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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 883 records · Page 49
All sourcesNASA NTRSDOE OSTI
DOE OSTI2019

Microstructure and Corrosion Properties of Laser-Welded SAF 2507 Super Duplex Stainless Steel Joints

SAF 2507 super duplex stainless steel has been welded using laser beam (LB) welding and laser/gas metal arc hybrid (LGH) welding processes. The pitting and intergranular corrosion properties of the welding joints have been tested using electrochemical testing and microstructure observations. The volume fraction of the ferrite phase reaches 70% in the weld zone of the LB welding joint, while the volume fraction of the ferrite phase is 60% for the welding joint of LGH due to the introduction of Ni from welding wire. The pitting corrosion resistance of the welding joint for LB is better than that of LGH. The pitting corrosion is easily conceived in the heat-affected zone (HAZ) because of the formation of Cr{sub 2}N in the HAZ during welding.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Correlation between Antimicrobial Activity and Bioactivity of Na-Mica and Na-Mica/Fluorapatite Glass and Glass-Ceramics and Their Corrosion Protection of Titanium in Simulated Body Fluid

The improvement in bioactivity of titanium (Ti) surface was achieved via coating it with Na-mica and Na-mica/fluorapatite glass and glass-ceramic using the low-cost electrophoretic deposition technique. Two compositions from pure Na-mica (M) and 80 Na-mica/20 fluorapatite glasses (MF) were prepared in the system SiO{sub 2}-Al{sub 2}O{sub 3}-MgO-MgF{sub 2}-Na{sub 2}O-B{sub 2}O{sub 3} using melting–quenching technique. Characterization of the as-prepared glasses and their counterpart glass-ceramics was studied using differential thermal analysis (DTA), x-ray diffraction (XRD), Scanning Electron Microscopy (SEM) and Fourier Transform-IR (FTIR) spectroscopy techniques. The bioactivity behavior was proved by studying the XRD, FTIR and SEM after immersing both glass and glass-ceramic samples in simulated body fluid (SBF). Both M and MF glasses and glass-ceramics showed high microhardness measurements and good antibacterial behavior. In vitro biodegradation was studied by using electrochemical corrosion behavior of the prepared glass- and glass-ceramic-coated Ti in SBF. The prepared coated Ti showed good corrosion resistance in SBF at 37 °C using potentiodynamic polarization technique, and the impedance data fitting explained the structure of the coating and the adsorption of SBF ions on the Ti surface. The MFGC provides the best corrosion-resistant coating, especially after sintering it.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Sequestration and release of nitrite and nitrate in alkali-activated slag: A route toward smart corrosion control

Intercalating the corrosion inhibitive ions in hydrotalcite is a promising approach to improve the long-term efficiency of inhibitors in corrosion protection of steel in reinforced concrete. In this work, the potential of autogenously generating nitrite- and nitrate-intercalated hydrotalcite in alkali-activated slag (AAS) is investigated. The results show that the added nitrite and nitrate ions are preferably uptaken in the interlayer structure of hydrotalcite in AAS, and the sequestered nitrite and nitrate are released upon chloride exposure in seawater and NaCl solution. The incorporation of nitrite and nitrate has little detrimental effects on the chloride binding capacity of AAS but slightly enhances the chloride ingress due to the pore coarsening effect. Similar to ordinary Portland cement (OPC), AAS is more permeable to the chloride in seawater than NaCl solution. However, unlike the release of bound chloride contributed by ettringite formation in seawater-exposed OPC, the enhanced chloride ingress in seawater-exposed AAS is primarily attributed to the aggravated pH reduction at the exposure front due to brucite formation. This study contributes to the design of alkali-activated binders with a smart inhibitor releasing ability for mitigating corrosion of steel in concrete.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Corrosion susceptibility and chromium loss in Austenitic steels and Nickel-based alloys in molten FLiNaK at 700 °C

A comparative study was conducted to evaluate the corrosion susceptibility of 316L, 316H, Ni 200, Inconel 625, and Hastelloy N in molten FLiNaK at 700 °C for 100 h. Top-view and cross-sectional scanning electron microscopy (SEM) imaging, combined with energy-dispersive X-ray spectroscopy (EDS) mapping, was performed to investigate microstructural and compositional changes. SEM images were further processed by introducing a contrast threshold to map cavity distribution. Using EDS mapping, intergranular and intragranular Cr loss were separately characterized. The ranking of mass loss after corrosion, from highest to lowest, is as follows: 316H > 316L > Inconel 625 > Hastelloy N > Ni 200. Cr loss was found to be correlated with Mo concentration, in agreement with many previous studies, with higher Mo content resulting in reduced Cr loss. On the other hand, there is no evidence that the high carbon content in 316H enhances corrosion resistance. The relatively low solubility of carbon in austenite at the testing temperature limits the amount of dissolved carbon. Therefore, the carbon-retarded vacancy diffusion, and consequently the reduced Cr diffusion, were not observed.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2012

Cluster formula of Fe-containing Monel alloys with high corrosion-resistance

The cluster-plus-glue-atom model is applied in the composition interpretation of Monel alloys. This model considers ideal atomic nearest neighbor configurations among the constituent elements and has been used in understanding compositions of complex alloys like quasicrystals, amorphous alloys, and cupronickels. According to this model, any structure can be expressed by cluster formula [cluster](glue atom){sub x}, x denoting the number of glue atoms matching one cluster. According to this model, two groups of experimental composition series [Fe{sub 1}Ni{sub 12}]Cu{sub x} and [Fe{sub y}Ni{sub 12}]Cu{sub 5} were designed which fell close to conventional Fe-containing Monel alloys. The designed alloys after solution treatment plus water quenching, are monolithic FCC Ni-based solid solutions. Among them, the [Fe{sub 1}Ni{sub 12}]Cu{sub 5} alloy has the highest corrosion resistance in simulated sea water, and its performance is superior to that of industrial Monel 400 alloy. - Highlights: Black-Right-Pointing-Pointer A stable solid solution model is proposed using our 'cluster-plus-glue-atom model'. Black-Right-Pointing-Pointer This model is used to develop Monel corrosion resistant alloys. Black-Right-Pointing-Pointer Single FCC structure is easily retained. Black-Right-Pointing-Pointer The alloys show good corrosion properties. Black-Right-Pointing-Pointer This work contributes to the general understanding of engineering alloys.

36 MATERIALS SCIENCE↗
DOE OSTI2016

Effect of aqueous‐based cathode slurry pH and immersion time on corrosion of aluminum current collector in lithium‐ion batteries

Corrosion of aluminum can occur during the manufacturing of lithium‐ion batteries when using aqueous‐based cathode slurries. In exposure tests, the alkaline pH value of aqueous‐based cathode slurries and immersing time were revealed as the principle factors that control the corrosion of aluminum during the cathode manufacturing process. The nickel manganese cobalt oxide active material used in the slurry does not have a direct impact on corrosion of the aluminum current collector. The initiation and evolution of localized corrosion on aluminum are closely related to the formation of galvanic cells between aluminum matrix and intermetallic particles. X‐ray photoelectron spectroscopy results confirmed that the pH of cathode slurry was the only factor that alters aluminum surface composition, during which the oxide passive film was gradually degraded into hydroxide. Electrochemical characterizations showed that aluminum electrodes gave remarkably different response to the different pH of test solutions. The time‐pH‐variant electrochemical response was ascribed to the change of passive film and electric double layer properties.

Li, S. Y.↗
DOE OSTI2017

Characterization of the Hydrothermal Corrosion Behavior of Ceramics for Accident Tolerant Fuel Cladding

Accident-tolerant fuel (ATF) is an increasingly important research topic for the nuclear industry, and ceramics such as SiC are strong contenders for deployment as ATF cladding. The hydrothermal corrosion characteristics of SiC and Al2O3 were investigated via constantly-refreshing autoclave corrosion and post exposure characterization. Four different types of chemical vapor deposited (CVD) SiC specimens were examined (two with high electrical resistance, one with low electrical resistance, and a single crystal 4H structural variant). Al2O3 specimens were prepared in single crystal and polycrystalline states. PWR primary water, BWR–HWC, and BWR–NWC environments were maintained throughout the experiments. Characterization conducted using SEM and EDS was used to determine factors affecting corrosion rates and susceptibility to grain boundary attack in each water chemistry condition. Raman spectroscopy was also used to determine chemical variation of the surface with corrosion. Grain boundary attack was found to be significant for both alumina and SiC polycrystalline variants.

Doyle, Peter↗
DOE OSTI2024

Operando carbon corrosion measurements in fuel cells using boron-doped carbon supports

Carbonaceous materials are the most common catalyst supports in proton exchange membrane fuel cell (PEMFCs), yet their corrosion is one of the limiting factors in achieving high durability. Herein, we doped carbon supports with boron (B) to increase the corrosion-resistance of the support. Two types of B-doped carbons were synthesized and studied as platinum support materials. Further, they varied in their morphologies, surface areas, and the types of boron species. The durability of Pt/B-doped carbon catalysts was investigated using the US-DOE catalysts’ supports accelerated stress test (AST) and a mass-spectrometer connected to the fuel cell effluent stream to quantify the mass of corroded carbon support in operando. The addition of boron to the carbon increased the stability of Pt catalysts in long-term usage of PEMFC. After 4000 AST cycles, more than 50% of initial current density was preserved for the boron-containing systems, while less than 30% of it remained with Vulcan carbon (Pt/V). Also, the Pt/B-doped carbon samples demonstrated better electrochemical active surface area (ECSA) stability when compared to Pt/V. Carbon loss measurements showed that B-doped carbons have higher resistance to electrochemical corrosion than unmodified carbon. Specifically, the substitutional boron-doped carbon demonstrated an extremely high stability and low corrosion rate.

25 ENERGY STORAGE↗
DOE OSTI2018

Machining-induced surface transformations of magnesium alloys to enhance corrosion resistance in human-like environment

We report that magnesium alloys are becoming increasingly attractive for producing temporary prosthetic devices thanks to their bioresorbable characteristics in human body. However, their poor corrosion resistance to body fluids seriously limits their applicability. In this work, machining-induced surface transformations are explored as means to enhance corrosion resistance of AZ31 magnesium alloy. Surface characteristics including topography, residual stresses, wettability, microstructures and depth of transformed layer, were analysed and correlated to in-vitro corrosion resistance. Results showed that cryogenic machining at low feed provided the most promising corrosion reduction. Finally, thorough physical characterizations gave fundamental insights into possible drivers for this enhanced resistance.

36 MATERIALS SCIENCE↗
DOE OSTI2018

A quantitative phase-field model for crevice corrosion

A quantitative phase-field model is developed for the investigation of crevice corrosion of iron in salt water. Six types of ionic species and some associated chemical reactions have been considered. In addition to the transient distributions of ion concentrations and electric potential in the electrolyte, some physical and chemical properties related to corrosion, such as overpotential, pH value and corrosion rate, under different metal potentials are studied. Benchmarking of the phase-field model against a sharp interface model is conducted. The corrosion rates predicted by the models are in the same order of magnitudes with experimental results.

Xiao, Z. H.↗
DOE OSTI2020

Localised instability of titanium during its erosion-corrosion in simulated acidic hydrometallurgical slurries

Electrochemical techniques were used to investigate the erosion-corrosion of titanium in simulated acidic mineral leaching slurries. Erosion-corrosion of titanium was caused by solid particle impingement. Electrochemical noise revealed that solid particle impacts resulted in localised fracture of the passive film, and erosion-corrosion of titanium proceeded in the form of current transients. As conditions become more abrasive, erosion-corrosion is an increasing threat to titanium equipment exposed to acidic slurries.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Ce post-treatment for increased corrosion resistance of AA2024-T3 anodized in tartaric-sulfuric acid

Here, the effect of a post-treatment for short time in 50 mM Ce(NO 3 ) 3 solution, with or without H 2 O 2 , on the corrosion of AA2024-T3 anodized in tartaric-sulfuric acid was investigated. Electrochemical (EIS, polarization curves) and corrosion (immersion) tests showed improved performance for samples post-treated at 50 °C in the H 2 O 2 containing solution. Microstructural characterization (SEM, STEM, GDOES) evidenced the presence of Ce oxyhydroxides both at the surface and within the pores of the anodized layer, and their preferential interaction with defective sites both at micro and nanoscale. Important amounts of Ce-species were found near corrosion products, indicating active corrosion protection by Ce ions.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Reverse martensitic transformation on the corrosion behavior of a 2304 lean duplex stainless steel

This study investigates the influence of the reverse martensitic transformation on the corrosion behavior of 2304 lean duplex stainless steel (LDSS) at low temperatures (400–600°C). The steel underwent cold rolling, followed by isochronal annealing for 0.5 h. Phase transformations and microstructures were analyzed using X-ray diffraction, scanning electron microscopy, and transmission electron microscopy. Corrosion resistance was evaluated using a syringe cell with cyclic potentiodynamic polarization in 0.6 M NaCl solution and double-loop electrochemical potentiokinetic reactivation in 0.5 M H 2 SO 4 + 0.001 M KSCN solution. A bimodal breakdown potential behavior, associated with either pitting or transpassivity, was observed in the as-received (AR) and samples annealed at 400°C. Pitting in the AR sample was associated with Al–Mg–Si–Ca–O inclusions, while pitting on the samples annealed at 400°C was linked to local reduced passive film resistance. Severe cold rolling enhanced the pitting resistance of 2304 LDSS. Selective electrochemical etching revealed preferential corrosion at phase interfaces and within the austenite phase. Additionally, annealing at 500°C to 600°C led to a marked decrease in pitting resistance and increased sensitization. Electron backscatter diffraction analysis of the corroded pits in the annealed specimens indicated that pits tend to nucleate and grow in α'-martensite/austenite regions. Furthermore, the nanostructure formed during low-temperature reversion, characterized by dislocation-cell martensite with high dislocation density and stacking faults, may adversely affect corrosion resistance due to heterogeneities associated with alloying element redistribution.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Electrochemical aspects of copper atmospheric corrosion in the presence of sodium chloride

Here, this study describes the evolving state of electrolyte and corrosion processes associated with sodium chloride on copper at the initial stage of corrosion and the critical implications of this behavior on controlling kinetics and damage distributions. Sodium chloride droplets were placed on copper in humid conditions and the resulting electrolyte properties, corrosion products and damage were characterized over time using time-lapse imaging, micro Raman spectroscopy, TOF-SIMS and optical profilometry. Within minutes of NaCl droplet placement, NaOH-rich films resultant from oxygen reduction advanced stepwise from the droplets, leaving behind concentric trenching attack patterns suggestive of moving anode-cathode pairs at the alkaline film front. Corrosion attack under these spreading alkaline films was up to 10x greater than under the original NaCl drops. Furthermore, solid Cu 2 Cl(OH) 3 shells formed over the surface of the NaCl drops within hours of exposure. Thermodynamic modeling along with immersed electrochemical experiments in simulated droplet and films electrolytes were used to rationalize this behavior and build a description of the rapidly evolving corroding system.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2013

Susceptibility of Aluminum Alloys to Corrosion in Simulated Fuel Blends Containing Ethanol

The compatibility of aluminum and aluminum alloys with synthetic fuel blends comprised of ethanol and reference fuel C (a 50/50 mix of toluene and iso-octane) was examined as a function of water content and temperature. Commercially pure wrought aluminum and several cast aluminum alloys were observed to be similarly susceptible to substantial corrosion in dry (< 50 ppm water) ethanol. Corrosion rates of all the aluminum materials examined was accelerated by increased temperature and ethanol content in the fuel mixture, but inhibited by increased water content. Pretreatments designed to stabilize passive films on aluminum increased the incubation time for onset of corrosion, suggesting film stability is a significant factor in the mechanism of corrosion.

Thomson, Jeffery K↗
DOE OSTI2020

Corrosion protection of steel pipelines with metal-polymer composite barrier liners

Pipelines are efficient in transporting natural gas over large distances. Wet carbon dioxide present in pipelines can create an environment that is corrosive to steel. Polymer liners made from either polyethylene or polyamide (nylon) are presently used to mitigate internal corrosion in natural gas pipelines. Gas diffuses through all polymers over time, and polymer-only liners lower the steel corrosion rate by reducing the reactive gas flux to the internal surface of a pipeline. Composite liners, which incorporate one or more metallic layers that are impermeable to corrosive gases, offer better protection than polymer-only liners. In this study, we measured the methane, water vapor, and carbon dioxide permeability of a multi-layer barrier film and found it to be more effective in resisting gas permeation than polyethylene and nylon-11 films.

03 NATURAL GAS↗
DOE OSTI2024

Corrosion protection of mild steel by superhydrophobic magnetite coating

Corrosion-resistant hydrophobic magnetite coatings on mild steel surfaces were developed by immersion method. The effect of steel surface roughness (R a ) on its hydrophobicity was systematically studied using contact angle measurement (CAM), scanning electron microscopy (SEM), and atomic force microscopy (AFM). The corrosion resistance of hydrophobic magnetite coatings was evaluated using a potentiodynamic polarization test. The durability of the coatings was assessed in air, tap water, and 3.5 wt% NaCl environments. Hydrophobic magnetite coating with a water contact angle of 146-152° showed excellent resistance to corrosion, longevity in atmospheric air, and significant self-cleaning properties. The primary focus of this study was to develop a quick and simple immersion technique to create hydrophobic surfaces on mild steel. Finally, results suggest that surface roughness plays a significant role in surface hydrophobicity, and enhancing the hydrophobicity of mild steel improves its corrosion resistance.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Moisture Corrosion of LiH: A Kinetic Investigation by DRIFT Spectroscopy

Lithium hydride (LiH) is a unique, ionic compound with applications in a variety of industries. Unfortunately, LiH is very reactive toward H 2 O even at ppm levels, forming oxide (Li 2 O) and hydroxide (LiOH) corrosion layers while outgassing H 2 . An effective means to eliminate unwanted outgassing is vacuum-heating to convert LiOH into Li 2 O, although subsequent re-exposure to moisture during transport/handling reconverts some Li 2 O back to LiOH. A corrosion growth model for previously vacuum-baked LiH is necessary for long-term prediction of the hydrolysis of LiH. In this work, a para-linear hydroxide corrosion growth model is proposed for the reaction of previously vacuum-baked LiH samples with moisture. This model, composed of two competing diffusion reaction fronts at the LiOH/Li 2 O and Li 2 O/LiH interfaces, is validated experimentally by subjecting a previously vacuum-baked polycrystalline LiH sample to 35 ppm of H 2 O at room temperature while monitoring the corrosion growth as a function of time with diffuse-reflectance infrared Fourier transform (DRIFT) spectroscopy. The para-linear growth model for the hydrolysis of previously vacuum-baked LiH proposed in this report can also serve as a template for the hydrolysis of other hygroscopic oxides grown on metal or metal hydride substrates.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗