Pub Date : 2024-05-14DOI: 10.1038/s41529-024-00461-x
Priyanka Adapala, Thomas Avey, Yudie Yuan, Mary Lyn Lim, Ganesh Bhaskaran, Sazol Das, Alan Luo, Gerald S. Frankel
The corrosion performance of 6xxx series Al alloys has been found to depend on small changes in composition and microstructure. The corrosion behaviors of three aluminum alloys, AA6111, AA6451, and AA6016, were investigated. AA6111, containing primarily α (Al15 (Fe,Mn)3Si2) intermetallic particles (IMPs), and AA6016, containing primarily β (Al8Fe2Si) IMPs, exhibited the best and the worst overall corrosion performances, respectively, as indicated by the extent of corrosion in exposure tests. However, this ranking was not predicted by the standard interpretation of potentiodynamic polarization curves measured on the alloys. The corrosion susceptibilities of the three alloys were further investigated by evaluating the electrochemical behavior of the component phases separately. Bulk analogs of the component phases were fabricated using standard alloy casting techniques. The fabricated bulk analogs of α and β IMPs, as well as the three alloy matrix phases, were tested using either macrocell or microcell testing. An explanation for the alloy performances was developed by combining the behavior of the component phases.
{"title":"Understanding the effect of microstructure and composition on localized corrosion susceptibility of 6xxx aluminum alloys","authors":"Priyanka Adapala, Thomas Avey, Yudie Yuan, Mary Lyn Lim, Ganesh Bhaskaran, Sazol Das, Alan Luo, Gerald S. Frankel","doi":"10.1038/s41529-024-00461-x","DOIUrl":"10.1038/s41529-024-00461-x","url":null,"abstract":"The corrosion performance of 6xxx series Al alloys has been found to depend on small changes in composition and microstructure. The corrosion behaviors of three aluminum alloys, AA6111, AA6451, and AA6016, were investigated. AA6111, containing primarily α (Al15 (Fe,Mn)3Si2) intermetallic particles (IMPs), and AA6016, containing primarily β (Al8Fe2Si) IMPs, exhibited the best and the worst overall corrosion performances, respectively, as indicated by the extent of corrosion in exposure tests. However, this ranking was not predicted by the standard interpretation of potentiodynamic polarization curves measured on the alloys. The corrosion susceptibilities of the three alloys were further investigated by evaluating the electrochemical behavior of the component phases separately. Bulk analogs of the component phases were fabricated using standard alloy casting techniques. The fabricated bulk analogs of α and β IMPs, as well as the three alloy matrix phases, were tested using either macrocell or microcell testing. An explanation for the alloy performances was developed by combining the behavior of the component phases.","PeriodicalId":19270,"journal":{"name":"npj Materials Degradation","volume":" ","pages":"1-12"},"PeriodicalIF":5.1,"publicationDate":"2024-05-14","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://www.nature.com/articles/s41529-024-00461-x.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140924940","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2024-05-11DOI: 10.1038/s41529-024-00471-9
Leandro Vaccari, Thomas Scheithauer, Ivan Lendiel, Jan Klett, Thomas Hassel, Hans Jürgen Maier
Marine structures such as ports, bridges, pipelines, vessels, and platforms are an essential part of modern infrastructure, where the use of higher-strength steel provides savings in logistics and construction. However, the repair of higher-strength steels can be challenging, especially underwater. Wet shielded metal arc welding is the most widely used and least expensive method for underwater welding repairs, but is very susceptible to hydrogen-induced cracking. Thus, researchers and welding engineers aim to reduce the amount of hydrogen in the weld material. Recent success has been achieved through the use of austenitic welding consumables, such as austenitic stainless steel and nickel-based electrodes. The use of these consumables drastically reduces the amount of diffusible hydrogen in the weld metal. However, these austenitic materials usually have different corrosion potential as compared to the structural steel the weld beads are applied to. This creates the risk of severe galvanic corrosion. In the presented study, the corrosion behavior of welds created with austenitic stainless steel and nickel-based electrodes were studied. Samples were aged for 1.5 years in the Baltic Sea. Simultaneously, the effectiveness of corrosion protection systems such as coating and Impressed Current Cathodic Protection (ICCP) were evaluated. Localized corrosion occurred in the heat-affected zone when austenitic electrodes were used in the corrosive environment. The localized corrosion depth after 1.5 years in the Baltic Sea and in the salt spray layer was approximately 250 µm and 390 µm, respectively. The ICCP system and the use of a coating were effective in preventing localized corrosion. The low pitting corrosion density of 2.5 × 103 m−2 corresponds to grade A1 according to the standard and was found to be negligible as compared to the localized corrosion in the heat-affect zone.
{"title":"Corrosion behavior of austenitic stainless steel and nickel-based welded joints in underwater wet welding","authors":"Leandro Vaccari, Thomas Scheithauer, Ivan Lendiel, Jan Klett, Thomas Hassel, Hans Jürgen Maier","doi":"10.1038/s41529-024-00471-9","DOIUrl":"10.1038/s41529-024-00471-9","url":null,"abstract":"Marine structures such as ports, bridges, pipelines, vessels, and platforms are an essential part of modern infrastructure, where the use of higher-strength steel provides savings in logistics and construction. However, the repair of higher-strength steels can be challenging, especially underwater. Wet shielded metal arc welding is the most widely used and least expensive method for underwater welding repairs, but is very susceptible to hydrogen-induced cracking. Thus, researchers and welding engineers aim to reduce the amount of hydrogen in the weld material. Recent success has been achieved through the use of austenitic welding consumables, such as austenitic stainless steel and nickel-based electrodes. The use of these consumables drastically reduces the amount of diffusible hydrogen in the weld metal. However, these austenitic materials usually have different corrosion potential as compared to the structural steel the weld beads are applied to. This creates the risk of severe galvanic corrosion. In the presented study, the corrosion behavior of welds created with austenitic stainless steel and nickel-based electrodes were studied. Samples were aged for 1.5 years in the Baltic Sea. Simultaneously, the effectiveness of corrosion protection systems such as coating and Impressed Current Cathodic Protection (ICCP) were evaluated. Localized corrosion occurred in the heat-affected zone when austenitic electrodes were used in the corrosive environment. The localized corrosion depth after 1.5 years in the Baltic Sea and in the salt spray layer was approximately 250 µm and 390 µm, respectively. The ICCP system and the use of a coating were effective in preventing localized corrosion. The low pitting corrosion density of 2.5 × 103 m−2 corresponds to grade A1 according to the standard and was found to be negligible as compared to the localized corrosion in the heat-affect zone.","PeriodicalId":19270,"journal":{"name":"npj Materials Degradation","volume":" ","pages":"1-11"},"PeriodicalIF":5.1,"publicationDate":"2024-05-11","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://www.nature.com/articles/s41529-024-00471-9.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140907144","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
In this work, the passivation and localized corrosion of selective laser melted (SLM) stainless steel 316 L when exposed to high pressures of CO2 with the presence of H2S and Cl− at 25 °C and 125 °C were studied. Depletion of Cr/Mo was observed at the cell interiors and melt-pool boundaries (MPBs) compared to the cell boundaries. Volta potential differences obtained from scanning Kelvin probe force microscopy (SKPFM) showed that the MPBs were 8–20 mV lower than the matrix, while the cell interiors were 20–50 mV lower than the cell boundaries. Electrochemical impedance spectroscopy (EIS) and Mott–Schottky tests indicated a more defective passive film at 125 °C, and X-ray photoelectron spectroscopy (XPS) confirmed the formation of a less protective film with an increased S/O ratio at 125 °C than 25 °C. Initiation of localized corrosion was observed at the MPBs and pits formed after a week of immersion were wider by an order of magnitude at 125 °C than 25 °C, with evidence of cell-interior dissolution. While passivity was observed even at elevated temperatures, local chemical heterogeneities compromised the stability of the film and contributed to localized corrosion in SLM SS316L.
在这项工作中，研究了选择性激光熔化（SLM）不锈钢 316 L 在 25 °C 和 125 °C 下暴露于存在 H2S 和 Cl- 的高压 CO2 时的钝化和局部腐蚀情况。与晶胞边界相比，在晶胞内部和熔池边界 (MPB) 观察到了铬/钼的损耗。从扫描开尔文探针力显微镜（SKPFM）获得的伏特电位差显示，MPB 比基质低 8-20 mV，而电池内部比电池边界低 20-50 mV。电化学阻抗谱（EIS）和莫特-肖特基测试表明，125 °C时被动膜的缺陷更大，X射线光电子能谱（XPS）证实，125 °C时形成的保护膜比25 °C时的S/O比更小。在 MPB 上观察到局部腐蚀的开始，浸泡一周后形成的凹坑在 125 °C时比 25 °C时宽一个数量级，并有细胞内部溶解的证据。虽然即使在高温下也能观察到钝化现象，但局部化学异质性损害了薄膜的稳定性，并导致了 SLM SS316L 的局部腐蚀。
{"title":"Localized corrosion in selective laser melted SS316L in CO2 and H2S brines at elevated temperatures","authors":"Deeparekha Narayanan, Alan Martinez, Ulises Martin, Bilal Mansoor, Raymundo Case, Homero Castaneda","doi":"10.1038/s41529-024-00468-4","DOIUrl":"10.1038/s41529-024-00468-4","url":null,"abstract":"In this work, the passivation and localized corrosion of selective laser melted (SLM) stainless steel 316 L when exposed to high pressures of CO2 with the presence of H2S and Cl− at 25 °C and 125 °C were studied. Depletion of Cr/Mo was observed at the cell interiors and melt-pool boundaries (MPBs) compared to the cell boundaries. Volta potential differences obtained from scanning Kelvin probe force microscopy (SKPFM) showed that the MPBs were 8–20 mV lower than the matrix, while the cell interiors were 20–50 mV lower than the cell boundaries. Electrochemical impedance spectroscopy (EIS) and Mott–Schottky tests indicated a more defective passive film at 125 °C, and X-ray photoelectron spectroscopy (XPS) confirmed the formation of a less protective film with an increased S/O ratio at 125 °C than 25 °C. Initiation of localized corrosion was observed at the MPBs and pits formed after a week of immersion were wider by an order of magnitude at 125 °C than 25 °C, with evidence of cell-interior dissolution. While passivity was observed even at elevated temperatures, local chemical heterogeneities compromised the stability of the film and contributed to localized corrosion in SLM SS316L.","PeriodicalId":19270,"journal":{"name":"npj Materials Degradation","volume":" ","pages":"1-14"},"PeriodicalIF":5.1,"publicationDate":"2024-05-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://www.nature.com/articles/s41529-024-00468-4.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140902849","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2024-05-08DOI: 10.1038/s41529-024-00470-w
Steffen Wackenrohr, Christof Johannes Jaime Torrent, Sebastian Herbst, Florian Nürnberger, Philipp Krooss, Johanna-Maria Frenck, Christoph Ebbert, Markus Voigt, Guido Grundmeier, Thomas Niendorf, Hans Jürgen Maier
Due to its excellent biocompatibility, pure iron is a very promising implant material, but often features corrosion rates that are too low. Using additive manufacturing and modified powders the microstructure and, thus, the material properties, e.g., the corrosion properties, can be tailored for specific applications. Within the scope of this study, pure iron powder was modified with different amounts of CeO2 or Fe2O3 nanoparticles and subsequently processed by Electron Beam Powder Bed Fusion (PBF-EB/M). The corrosion-fatigue behavior of CeO2 and Fe2O3 modified iron was investigated using rotation bending tests under the influence of simulated body fluid (m-SBF). While the modification using Fe2O3 showed reduced fatigue and corrosion-fatigue strengths, it could be demonstrated that the modification with CeO2 is characterized by improved fatigue properties. The superior fatigue properties in air are attributed to the positive impact of dispersion strengthening. Additionally, an increased degradation rate compared to pure iron could be observed, eventually promoting an earlier failure of the specimens in the corrosion fatigue tests.
{"title":"Corrosion fatigue behavior of nanoparticle modified iron processed by electron powder bed fusion","authors":"Steffen Wackenrohr, Christof Johannes Jaime Torrent, Sebastian Herbst, Florian Nürnberger, Philipp Krooss, Johanna-Maria Frenck, Christoph Ebbert, Markus Voigt, Guido Grundmeier, Thomas Niendorf, Hans Jürgen Maier","doi":"10.1038/s41529-024-00470-w","DOIUrl":"10.1038/s41529-024-00470-w","url":null,"abstract":"Due to its excellent biocompatibility, pure iron is a very promising implant material, but often features corrosion rates that are too low. Using additive manufacturing and modified powders the microstructure and, thus, the material properties, e.g., the corrosion properties, can be tailored for specific applications. Within the scope of this study, pure iron powder was modified with different amounts of CeO2 or Fe2O3 nanoparticles and subsequently processed by Electron Beam Powder Bed Fusion (PBF-EB/M). The corrosion-fatigue behavior of CeO2 and Fe2O3 modified iron was investigated using rotation bending tests under the influence of simulated body fluid (m-SBF). While the modification using Fe2O3 showed reduced fatigue and corrosion-fatigue strengths, it could be demonstrated that the modification with CeO2 is characterized by improved fatigue properties. The superior fatigue properties in air are attributed to the positive impact of dispersion strengthening. Additionally, an increased degradation rate compared to pure iron could be observed, eventually promoting an earlier failure of the specimens in the corrosion fatigue tests.","PeriodicalId":19270,"journal":{"name":"npj Materials Degradation","volume":" ","pages":"1-7"},"PeriodicalIF":5.1,"publicationDate":"2024-05-08","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://www.nature.com/articles/s41529-024-00470-w.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140881230","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2024-05-04DOI: 10.1038/s41529-024-00459-5
Clara Linder, Bharat Mehta, Salil Sainis, Johan B. Lindén, Caterina Zanella, Lars Nyborg
Additive manufacturing opens new possibilities for designing light-weight structures using aluminium alloys. The microstructure of two Al alloys and their corrosion resistance in NaCl and natural seawater environments were investigated. The newly designed Al-Mn-Cr-Zr based alloy showed a higher corrosion resistance than reference AlSi10Mg alloy in both environments in as printed and heat-treated conditions. The corrosion initiated in the Al matrix along the precipitates in the alloys where the Volta potential difference was found the highest. The coarser microstructure and precipitate composition of the new Al-alloy led to the formation of a resistant passive film which extended the passivity region of the Al-Mn-Cr-Zr alloy compared to the AlSi10Mg alloy. The effect of heat treatment could be seen in the microstructure as more precipitates were found in between the melt pool boundaries, which affected the corrosion initiation and slightly the pitting resistance. Overall, this study shows that a newly designed Al-alloy for additive manufacturing has a suitable corrosion resistance for applications in marine environments.
{"title":"Corrosion resistance of additively manufactured aluminium alloys for marine applications","authors":"Clara Linder, Bharat Mehta, Salil Sainis, Johan B. Lindén, Caterina Zanella, Lars Nyborg","doi":"10.1038/s41529-024-00459-5","DOIUrl":"10.1038/s41529-024-00459-5","url":null,"abstract":"Additive manufacturing opens new possibilities for designing light-weight structures using aluminium alloys. The microstructure of two Al alloys and their corrosion resistance in NaCl and natural seawater environments were investigated. The newly designed Al-Mn-Cr-Zr based alloy showed a higher corrosion resistance than reference AlSi10Mg alloy in both environments in as printed and heat-treated conditions. The corrosion initiated in the Al matrix along the precipitates in the alloys where the Volta potential difference was found the highest. The coarser microstructure and precipitate composition of the new Al-alloy led to the formation of a resistant passive film which extended the passivity region of the Al-Mn-Cr-Zr alloy compared to the AlSi10Mg alloy. The effect of heat treatment could be seen in the microstructure as more precipitates were found in between the melt pool boundaries, which affected the corrosion initiation and slightly the pitting resistance. Overall, this study shows that a newly designed Al-alloy for additive manufacturing has a suitable corrosion resistance for applications in marine environments.","PeriodicalId":19270,"journal":{"name":"npj Materials Degradation","volume":" ","pages":"1-12"},"PeriodicalIF":5.1,"publicationDate":"2024-05-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://www.nature.com/articles/s41529-024-00459-5.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140834038","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2024-05-04DOI: 10.1038/s41529-024-00469-3
Shuyu Li, Hao Li, Yan Zhang, Wei Yang, Peng Guo, Xiaowei Li, Kazuhito Nishimura, Peiling Ke, Aiying Wang
The corrosion failure of amorphous carbon (a-C) coatings is commonly ascribed to the existence of growth microdefects, which serve as pathways for corrosive fluids to permeate the substrate. Atomic layer deposition (ALD) is renowned for its ability to augment the corrosion resistance of metallic materials. Graphite-like carbon (GLC) is one of the amorphous carbon materials dominated by hybridized sp2-C bonds. In this study, an ALD-deposited Al2O3 layer is specially introduced on the Cr/GLC multilayer coating to solve the aforementioned corrosion risk of a-C by taking the sealing conception for defects. Compared to the as-deposited Cr/GLC coating, the coating encapsulated with Al2O3 layer depicts the reduction of corrosion current density over two orders of magnitude under a wide pressure range of 0.1 ~ 15 MPa. Particularly, the presence of released Crn+ and Fen+ in the corrosion solution is significantly diminished, accompanying with a small quantity of Aln+ generated in sealed coating during corrosion. Microstructural analysis and electrochemical results identified that both the dense Al2O3 layer offered strong safeguard for Cr elements released from multilayers, whilst amorphous carbon network inhibited the likelihood chloride penetration induced by partially infiltrated Al2O3, which made the synergistic contributions to the enhancement of corrosion resistance for Cr/GLC coating for deep-sea applications.
{"title":"Dense Al2O3 sealing inhibited high hydrostatic pressure corrosion of Cr/GLC coating","authors":"Shuyu Li, Hao Li, Yan Zhang, Wei Yang, Peng Guo, Xiaowei Li, Kazuhito Nishimura, Peiling Ke, Aiying Wang","doi":"10.1038/s41529-024-00469-3","DOIUrl":"10.1038/s41529-024-00469-3","url":null,"abstract":"The corrosion failure of amorphous carbon (a-C) coatings is commonly ascribed to the existence of growth microdefects, which serve as pathways for corrosive fluids to permeate the substrate. Atomic layer deposition (ALD) is renowned for its ability to augment the corrosion resistance of metallic materials. Graphite-like carbon (GLC) is one of the amorphous carbon materials dominated by hybridized sp2-C bonds. In this study, an ALD-deposited Al2O3 layer is specially introduced on the Cr/GLC multilayer coating to solve the aforementioned corrosion risk of a-C by taking the sealing conception for defects. Compared to the as-deposited Cr/GLC coating, the coating encapsulated with Al2O3 layer depicts the reduction of corrosion current density over two orders of magnitude under a wide pressure range of 0.1 ~ 15 MPa. Particularly, the presence of released Crn+ and Fen+ in the corrosion solution is significantly diminished, accompanying with a small quantity of Aln+ generated in sealed coating during corrosion. Microstructural analysis and electrochemical results identified that both the dense Al2O3 layer offered strong safeguard for Cr elements released from multilayers, whilst amorphous carbon network inhibited the likelihood chloride penetration induced by partially infiltrated Al2O3, which made the synergistic contributions to the enhancement of corrosion resistance for Cr/GLC coating for deep-sea applications.","PeriodicalId":19270,"journal":{"name":"npj Materials Degradation","volume":" ","pages":"1-10"},"PeriodicalIF":5.1,"publicationDate":"2024-05-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://www.nature.com/articles/s41529-024-00469-3.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140833874","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2024-05-04DOI: 10.1038/s41529-024-00460-y
Dong-Ho Shin, Seong-Jong Kim
Diamond-like carbon (DLC) coating is a surface coating technology with excellent hydrogen permeation resistance and wear resistance. However, it is difficult to completely prevent hydrogen permeation, and when hydrogen penetrates into the coating layer, the DLC coating is adversely affected. Therefore, we investigated the effect of hydrogen embrittlement on the adhesion strength and wear resistance of the DLC coating layer. As the results of the research, the surface roughness of the DLC coating was increased by a maximum of 3.8 times with hydrogen charging, and the delamination ratio of the DLC coating reached about 58%. In addition, the Lc3, which refers to the adhesion strength corresponding to the complete delamination of the DLC coating, was decreased by a maximum of 2.0 N due to hydrogen permeation. In addition, the wear resistance decreased due to hydrogen permeation, and the exposed width of the substrate due to wear increased by more than 4 times. It was also determined that hydrogen blistering or hydrogen-induced cracking occurred at the interface between the DLC coating and the chromium buffer layer due to hydrogen permeation, which decreased the durability of the DLC coating.
{"title":"Effect of hydrogen embrittlement on mechanical characteristics of DLC-coating for hydrogen valves of FCEVs","authors":"Dong-Ho Shin, Seong-Jong Kim","doi":"10.1038/s41529-024-00460-y","DOIUrl":"10.1038/s41529-024-00460-y","url":null,"abstract":"Diamond-like carbon (DLC) coating is a surface coating technology with excellent hydrogen permeation resistance and wear resistance. However, it is difficult to completely prevent hydrogen permeation, and when hydrogen penetrates into the coating layer, the DLC coating is adversely affected. Therefore, we investigated the effect of hydrogen embrittlement on the adhesion strength and wear resistance of the DLC coating layer. As the results of the research, the surface roughness of the DLC coating was increased by a maximum of 3.8 times with hydrogen charging, and the delamination ratio of the DLC coating reached about 58%. In addition, the Lc3, which refers to the adhesion strength corresponding to the complete delamination of the DLC coating, was decreased by a maximum of 2.0 N due to hydrogen permeation. In addition, the wear resistance decreased due to hydrogen permeation, and the exposed width of the substrate due to wear increased by more than 4 times. It was also determined that hydrogen blistering or hydrogen-induced cracking occurred at the interface between the DLC coating and the chromium buffer layer due to hydrogen permeation, which decreased the durability of the DLC coating.","PeriodicalId":19270,"journal":{"name":"npj Materials Degradation","volume":" ","pages":"1-15"},"PeriodicalIF":5.1,"publicationDate":"2024-05-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://www.nature.com/articles/s41529-024-00460-y.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140834161","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2024-04-30DOI: 10.1038/s41529-024-00464-8
Evan DelVecchio, Tiffany Liu, Yen-Ting Chang, Yuheng Nie, Maryam Eslami, Marie A. Charpagne
The rapid solidification associated with additive manufacturing (AM) leads to complex microstructures with peculiar features amongst which cellular solidification structures are the most remarkable. These metastable structures possess a clear segregation pattern dictated by the solidification pathway of the alloy and are bounded by dislocation walls. While they confer exceptional strength and ductility to AM 316L stainless steel, their effect on localized corrosion in chloride environments remains to be established. Here, we employ correlative electron microscopy to reveal coupled chemical, electrochemical, and crystallographic effects on localized corrosion attack and its development. We show that the Cr and Mo-depleted interior of the cellular solidification structures dissolves selectively, giving rise to an intricate damage morphology, that is directly related to the underlying crystallographic orientation. Whereas surface observations only reveal apparently shallow micrometer-size cavities, 3D tomography via focused ion beam serial-sectioning shows a high degree of connectivity between these features underneath the surface. We reveal this intricate morphology, propose a formation mechanism, and discuss alloy design guidelines to mitigate this phenomenon.
与增材制造（AM）相关的快速凝固会导致具有特殊特征的复杂微结构，其中蜂窝状凝固结构最为显著。这些可转移结构具有由合金凝固路径决定的明显偏析模式，并以位错壁为界。虽然它们赋予了 AM 316L 不锈钢优异的强度和延展性，但它们对氯化物环境中局部腐蚀的影响仍有待确定。在这里，我们利用相关电子显微镜揭示了化学、电化学和晶体学对局部腐蚀及其发展的耦合影响。我们的研究表明，细胞凝固结构内部的缺铬和缺钼结构会选择性溶解，从而产生错综复杂的损伤形态，这与底层晶体学取向直接相关。表面观察只能发现明显的浅层微米级空洞，而通过聚焦离子束序列切片进行的三维断层扫描则显示出表面下这些特征之间的高度连通性。我们揭示了这种错综复杂的形态，提出了一种形成机制，并讨论了减轻这种现象的合金设计指南。
{"title":"Metastable cellular structures govern localized corrosion damage development in additive manufactured stainless steel","authors":"Evan DelVecchio, Tiffany Liu, Yen-Ting Chang, Yuheng Nie, Maryam Eslami, Marie A. Charpagne","doi":"10.1038/s41529-024-00464-8","DOIUrl":"10.1038/s41529-024-00464-8","url":null,"abstract":"The rapid solidification associated with additive manufacturing (AM) leads to complex microstructures with peculiar features amongst which cellular solidification structures are the most remarkable. These metastable structures possess a clear segregation pattern dictated by the solidification pathway of the alloy and are bounded by dislocation walls. While they confer exceptional strength and ductility to AM 316L stainless steel, their effect on localized corrosion in chloride environments remains to be established. Here, we employ correlative electron microscopy to reveal coupled chemical, electrochemical, and crystallographic effects on localized corrosion attack and its development. We show that the Cr and Mo-depleted interior of the cellular solidification structures dissolves selectively, giving rise to an intricate damage morphology, that is directly related to the underlying crystallographic orientation. Whereas surface observations only reveal apparently shallow micrometer-size cavities, 3D tomography via focused ion beam serial-sectioning shows a high degree of connectivity between these features underneath the surface. We reveal this intricate morphology, propose a formation mechanism, and discuss alloy design guidelines to mitigate this phenomenon.","PeriodicalId":19270,"journal":{"name":"npj Materials Degradation","volume":" ","pages":"1-8"},"PeriodicalIF":5.1,"publicationDate":"2024-04-30","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://www.nature.com/articles/s41529-024-00464-8.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140817301","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2024-04-25DOI: 10.1038/s41529-024-00462-w
Rakesh Bhaskaran Nair, Dermot Brabazon
Calcia-Magnesia-Alumino Silicate (CMAS) is a form of molten siliceous residue generated at elevated temperatures within aeroengines. CMAS adheres to the surface of thermal barrier coatings (TBCs) and has the potential to cause significant damage to engine components, resulting in TBC failures. The aviation industry has long recognized CMAS as a substantial threat to aircraft engines, and this threat persists today. A substantial amount of research has been carried out, primarily focusing on gaining a fundamental understanding of the degradation mechanism of traditional TBCs manufactured using air plasma spraying (APS) and electron beam physical vapor deposition (EB-PVD) technologies after CMAS attack. A thorough understanding of why CMAS forms, its role in causing severe spallation, and how to prevent it is of significant concern both academically and industrially. This review article provides a detailed examination of the chemistry of CMAS and the resulting degradation mechanisms that the TBC may encounter throughout the aeroengine service life. This article also explores recent research, incorporating case studies, on the impact of CMAS attack on the resulting chemical and structural modifications of the ceramic topcoats. Current strategies designed to mitigate CMAS infiltration and perspectives for enhanced mitigation are discussed.
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State-of-the-art lithium-ion batteries inevitably suffer from electrode corrosion over long-term operation, such as corrosion of Al current collectors. However, the understanding of Al corrosion and its impacts on the battery performances have not been evaluated in detail. The passivation, its breakdown, and corrosion of the Al resulted in the deterioration of the solid/solid interface and electrode integrity. Additionally, localized diffusion of F−/Al3+ brought the irreversible current detrimental to the Coulomb efficiency (1.14% loss). Eventually, the behavior led to extensive capacity damage (>20%) to battery performance until lifespan. During the battery cycling, the passivation layer greater than 20 nm was generated near the median voltage. When the charging voltage rose, the passivation layer was squeezed and deformed by the newly generated Al-F-O particles, resulting in stress corrosion cracks. The passivation layer peeled off, and the nano-passivation layer material was re-generated as the voltage continued to rise. The above results were repeated, and the Al matrix was continuously consumed. The passivity breakdown with localized corrosion was derived from ethylene carbonate adsorption, which was highly correlated to the charge voltages, especially at 4.4 V and 4.8 V. The results will serve as a benchmark for electrode corrosion of other advanced energy storage materials, which is crucial for electrode engineering and performance modulation using interfacial design.
最先进的锂离子电池在长期运行过程中不可避免地会受到电极腐蚀的影响，如铝集流体的腐蚀。然而，人们对铝腐蚀及其对电池性能影响的了解还不够详细。铝的钝化、破坏和腐蚀导致固/固界面和电极完整性恶化。此外，F-/Al3+ 的局部扩散带来了不可逆电流，损害了库仑效率（损失 1.14%）。最终，这种行为导致电池容量大面积受损（20%），影响电池性能直至使用寿命。在电池循环过程中，中值电压附近会产生大于 20 nm 的钝化层。当充电电压升高时，钝化层受到新生成的 Al-F-O 颗粒的挤压并发生变形，从而产生应力腐蚀裂纹。随着电压继续升高，钝化层脱落，纳米钝化层材料重新生成。重复上述结果，铝基体不断被消耗。局部腐蚀导致的钝性击穿源于碳酸乙烯的吸附，这与电荷电压高度相关，尤其是在 4.4 V 和 4.8 V 时。研究结果将作为其他先进储能材料电极腐蚀的基准，这对利用界面设计进行电极工程和性能调节至关重要。
{"title":"Passivation and corrosion of Al current collectors in lithium-ion batteries","authors":"Pin Du, Jiale Wan, Jiakang Qu, Hongwei Xie, Dihua Wang, Huayi Yin","doi":"10.1038/s41529-024-00453-x","DOIUrl":"10.1038/s41529-024-00453-x","url":null,"abstract":"State-of-the-art lithium-ion batteries inevitably suffer from electrode corrosion over long-term operation, such as corrosion of Al current collectors. However, the understanding of Al corrosion and its impacts on the battery performances have not been evaluated in detail. The passivation, its breakdown, and corrosion of the Al resulted in the deterioration of the solid/solid interface and electrode integrity. Additionally, localized diffusion of F−/Al3+ brought the irreversible current detrimental to the Coulomb efficiency (1.14% loss). Eventually, the behavior led to extensive capacity damage (>20%) to battery performance until lifespan. During the battery cycling, the passivation layer greater than 20 nm was generated near the median voltage. When the charging voltage rose, the passivation layer was squeezed and deformed by the newly generated Al-F-O particles, resulting in stress corrosion cracks. The passivation layer peeled off, and the nano-passivation layer material was re-generated as the voltage continued to rise. The above results were repeated, and the Al matrix was continuously consumed. The passivity breakdown with localized corrosion was derived from ethylene carbonate adsorption, which was highly correlated to the charge voltages, especially at 4.4 V and 4.8 V. The results will serve as a benchmark for electrode corrosion of other advanced energy storage materials, which is crucial for electrode engineering and performance modulation using interfacial design.","PeriodicalId":19270,"journal":{"name":"npj Materials Degradation","volume":" ","pages":"1-11"},"PeriodicalIF":5.1,"publicationDate":"2024-04-25","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://www.nature.com/articles/s41529-024-00453-x.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140642039","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
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