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At least 811 records · Page 45
All sourcesNASA NTRSDOE OSTI
DOE OSTI2017

Corrosion Characteristics of New Superalloy Under Industrial Environmental Conditions

Corrosion behavior of new superalloy was studied in industrial environment at different temperatures by using various selected electrochemical techniques. The results revealed that the alloy is able to form protective oxide scale on its surface at higher temperatures and consequently the corrosion rate is low. The new alloy is found to degrade due to pitting corrosion at 40 and 50 °C and general corrosion at 25 °C. The scanning electron microscope results confirmed the electrochemical results. The energy-dispersive spectroscopy results confirmed the presence of oxides of nickel and alloying elements present in the superalloy. Based on the results obtained with different techniques, the alloy is recommended to fabricate different components for industrial applications with suitable protective coatings.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Plasma Electrolytic Oxidation Coatings on Pure Ti Substrate: Effects of Na{sub 3}PO{sub 4} Concentration on Morphology and Corrosion Behavior of Coatings in Ringer’s Physiological Solution

Plasma electrolytic oxidation has been used as a relatively new method for applying ceramic coatings having different features. In the present study, commercially pure titanium is used as substrate, and effects of trisodium phosphate electrolyte concentration on the microstructure, as well as corrosion behavior of the coating in Ringer’s physiological solution are investigated. The morphology and phase compositions of coatings were analyzed by using scanning electron microscopy (SEM) and x-ray diffraction patterns. The study on the corrosion behavior of samples in a Ringer’s physiological solution was carried out using open-circuit potential potentiodynamic polarization and electrochemical impedance spectroscopy. The results of electrochemical analysis proved that higher concentration of phosphate electrolyte leads to increase in the corrosion resistance of applied coatings. Accordingly, obtained results revealed that the optimum electrolyte concentration for the best corrosion behavior was 20 g L{sup −1}. Furthermore, SEM images and reduction in the dielectric breakdown potential indicated that increase in the electrolyte concentration leads to morphological improvement and smoothening of the surface.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Study on the Microstructure, Mechanical Properties and Corrosion Behavior of Mg-Zn-Ca Alloy Wire for Biomaterial Application

Due to their excellent biocompatibility and biodegradability, magnesium alloy wires have attracted much attention for biomaterial applications including orthopedic K-wires and sutures in wound closure. In this study, Mg-3Zn-0.2Ca alloy wires were prepared by cold drawing combined with proper intermediate annealing process. Microstructures, texture, mechanical properties and corrosion behavior of Mg-3Zn-0.2Ca alloy wire in a simulated body fluid were investigated. The results showed that the secondary phase and average grain size of the Mg-3Zn-0.2Ca alloy were refined in comparison with the as-extruded alloy and a strong (0002)<10-10>//DD basal fiber texture system was formed after multi-pass cold drawing. After the annealing, most of the basal planes were tilted to the drawing direction (DD) by about 35°, presenting the characteristics of random texture, and the texture intensity decreased. The as-annealed wire shows good mechanical properties with the ultimate tensile strength (UTS), yield strength (YS) and elongation of 253 ± 8.5 MPa, 212 ± 11.3 MPa and 9.2 ± 0.9%, respectively. Electrochemical and hydrogen evolution measurements showed that the corrosion resistance of the Mg-3Zn-0.2Ca alloy wire was improved after the annealing. The immersion test indicated that the Mg-3Zn-0.2Ca wire exhibited uniform corrosion behavior during the initial period of immersion, but then exhibited local corrosion behavior.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Effects of In Situ Intermetallics on the Microstructural Array and Saline Corrosion Performance of Cast Al/WCp Composites

Al-matrix composites, ex situ reinforced with WC nanoparticles and in situ reinforced with Al{sub 3}(Ti,W), Al{sub 12}W, Al{sub 5}W and Al{sub 4}W, have been fabricated by casting assisted by K{sub 2}TiF{sub 6} wetting agent addition and mechanical stirring. A satisfactory particle incorporation and distribution accompanied by a high reactivity have been attained. The presence, topography, chemical composition of all included phases and their occurrence as clusters or single particles are clarified and justified. Al{sub 12}W is the predominant aluminide phase at WC ≤ 1.5 vol.%. Al{sub 4}W (primarily) and Al{sub 5}W (secondarily) are the predominant aluminide phases at WC ≥ 2.0 vol.%. WC nanoparticles have acted as heterogeneous nucleation sites to Al{sub 3}Ti particles. Reverse polarization tests in 3.5 wt.% NaCl show that the governing form of corrosion is intergranular corrosion of Al around Al{sub 3}FeSi{sub 2} eutectic, fine plates. The corrosion steps/mechanisms are identified. Clusters of aluminides and carbide nanoparticles, as well as intergranular WC nano-dispersoids and their Al-matrix have remained corrosion-free. The role of the aluminides combined with WC remaining nano-cores as inhibitors of the eutectic Al{sub 3}FeSi{sub 2} cathodic activity is highlighted.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Severe Hot Corrosion of the Superalloy IN718 in Mixed Salts of Na{sub 2}SO{sub 4} and V{sub 2}O{sub 5} at 700 °C

This study presents hot corrosion behavior of the superalloy IN718 in 100 wt.% NaCl (salt S) and in salt mixtures of 60 wt.% Na{sub 2}SO{sub 4} + 40 wt.% V{sub 2}O{sub 5} (SM1) and 75 wt.% Na{sub 2}SO{sub 4} + 15 wt.% NaCl + 10 wt.% V{sub 2}O{sub 5} (SM2), deposited separately by spray gun technique, at elevated temperature of 700 °C. The weight gain per unit area at 700 °C was increased by 49% for salt S, 153% for the dual salt mixture SM1, and only 8% for the triple salt mixture SM2, in comparison with that observed earlier at 600 °C. The marked increase in the severity of corrosion at 700 °C is attributed to formation of the highly damaging compound NaVO{sub 3} that significantly enhances the oxygen activity, in the SM1 coated samples. The effect of surface roughness and dislocation density on corrosion behavior at 700 °C, however, is found to be similar to that at 600 °C. Ultrasonic shot peening, a novel technique of surface modification, is found to enhance the hot corrosion resistance in the salt mixture SM1 at 700 °C appreciably due to extensive grain refinement to nanoscale and formation of highly protective Cr{sub 2}O{sub 3} layer in the surface region.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Effect of Welding Parameters on the Corrosion Behavior of Dissimilar Alloy Welds of T6 AA6061 Al-Galvanized Mild Steel

Partial replacement of steel by Aluminium (Al) alloys is a promising approach adopted by automotive sector to improve fuel efficiency without compromising on the strength. However, this results in the generation of dissimilar welds of Al alloys and steel. Understanding the corrosion behavior of Al alloys–steel welds as a function of welding parameters is critical in the successful application of such alloys. The present study reports the intergranular corrosion behavior of T6 heat-treated AA6061 Al alloy-galvanized mild steel lap joints, welded by metal inert gas welding–brazing technique as a function of different welding parameters, viz. weld speed (4-6 m/min) and wire feed rate (0.8-0.9 m/min), following ASTM G 67-04. Weld characterization was performed by field emission scanning electron microscopy (FESEM), x-ray diffraction and nano-hardness measurement. Results indicate heavy dissolution and metal loss at the interface. A high volume fraction of Al-Fe intermetallics was precipitated at the weld interfaces, resulting in high hardness and higher localized corrosion. The thickness of Al-Fe intermetallic layer increased with increasing wire feed rate and lower weld speed which enhanced the severity of galvanic and intergranular corrosion.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Corrosion Behavior of Plasma-Nitrided 904L Austenitic Stainless Steel in Hydrofluoric Acid

A new type of high-chromium nickel molybdenum super austenitic stainless steel, 904L, has excellent corrosion resistance in acidic environments. However, the service life of 904L decreases significantly in a mixed acid system that includes hydrogen fluoride and sulfuric acid. In this article, different plasma nitriding processes were used to modify the surface of 904L stainless steel. X-ray diffraction was used to analyze the phase composition after nitriding; scanning electron microscopy and atomic force microscopy were used to examine the surface morphology after nitriding; electrochemical noise and electrochemical methods were used to study the localized corrosion behavior and the damage mechanism of the ion nitride layer; and the effect of the plasma nitride layer on the corrosion resistance was explored. The results show that with increasing nitriding time, the thickness of the nitride layer increased. Ion nitriding resulted in the coarsening of the 904L austenitic stainless steel surface. A long nitriding treatment time resulted in the precipitation of CrN in the modified layer, depleting the chromium from the matrix and remarkably reducing the corrosion resistance.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Improved Corrosion Resistance of Ni-Co Coatings Prepared by Electrodeposition with Large Centrifugal Acceleration

A higher Co content in Ni-Co coatings leads to better corrosion resistance to a certain degree. In this paper, centrifugal acceleration was introduced in the electrodeposition of Ni-Co coatings in order to obtain improved Ni-Co coatings with high Co content. With different centrifugal accelerations, the Co content, morphology, preferred coating orientation, microhardness, and wear and corrosion resistance were examined. Under large centrifugal acceleration, a maximal Co content of 38.25% was obtained according to the EDS results, which was higher than that obtained using normal electrodeposition. The SEM images indicated that the morphology of the prepared Ni-Co coatings with the highest Co content was smoothened. In addition, the microhardness of Ni-Co coatings with increased Co content was improved to about 530HV, which was hardly achieved under normal electrodeposition. Most of all, based on the polarization curve and EIS results, the corrosion resistance was significantly enhanced as the Co content reached the maximum. In general, corrosion resistance of the deposited Ni-Co coatings can be improved with large centrifugal acceleration.

36 MATERIALS SCIENCE↗
DOE OSTI2019

The Microstructure, and Mechanical and Corrosion Properties of As-Cast and As-Extruded Mg-2%Zn-x%Cu Alloys After Solution and Aging Heat Treatments

The effects of different Cu concentrations and heat treatment on the microstructure, mechanical and corrosion properties of the as-cast and hot-extruded Mg-2%Zn alloys were studied. The results showed that T6 heat treatment led to the dissolution of intermetallics and breaking the continuous networks of intermetallics. Also, the grain size of the base alloy decreased with further Cu additions after solution and aging heat treatments. Microstructural characterization indicated that Mg(Zn,Cu) and Mg(Zn,Cu){sub 2} intermetallics were formed which their volume fractions increased with exceeding Cu additions. Moreover, the addition of 3 wt.% Cu and T6 heat treatment increased the Brinell hardness of both as-cast and hot-extruded specimens reached to 94 HBN and 116 HBN, respectively. The optimum amounts of the ultimate tensile strength and elongation values obtained from 0.1 wt.% Cu addition for both conditions after T6 treatment which were 253 MPa, 11.5% and 263 MPa, 14.7%, respectively. However, more Cu addition (> 0.5 wt.%) deteriorated the tensile properties of the alloy due to the high volume fraction of intermetallics. The yield tensile strength increased continuously with different Cu additions for the cast and extruded alloys after solution and aging heat treatments. After T6 heat treatment, extruded alloys showed better anti-corrosion properties than those of the cast alloys, while the extruded Mg-2%Zn-0.1%Cu alloy exhibited the best anti-corrosion property. Further Cu addition increased the volume fraction of intermetallics and enhanced the corrosion rate which was due to the galvanic couple effect.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Surface Structure and Corrosion Behavior of Mg{sub 68−x}Zn{sub 28+x}Ca{sub 4}(x = 0.4) Bulk Metallic Glasses after Immersion in Ringer’s Solution

The main aim of the present study was to determine the impact of Zn on the surface structure and corrosion behavior of Mg-based metallic glasses after immersion in Ringer’s solution. The corrosion rate expressed by the volume of released hydrogen in the form of a function of immersion time in Ringer’s solution at 37 °C was presented. The surface structure and corrosion products, which were formed during the immersion tests, were examined by means of scanning electron microscopy and the following spectroscopic methods: x-ray photoelectron spectroscopy, x-ray diffractometry, secondary ion mass spectrometry and energy-dispersive x-ray spectroscopy. As a result of the investigations of the surface structure, oxides (MgO, CaO, ZnO), hydroxides (Mg(OH){sub 2}, Ca(OH){sub 2}) and carbonates (CaCO{sub 3}) were identified. The analysis of the research results allowed the determination of a probable course and corrosion mechanism of the above-mentioned metallic glasses during immersion in Ringer’s solution.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Microstructure and Corrosion Behavior of Cr Coating on M50 Steel Fabricated by Electrospark Deposition

Cr coatings are deposited on M50 steel by electrospark deposition with different parameters (100 V-60 μF, 100 V-90 μF, 100 V-120 μF, 150 V-60 μF, 150 V-90 μF and 150 V-120 μF). Influences of the depositing parameters on the microstructure and the corrosion behavior of the coatings were experimentally investigated. There is a linear trend of growth between the mass gain per area and the deposition cycles before reaching the maximum values. The voltage has more influence on the mass gain per area than the capacitance. The coatings display a splash-like pattern decorated with a few of micro-cracks. The micro-cracks are more sensitive to the voltage than the capacitance. The anti-corrosion ability of the coating is significantly better than the M50 steel. Local corrosion occurs in the coating when there are through-coating cracks. The coating deposited under 150 V-60 μF has the minimum defect density and the best anti-corrosion behavior.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Comparative Corrosion Behavior of Five Different Microstructures of Rebar Steels in Simulated Concrete Pore Solution with and Without Chloride Addition

The present work discusses the effect of five different microstructures, coarse, fine and very fine ferrite–pearlite, martensite and tempered martensite, made by furnace cooling, air cooling, forced air-cooling, water quenching and tempering, respectively, of a rebar steel on its corrosion performance in freely aerated with and without chloride-contaminated simulated concrete pore solution using the dynamic polarization and electrochemical impedance spectroscopy. The corrosion performance of the steels with five different microstructures relates to the polarization resistance, protective ability of rusts and the extent of the galvanic attack. The corrosion rate of the steels has been found to be comparable in the simulated concrete pore (SCP) solution. However, in chloride-containing SCP solution, corrosion rate has been found to increase in the following sequence: forced air-cooled–air-cooled–quenched–furnace-cooled–tempered steels.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Mechanical and Corrosion Properties of Additively Manufactured CoCrFeMnNi High Entropy Alloy

Here, this study investigates the mechanical and corrosion properties of as-built and annealed equiatomic CoCrFeMnNi alloy produced by laser-based directed energy deposition (DED) Additive Manufacturing (AM). The high cooling rates of DED produced a single-phase, cellular microstructure with cells on the order of 4 μm in diameter and inter-cellular regions that were enriched in Mn and Ni. Annealing created a chemically homogeneous recrystallized microstructure with a high density of annealing twins. The average yield strength of the as-built condition was 424 MPa and exceeded the annealed condition (232 MPa), however; the strain hardening rate was lower for the as-built material stemming from higher dislocation density associated with DED parts and the fine cell size. In general, the yield strength, ultimate tensile strength, and elongation-to-failure for the as-built material exceeded values from previous studies that explored other AM techniques to produce the CoCrFeMnNi alloy. Ductile fracture occurred for all specimens with dimple initiation associated with nanoscale oxide inclusions. The breakdown potential (onset of pitting corrosion) was similar for the as-built and annealed conditions at 0.40 V Ag/AgCl when immersed in 0.6 M NaCl. Pit morphology/propagation for the as-built condition exhibited preferential corrosion of inter-cellular Ni/Mn regions leading to a tortuous pit bottom and cover, while the annealed conditions pits resembled lacy pits similar to 304 L steel. Lastly, a passive oxide film depleted in Cr cations with substantial incorporation of Mn cations is proposed as the primary mechanism for local corrosion susceptibility of the CoCrFeMnNi alloy.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Carburization effects on the corrosion of Cr, Fe, Ni, W, and Mo in fluoride-salt cooled high temperature reactor (FHR) coolant

Corrosion of structural alloys in fluoride salt cooled high temperature reactors (FHRs) is affected by the presence of carbon. The stability of the carbides of alloying elements augments their corrosion, however the same property can be useful if these stable carbides are used to protect materials. Exposure tests of pure elements Cr, Fe, Ni, W, and Mo in graphite crucibles at 700 °C were conducted in molten FLiNaK salt for 100 h. Carbide particles were detected on the surfaces of Cr, Mo, and W samples after exposure. The ranking of these elements, from least to greatest corrosion resistance by mass loss per unit area was Cr < Fe < W < Mo < Ni. The stability of chromium carbides was further investigated using chromium samples which were pre-carburized in a reducing hydrocarbon environment at 800 °C prior to exposure tests in molten FLiNaK. In conclusion, the chromium carbide layer produced by pre-carburization was resistant to attack by molten fluoride and slowed corrosion of the underlying chromium metal.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2013

Corrosion of aluminium metal in OPC- and CAC-based cement matrices

Corrosion of aluminium metal in ordinary Portland cement (OPC) based pastes produces hydrogen gas and expansive reaction products causing problems for the encapsulation of aluminium containing nuclear wastes. Although corrosion of aluminium in cements has been long known, the extent of aluminium corrosion in the cement matrices and effects of such reaction on the cement phases are not well established. The present study investigates the corrosion reaction of aluminium in OPC, OPC-blast furnace slag (BFS) and calcium aluminate cement (CAC) based systems. The total amount of aluminium able to corrode in an OPC and 4:1 BFS:OPC system was determined, and the correlation between the amount of calcium hydroxide in the system and the reaction of aluminium obtained. It was also shown that a CAC-based system could offer a potential matrix to incorporate aluminium metal with a further reduction of pH by introduction of phosphate, producing a calcium phosphate cement.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Early age hydration and application of blended magnesium potassium phosphate cements for reduced corrosion of reactive metals

Highlights: • Magnesium potassium phosphate cements were studied for nuclear waste encapsulation. • The optimised formulation in this study was determined to be 0.24 w/s ratio. • Different reaction kinetics were discovered for the FA/MKPC and BFS/MKPC binders. • Struvite-K was the only crystalline reaction product observed via in-situ SXPD. • Uranium trials revealed MKPC corrosion was reduced compared to a UK nuclear grout. Magnesium potassium phosphate cements (MKPC) were investigated to determine their efficacy towards retardation of reactive uranium metal corrosion. Optimised low-water content, fly ash (FA) and blast furnace slag (BFS) blended MKPC formulations were developed and their fluidity, hydration behaviour, strength and phase assemblage investigated. In-situ time resolved synchrotron powder X-ray diffraction was used to detail the early age (~60 h) phase assemblage development and hydration kinetics, where the inclusion of BFS was observed to delay the formation of struvite-K by ~14 h compared to FA addition (~2 h). All samples set within this period, suggesting the possible formation of a poorly crystalline binding phase prior to struvite-K crystallisation. Long-term corrosion trials using metallic uranium indicated that MKPC systems are capable of limiting uranium corrosion rates (reduced by half), when compared to a UK nuclear industry grout, which highlights their potential application radioactive waste immobilisation.

36 MATERIALS SCIENCE↗
DOE OSTI2021

A time-dependent chloride diffusion model for predicting initial corrosion time of reinforced concrete with slag addition

The effect of granulated blast furnace slag (GBFS) addition on the threshold chloride concentration (TCC) for rebar corrosion was investigated. A modified diffusion model, coupled with a time-dependent effective diffusion coefficient and surface chloride concentration, was proposed to predict the chloride profile. The corrosion initiation time was estimated based on the model predictions and the measured TCC. The results indicate that adding GBFS decreases the TCC by lowering the pH value of the pore solution. The evolution of corrosion potential and current density is found to obey a 3-parameter Weibull distribution. MIP tests show that adding GBFS contributes to refinement of pore structure by decreasing the fraction of large capillary pores. The time-dependent model exhibits good predictive strength and helps understand how GBFS addition delays the corrosion initiation by retarding the chloride diffusion, though a lower TCC is obtained.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Influence of SiC microstructure on its corrosion behavior in molten FLiNaK salt

The influence of the microstructure on the corrosion rate of three monolithic SiC samples in FLiNaK salt at 900 °C for 250 h was studied. The SiC samples, labeled as SiC-1, SiC-2, and SiC-3, had corrosion rates of 0.137, 0.020, and 0.043 mg/cm 2 h, respectively. Compared with grain size and the presence of special grain boundaries (i.e., Σ3), the content of high-angle grain boundaries (HAGBs) appeared to have the strongest influence on the corrosion rate of SiC in FLiNaK salt, since the corrosion rate increased six times as the concentration of high-angle grain boundaries increased from 19 to 32% for SiC-2 and SiC-1, respectively. The results here stress the importance of controlling the content of HAGBs during the production process of SiC.

36 MATERIALS SCIENCE↗