperature seawater

In the case of cooling system failure in spent fuel pools (SFP) due to station black out and/or loss of coolant accidents, a pool water level must be kept high enough to avoid overheat of spent fuels. Seawater is one of the candidate coolant materials in such emergencies. In the present work, we have studied the corrosion behavior of zirconium alloys in seawater. Tube samples of Zircaloy-2 and -4 claddings were immersed in artificial seawater (3, 10 and 20 wt.%) at high temperature (80 - 85 Celsius degrees). Boric acid was added to the seawater at a corrosion test of Zircaloy-4. Two types of specimens were prepared according to the simulation of circumferential tensile stress. One was a plugged tube specimen, which was pressurized to around fuel rod pressure in a spent fuel pool by argon gas. Another specimen was of C-ring shape, where large circumferential tensile stress was partially induced at the surface. A notch was longitudinally grooved to increase the local tensile stress on some of the C-ring specimens. The specimen surface was observed by a scanning electron microscopy (SEM) after the corrosion test. After the 200 day long corrosion test for the plugged tube specimens without boric acid, Mg(OH){sub 2} deposits were observed on the surface of Zircaloy-2 and -4 specimens whereas Mg(OH){sub 2} was not observed with boric acid because of probably a lower pH. Neither pitting corrosion nor stress corrosion cracking (SCC) was observed on the surface of all plugged tube specimens. Only in the C-ring specimens in 20 wt.% seawater without boric acid and in 3 and 10 wt.% seawater with boric acid, small cracks were observed at the notch. The results of the present work show that Zircaloy-2 and -4 have a high tolerance towards corrosion and SCC in high temperature seawater.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2016

Hanford Double Shell Waste Tank Corrosion Studies - Final Report FY2015

During FY15, SRNL performed corrosion testing that supported Washington River Protection Solutions (WRPS) with their double shell tank (DST) integrity program. The testing investigated six concerns including, 1) the possibility of corrosion of the exterior of the secondary tank wall; 2) the effect of ammonia on vapor space corrosion (VSC) above waste simulants; 3) the determination of the minimum required nitrite and hydroxide concentrations that prevent pitting in concentrated nitrate solutions (i.e., waste buffering); 4) the susceptibility to liquid air interface (LAI) corrosion at proposed stress corrosion cracking (SCC) inhibitor concentrations; 5) the susceptibility of carbon steel to pitting in dilute solutions that contain significant quantities of chloride and sulfate; and 6) the effect of different heats of A537 carbon steel on the corrosion response. For task 1, 2, and 4, the effect of heat treating and/ or welding of the materials was also investigated.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2019

The Electrochemical Corrosion Behavior of Plasma Electrolytic Oxidation Coatings Fabricated on Aluminum in Silicate Electrolyte

Plasma electrolytic oxidation (PEO) coatings were fabricated on the aluminum in silicate electrolyte. Microstructures and elemental compositions of these PEO coatings were examined by scanning electron microscopy (SEM) equipped with an energy-dispersive x-ray spectroscopy (EDS). Corrosion resistances of the coated samples were evaluated using the measurements of open-circuit potential (OCP), repetitive polarization and electrochemical impedance spectroscopy (EIS) in 3.5 wt.% NaCl solution. The results indicated that the PEO coatings not only act as a physical shield limiting the penetration of corrosive solution, but also establish an anodic location with high concentration of H{sup +} ions and other product ions as pitting corrosion begins. With the development of pitting corrosion, the accumulation of corrosion products inside the pits and pores of the coatings decreases the corrosion process effectively.

36 MATERIALS SCIENCE↗

DOE OSTI2022

Integrated High‐Throughput and Machine Learning Methods to Accelerate Discovery of Molten Salt Corrosion‐Resistant Alloys

Insufficient availability of molten salt corrosion-resistant alloys severely limits the fruition of a variety of promising molten salt technologies that could otherwise have significant societal impacts. To accelerate alloy development for molten salt applications and develop fundamental understanding of corrosion in these environments, here an integrated approach is presented using a set of high-throughput (HTP) alloy synthesis, corrosion testing, and modeling coupled with automated characterization and machine learning. By using this approach, a broad range of Cr-Fe-Mn-Ni alloys are evaluated for their corrosion resistances in molten salt simultaneously demonstrating that corrosion-resistant alloy development can be accelerated by 2 to 3 orders of magnitude. Based on the obtained results, a sacrificial protection mechanism is unveiled in the corrosion of Cr-Fe-Mn-Ni alloys in molten salts which can be applied to protect the less unstable elements in the alloy from being depleted, and provided new insights on the design of high-temperature molten salt corrosion-resistant alloys.

36 MATERIALS SCIENCE↗

DOE OSTI2018

Analysis of Brazing Effect on Hot Corrosion Behavior of a Nickel-Based Aerospace Superalloy

The effects of brazing and use of composite powder mixture as interlayer material on hot corrosion resistance of brazed IN738 superalloy were studied. Brazing was observed to result in significant reduction in the hot corrosion resistance of the superalloy. However, application of composite powder mixture, which consists of additive superalloy powder, enhanced the hot corrosion resistance of brazed samples. It is also found that although the use of composite powder mixture increased hot corrosion resistance of brazed alloy, if the additive powder completely melts, which is possible during brazing, it can significantly reduce the hot corrosion resistance of the brazed joint. Elemental micro-segregation during solidification of the joint with completely melted powder mixture produces chromium-depleted zones and consequently reduces hot corrosion resistance, since a uniform distribution and adequate chromium concentration are necessary to combat hot corrosion. This has not been previously reported in the literature and it is crucial to the use of composite powder mixture for enhancing the properties of brazed superalloys.

36 MATERIALS SCIENCE↗

DOE OSTI2017

Preliminary Investigation of the Corrosion Behavior of Proprietary Micro-alloyed Steels in Aerated and Deaerated Brine Solutions

The corrosion performance of fairly new generation of micro-alloyed steels was compared in different concentrations of aerated and deaerated brines. Electrochemical polarization, weight loss and surface analyses techniques were employed. The results showed a threshold of corrosion rate at 3.5 wt.% NaCl in both aerated and deaerated solutions. The average corrosion current density for steel B, for example, increased from 1.3 µA cm{sup −2} in 1 wt.% NaCl to 1.5 µA cm{sup −2} in 3.5 wt.% NaCl, but decreased to 1.4 µA cm{sup −2} in 10 wt.% deaerated NaCl solutions. The aerated solutions exhibited an average of over 80% increase in corrosion current density in the respective concentrations when compared with the deaerated solution. These results can be attributed to the effects of dissolved oxygen (DO) which has a maximum solubility in 3.5 wt.% NaCl. DO as a depolarizer and electron acceptor in cathodic reactions accelerates anodic metal dissolution. The difference in carbon content and microstructures occasioned by thermo-mechanical treatment contributed to the witnessed variation in corrosion performance of the steels. Specifically, the results of the various corrosion techniques corroborated each other and showed that the corrosion rate of the micro-alloyed steels can be ranked as CR{sub Steel A} < CR{sub X65} < CR{sub Steel B} < CR{sub Steel C}.

36 MATERIALS SCIENCE↗

DOE OSTI2018

A Micro-Mechanism-Based Continuum Corrosion Fatigue Damage Model for Steels

A micro-mechanism-based corrosion fatigue damage model is developed for studying the high-cycle corrosion fatigue of steel from multi-scale viewpoint. The developed physical corrosion fatigue damage model establishes micro-macro relationships between macroscopic continuum damage evolution and collective evolution behavior of microscopic pits and cracks, which can be used to describe the multi-scale corrosion fatigue process of steel. As a case study, the model is used to predict continuum damage evolution and number density of the corrosion pit and short crack of steel component in 5% NaCl water under constant stress amplitude at 20 kHz, and the numerical results are compared with experimental results. It shows that the model is effective and can be used to evaluate the continuum macroscopic corrosion fatigue damage and study microscopic corrosion fatigue mechanisms of steel.

36 MATERIALS SCIENCE↗