Pub Date : 2026-01-29DOI: 10.1016/j.corsci.2026.113678
Yusheng Yan , Xiaoze Liu , Youhui Sun , Yongzhen Liu , Wenzhou Liang , Lianyong Xu , Kangda Hao , Yongdian Han
The effect of shielding-gas composition on weld formation, microstructure, and H2S stress corrosion cracking (SSCC) in cold metal transfer (CMT) welds was examined. Pure argon shielding led to incomplete penetration and carbide precipitation. Moderate addition of CO2 (10–20 %) improved arc stability and weld quality, yielding a bainite-dominated coarse-grained heat-affected zone (CGHAZ) microstructure. Excessive CO2 (50 %) increased the cooling rate and induced martensite formation in the CGHAZ. Severe pitting occurred in both the weld metal and CGHAZ. Strong Si segregation in the weld metal produced Volta potential differences > 50 mV, driving microgalvanic dissolution. Although the CGHAZ showed minimal elemental segregation, its microstructural heterogeneity, characterized by coarse grains, high dislocation density, and hydrogen trapping, enhanced local anodic activity even with a potential difference below 35 mV. Acicular ferrite impeded microcrack propagation, whereas martensite promoted hydrogen accumulation and accelerated crack growth.
{"title":"Effect of shielding gas composition on weld formation and H2S stress corrosion susceptibility of X65 pipeline steel","authors":"Yusheng Yan , Xiaoze Liu , Youhui Sun , Yongzhen Liu , Wenzhou Liang , Lianyong Xu , Kangda Hao , Yongdian Han","doi":"10.1016/j.corsci.2026.113678","DOIUrl":"10.1016/j.corsci.2026.113678","url":null,"abstract":"<div><div>The effect of shielding-gas composition on weld formation, microstructure, and H<sub>2</sub>S stress corrosion cracking (SSCC) in cold metal transfer (CMT) welds was examined. Pure argon shielding led to incomplete penetration and carbide precipitation. Moderate addition of CO<sub>2</sub> (10–20 %) improved arc stability and weld quality, yielding a bainite-dominated coarse-grained heat-affected zone (CGHAZ) microstructure. Excessive CO<sub>2</sub> (50 %) increased the cooling rate and induced martensite formation in the CGHAZ. Severe pitting occurred in both the weld metal and CGHAZ. Strong Si segregation in the weld metal produced Volta potential differences > 50 mV, driving microgalvanic dissolution. Although the CGHAZ showed minimal elemental segregation, its microstructural heterogeneity, characterized by coarse grains, high dislocation density, and hydrogen trapping, enhanced local anodic activity even with a potential difference below 35 mV. Acicular ferrite impeded microcrack propagation, whereas martensite promoted hydrogen accumulation and accelerated crack growth.</div></div>","PeriodicalId":290,"journal":{"name":"Corrosion Science","volume":"262 ","pages":"Article 113678"},"PeriodicalIF":7.4,"publicationDate":"2026-01-29","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146075824","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2026-01-28DOI: 10.1016/j.corsci.2026.113675
Xiaozhi Xu , Xinyi Liu , Yingran Zhu , Xu Luo , Yutong Zhao , Shucheng Sun , Kai Sun , Xiaodong Hao , Zhigang Shao
Although the proton exchange membrane water electrolyzer (PEMWE) is considered one of the most promising technologies for green hydrogen production, the high cost of precious-metal coatings and the insufficient durability of non-precious alternatives in bipolar plates (BPs) continue to restrict large-scale commercialization. To balance cost and durability, a Pt/TaPt/Ta composite coating was fabricated on Ti substrates using magnetron sputtering (MS). The Pt loading was reduced to only 0.012 mg cm–2. A 3–5 nm Pt top layer effectively suppressed interfacial Schottky barrier formation, while a 10–15 nm PtTa mixed layer facilitated electron transport through the oxide, ensuring excellent electrical conductivity. At the same time, the underlying Ta corrosion-resistant layer provided reliable protection for the Ti substrate. After 48 h of durability testing at 2 V vs. SCE, the interfacial contact resistance (ICR) remained as low as 2.14 mΩ cm2 at 1.4 MPa, and Ti ion dissolution was reduced to 0.23 ppb (1.7 % of bare Ti). These results demonstrate that the Pt/TaPt/Ta multilayer coating provides a feasible pathway for cost-effective and durable BPs in PEMWE.
尽管质子交换膜水电解槽（PEMWE）被认为是最有前途的绿色制氢技术之一，但贵金属涂层的高成本和双极板（bp）中非贵金属替代品的耐久性不足继续限制大规模商业化。为了平衡成本和耐用性，采用磁控溅射技术在Ti衬底上制备了Pt/ tpt /Ta复合涂层。Pt加载量降至0.012 mg cm-2。3-5 nm的Pt顶层有效抑制了界面肖特基势垒的形成，而10-15 nm的PtTa混合层促进了电子通过氧化物的传递，确保了优异的导电性。同时，下面的耐腐蚀层为钛基板提供了可靠的保护。在2 V vs. SCE下进行48 h的耐久性测试后，在1.4 MPa下，界面接触电阻（ICR）保持在2.14 mΩ cm2的低水平，Ti溶解降低到0.23 ppb（占裸Ti的1.7 %）。这些结果表明，Pt/ tpt /Ta多层涂层为PEMWE中具有成本效益和耐用性的bp提供了可行的途径。
{"title":"A cost-effective Pt-Ta multilayer coating strategy for highly durable bipolar plates in PEMWE","authors":"Xiaozhi Xu , Xinyi Liu , Yingran Zhu , Xu Luo , Yutong Zhao , Shucheng Sun , Kai Sun , Xiaodong Hao , Zhigang Shao","doi":"10.1016/j.corsci.2026.113675","DOIUrl":"10.1016/j.corsci.2026.113675","url":null,"abstract":"<div><div>Although the proton exchange membrane water electrolyzer (PEMWE) is considered one of the most promising technologies for green hydrogen production, the high cost of precious-metal coatings and the insufficient durability of non-precious alternatives in bipolar plates (BPs) continue to restrict large-scale commercialization. To balance cost and durability, a Pt/TaPt/Ta composite coating was fabricated on Ti substrates using magnetron sputtering (MS). The Pt loading was reduced to only 0.012 mg cm<sup>–2</sup>. A 3–5 nm Pt top layer effectively suppressed interfacial Schottky barrier formation, while a 10–15 nm PtTa mixed layer facilitated electron transport through the oxide, ensuring excellent electrical conductivity. At the same time, the underlying Ta corrosion-resistant layer provided reliable protection for the Ti substrate. After 48 h of durability testing at 2 V vs. SCE, the interfacial contact resistance (ICR) remained as low as 2.14 mΩ cm<sup>2</sup> at 1.4 MPa, and Ti ion dissolution was reduced to 0.23 ppb (1.7 % of bare Ti). These results demonstrate that the Pt/TaPt/Ta multilayer coating provides a feasible pathway for cost-effective and durable BPs in PEMWE.</div></div>","PeriodicalId":290,"journal":{"name":"Corrosion Science","volume":"262 ","pages":"Article 113675"},"PeriodicalIF":7.4,"publicationDate":"2026-01-28","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146075763","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2026-01-28DOI: 10.1016/j.corsci.2026.113672
Tao Huang , Fujie Zhou , Shixin Gao , Huifang Yue , Kun Zhang , Junsen Fu , Yao Xiao , Zhao Shen , Hua Pang , Lefu Zhang , Kai Chen
The redox condition plays a decisive role in the high temperature corrosion resistance of Cr coatings, while its influence on corrosion product deposition remains insufficiently understood. In this study, long-term deposition tests were conducted in an internally heated recirculating loop, combined with high-resolution characterization, to investigate the corrosion product deposition behavior of Cr-coating in high-temperature water under different redox conditions. Results show that under reducing conditions, the deposits primarily consist of coarse Fe3O4 and NiFe2O4 particles. Although Cr species were barely detectable in water (<1 ppb), the Cr coating undergoes slight dissolution-redeposition, leading to the accumulation of Cr oxides that accounted for nearly 20 % of the inner deposits. In contrast, under oxidizing conditions, the Cr coating experiences severe porous dissolution, accompanied by significant dissolution-redeposition. The deposit layer is considerably thicker and is mainly composed of fine Fe2O3/Cr2O3 and NiFe2O4/(Ni,Fe)Cr2O4 core-shell structured particles, with locally dense CrOOH precipitates within the inner deposits. A thermodynamic Fe-Cr-Ni precipitation model was developed to elucidate the underlying deposition mechanisms under different redox conditions.
{"title":"Unraveling the influence of redox conditions on corrosion product deposition in Cr-coated cladding","authors":"Tao Huang , Fujie Zhou , Shixin Gao , Huifang Yue , Kun Zhang , Junsen Fu , Yao Xiao , Zhao Shen , Hua Pang , Lefu Zhang , Kai Chen","doi":"10.1016/j.corsci.2026.113672","DOIUrl":"10.1016/j.corsci.2026.113672","url":null,"abstract":"<div><div>The redox condition plays a decisive role in the high temperature corrosion resistance of Cr coatings, while its influence on corrosion product deposition remains insufficiently understood. In this study, long-term deposition tests were conducted in an internally heated recirculating loop, combined with high-resolution characterization, to investigate the corrosion product deposition behavior of Cr-coating in high-temperature water under different redox conditions. Results show that under reducing conditions, the deposits primarily consist of coarse Fe<sub>3</sub>O<sub>4</sub> and NiFe<sub>2</sub>O<sub>4</sub> particles. Although Cr species were barely detectable in water (<1 ppb), the Cr coating undergoes slight dissolution-redeposition, leading to the accumulation of Cr oxides that accounted for nearly 20 % of the inner deposits. In contrast, under oxidizing conditions, the Cr coating experiences severe porous dissolution, accompanied by significant dissolution-redeposition. The deposit layer is considerably thicker and is mainly composed of fine Fe<sub>2</sub>O<sub>3</sub>/Cr<sub>2</sub>O<sub>3</sub> and NiFe<sub>2</sub>O<sub>4</sub>/(Ni,Fe)Cr<sub>2</sub>O<sub>4</sub> core-shell structured particles, with locally dense CrOOH precipitates within the inner deposits. A thermodynamic Fe-Cr-Ni precipitation model was developed to elucidate the underlying deposition mechanisms under different redox conditions.</div></div>","PeriodicalId":290,"journal":{"name":"Corrosion Science","volume":"262 ","pages":"Article 113672"},"PeriodicalIF":7.4,"publicationDate":"2026-01-28","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146075756","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2026-01-28DOI: 10.1016/j.corsci.2026.113662
Mingkun Xiao , Yaofeng Wu , Qing Chang , Yanjiao Liu , Ce Zheng , Xiaoqiang Li , Chao Ye
SiC-reinforced MoAlB composites (5–20 wt%) were fabricated via fast hot-pressing (FHP) to enhance high-temperature performance. Phase-pure MoAlB powder was first synthesized by vacuum sintering stoichiometric Mo/Al/B (1:1.3:1 mol) at 1250 ℃ (<10⁻³ Pa). Composites were consolidated by FHP (1200 °C, 40 MPa, 10 min, vacuum), achieving near-full densification (98.3 % relative density) with chemically inert MoAlB-SiC interfaces, as confirmed by XRD/SEM-EDS. The 10 wt% SiC composite delivered optimal mechanical properties: flexural strength to 615 MPa (+35 %), hardness to 30.6 GPa (+60 %), Vickers hardness to 12.8 Gpa (+62 %) and indentation fracture toughness to 8.95 MPa·m1/2 (+70 %) versus monolithic MoAlB. Cyclic oxidation (900–1200 °C) demonstrated SiC-induced formation of a protective dual-phase (Al₂O₃-SiO₂) scale following parabolic kinetics. This synergistic barrier suppressed cation interdiffusion, reducing oxidation rates by 42–68 % across temperatures compared to unmodified MoAlB. The results establish MoAlB-SiC composites as promising candidates for extreme-environment applications.
{"title":"Synthesis, microstructure and properties of SiC reinforced MoAlB composites prepared by fast hot-pressing sintering","authors":"Mingkun Xiao , Yaofeng Wu , Qing Chang , Yanjiao Liu , Ce Zheng , Xiaoqiang Li , Chao Ye","doi":"10.1016/j.corsci.2026.113662","DOIUrl":"10.1016/j.corsci.2026.113662","url":null,"abstract":"<div><div>SiC-reinforced MoAlB composites (5–20 wt%) were fabricated via fast hot-pressing (FHP) to enhance high-temperature performance. Phase-pure MoAlB powder was first synthesized by vacuum sintering stoichiometric Mo/Al/B (1:1.3:1 mol) at 1250 ℃ (<10⁻³ Pa). Composites were consolidated by FHP (1200 °C, 40 MPa, 10 min, vacuum), achieving near-full densification (98.3 % relative density) with chemically inert MoAlB-SiC interfaces, as confirmed by XRD/SEM-EDS. The 10 wt% SiC composite delivered optimal mechanical properties: flexural strength to 615 MPa (+35 %), hardness to 30.6 GPa (+60 %), Vickers hardness to 12.8 Gpa (+62 %) and indentation fracture toughness to 8.95 MPa·m<sup>1/2</sup> (+70 %) versus monolithic MoAlB. Cyclic oxidation (900–1200 °C) demonstrated SiC-induced formation of a protective dual-phase (Al₂O₃-SiO₂) scale following parabolic kinetics. This synergistic barrier suppressed cation interdiffusion, reducing oxidation rates by 42–68 % across temperatures compared to unmodified MoAlB. The results establish MoAlB-SiC composites as promising candidates for extreme-environment applications.</div></div>","PeriodicalId":290,"journal":{"name":"Corrosion Science","volume":"262 ","pages":"Article 113662"},"PeriodicalIF":7.4,"publicationDate":"2026-01-28","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146075762","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2026-01-27DOI: 10.1016/j.corsci.2026.113671
Puren Liu , Wenhui Ye , Qing Zheng , Lining Xu , Jinyang Zhu , Lijie Qiao
Duplex stainless steels (DSSs) are widely used in hydrogen-containing environments owing to their excellent mechanical properties and corrosion resistance. However, hydrogen-induced localized corrosion, particularly hydrogen damage to welded joints, poses a major challenge that requires further understanding. Accordingly, This study examines a 2205 DSS welded joint using electron backscatter diffraction, hydrogen microprint testing, local electrochemical measurements, and in situ corrosion monitoring. The results show that the heat-affected zone (HAZ) exhibits the highest pitting susceptibility under hydrogen exposure, primarily due to its high residual stress concentration, which promotes localized hydrogen accumulation. This stress-assisted hydrogen enrichment accelerates pit initiation and growth at microstructural features such as inclusions and phase boundaries, ultimately leading to preferential failure in the HAZ. The findings clarify the mechanism of stress‑driven hydrogen localization and its role in corrosion failure, providing a theoretical basis for designing hydrogen-embrittlement-resistant DSS weldments.
{"title":"Synergistic effect of residual stress and hydrogen trapping on pitting corrosion in 2205 duplex stainless steel welded joints","authors":"Puren Liu , Wenhui Ye , Qing Zheng , Lining Xu , Jinyang Zhu , Lijie Qiao","doi":"10.1016/j.corsci.2026.113671","DOIUrl":"10.1016/j.corsci.2026.113671","url":null,"abstract":"<div><div>Duplex stainless steels (DSSs) are widely used in hydrogen-containing environments owing to their excellent mechanical properties and corrosion resistance. However, hydrogen-induced localized corrosion, particularly hydrogen damage to welded joints, poses a major challenge that requires further understanding. Accordingly, This study examines a 2205 DSS welded joint using electron backscatter diffraction, hydrogen microprint testing, local electrochemical measurements, and in situ corrosion monitoring. The results show that the heat-affected zone (HAZ) exhibits the highest pitting susceptibility under hydrogen exposure, primarily due to its high residual stress concentration, which promotes localized hydrogen accumulation. This stress-assisted hydrogen enrichment accelerates pit initiation and growth at microstructural features such as inclusions and phase boundaries, ultimately leading to preferential failure in the HAZ. The findings clarify the mechanism of stress‑driven hydrogen localization and its role in corrosion failure, providing a theoretical basis for designing hydrogen-embrittlement-resistant DSS weldments.</div></div>","PeriodicalId":290,"journal":{"name":"Corrosion Science","volume":"262 ","pages":"Article 113671"},"PeriodicalIF":7.4,"publicationDate":"2026-01-27","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146075758","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2026-01-26DOI: 10.1016/j.corsci.2026.113664
Xiangsen Zeng , Minghao Yang , Qing Hu , Zhong Wu , Da-Hai Xia , Yiwen Zhang , Zhenbo Qin , Qiang Li , Wenbin Hu
The corrosion behavior of Monel K500 alloy in sulfurous environments, relevant to oil and gas extraction, was systematically investigated. Electrochemical tests, microstructural characterization, and in-situ scanning vibrating electrode technique were employed to elucidate the corrosion mechanism. Results revealed that Monel K500 alloy suffered pitting corrosion in sulfur-containing environments, with pits preferentially initiating at the interfaces of TiC precipitates due to micro-galvanic coupling. The passivation film formed in Na2S solution was inherently loose and non-protective, as it was composed of porous corrosion products such as NiS and Cu2S. Critically, sulfide accumulation in the initially formed pits triggered catalytic-occluded cell effect, leading to acidification and sustained pitting propagation. This study demonstrates that the severe pitting susceptibility of Monel K500 in sulfide-containing media arises from the combined effect of active TiC sites and the formation of non-protective sulfides.
{"title":"Unraveling the corrosion mechanism of Monel K500 in a sulfurous environment: Pitting initiation and propagation","authors":"Xiangsen Zeng , Minghao Yang , Qing Hu , Zhong Wu , Da-Hai Xia , Yiwen Zhang , Zhenbo Qin , Qiang Li , Wenbin Hu","doi":"10.1016/j.corsci.2026.113664","DOIUrl":"10.1016/j.corsci.2026.113664","url":null,"abstract":"<div><div>The corrosion behavior of Monel K500 alloy in sulfurous environments, relevant to oil and gas extraction, was systematically investigated. Electrochemical tests, microstructural characterization, and in-situ scanning vibrating electrode technique were employed to elucidate the corrosion mechanism. Results revealed that Monel K500 alloy suffered pitting corrosion in sulfur-containing environments, with pits preferentially initiating at the interfaces of TiC precipitates due to micro-galvanic coupling. The passivation film formed in Na<sub>2</sub>S solution was inherently loose and non-protective, as it was composed of porous corrosion products such as NiS and Cu<sub>2</sub>S. Critically, sulfide accumulation in the initially formed pits triggered catalytic-occluded cell effect, leading to acidification and sustained pitting propagation. This study demonstrates that the severe pitting susceptibility of Monel K500 in sulfide-containing media arises from the combined effect of active TiC sites and the formation of non-protective sulfides.</div></div>","PeriodicalId":290,"journal":{"name":"Corrosion Science","volume":"262 ","pages":"Article 113664"},"PeriodicalIF":7.4,"publicationDate":"2026-01-26","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146075767","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
The corrosion fatigue crack growth (CFCG) behavior of a Zr–Sn–Nb alloy was systematically investigated in simulated PWR primary water (320 °C, 12.5 MPa) under controlled dissolved oxygen (DO: 10–500 ppb) and dissolved hydrogen (DH: 0–30 cc (STP)/kg H₂O) conditions. A pronounced environmental acceleration is demonstrated, with the CFCG rate under low frequency (0.001 Hz), high stress ratio (0.9), and 100 ppb DO exceeding the air value by up to a factor of 250. In contrast, DO and DH variations exhibit only a modest influence on crack growth kinetics within the tested ranges. Microstructural analyses reveal a crack-tip oxide scale predominantly composed of monoclinic ZrO₂, accompanied by limited dislocation activity and extensive needle-shaped hydride precipitation in the adjacent matrix. The observed behavior is consistent with a slip-oxidation-rupture mechanism, which is established as the governing process. These findings underscore that mechanical driving forces (frequency, stress ratio), rather than bulk water redox chemistry, dominate the CFCG response of zirconium alloys in this environment.
{"title":"Insight into the corrosion fatigue crack growth mechanism of a ZrSnNb alloy in simulated PWR primary water","authors":"Yuqi Zheng, Jun Xiao, Ting Xiao, Wanli Ma, Jingjing Liao, Yong Chen, Hao Wang, Qi Xu","doi":"10.1016/j.corsci.2026.113668","DOIUrl":"10.1016/j.corsci.2026.113668","url":null,"abstract":"<div><div>The corrosion fatigue crack growth (CFCG) behavior of a Zr–Sn–Nb alloy was systematically investigated in simulated PWR primary water (320 °C, 12.5 MPa) under controlled dissolved oxygen (DO: 10–500 ppb) and dissolved hydrogen (DH: 0–30 cc (STP)/kg H₂O) conditions. A pronounced environmental acceleration is demonstrated, with the CFCG rate under low frequency (0.001 Hz), high stress ratio (0.9), and 100 ppb DO exceeding the air value by up to a factor of 250. In contrast, DO and DH variations exhibit only a modest influence on crack growth kinetics within the tested ranges. Microstructural analyses reveal a crack-tip oxide scale predominantly composed of monoclinic ZrO₂, accompanied by limited dislocation activity and extensive needle-shaped hydride precipitation in the adjacent matrix. The observed behavior is consistent with a slip-oxidation-rupture mechanism, which is established as the governing process. These findings underscore that mechanical driving forces (frequency, stress ratio), rather than bulk water redox chemistry, dominate the CFCG response of zirconium alloys in this environment.</div></div>","PeriodicalId":290,"journal":{"name":"Corrosion Science","volume":"262 ","pages":"Article 113668"},"PeriodicalIF":7.4,"publicationDate":"2026-01-26","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146075754","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2026-01-26DOI: 10.1016/j.corsci.2026.113665
Yongsheng Gu , Kangjia Liu , Wenke Lu , Zhijie Wang , Xiaolong Li , Yanfei Chen , Daining Fang
While numerous studies have examined C/SiC composites under ultra-high temperatures in air, inert, or vacuum atmospheres, the actual service environment of hypersonic vehicles features ultra-high temperatures and low pressure. To address this gap, we analyzed the residual mechanical properties, surface morphology, and pore-structure evolution of C/SiC composites after exposure to different temperatures, pressures, and loads. Mechanical testing, SEM, and in-situ CT were jointly employed. The results show that, when the temperature increases from 1200 °C to 1400 °C, the average residual strength and modulus exhibit increases of approximately 4 % and 18 %, respectively. Increasing pressure from 5 kPa to 15 kPa and 25 kPa leads to progressive reductions in residual strength by about 8 % and 30 %, while the residual modulus increases modestly by approximately 3 % and 12 %, indicating distinct controlling mechanisms. Notably, at 1200 °C and 5 kPa, an oxygen-diffusion shielding effect was observed: low loads enhance residual strength and modulus by closing pores and suppressing oxygen diffusion, whereas high loads reopen pores and accelerate crack-tip oxidation. In-situ CT analysis further reveals that porosity and fractal dimension decrease at low stress levels before increasing again with increasing stress. Based on these observations, an oxygen-diffusion shielding model that incorporates pore closure and fractal characteristics and a coupled thermo-mechanical-oxidation predictive expression was developed. It accurately captures the three-dimensional dependence of degradation on temperature, pressure, and load, and successfully predicts experimental results at 1400 °C under different loading conditions.
{"title":"Oxygen-diffusion shielding: A novel mechanism governing the thermo-mechanical-oxidative behavior of C/SiC composites via In-situ CT","authors":"Yongsheng Gu , Kangjia Liu , Wenke Lu , Zhijie Wang , Xiaolong Li , Yanfei Chen , Daining Fang","doi":"10.1016/j.corsci.2026.113665","DOIUrl":"10.1016/j.corsci.2026.113665","url":null,"abstract":"<div><div>While numerous studies have examined C/SiC composites under ultra-high temperatures in air, inert, or vacuum atmospheres, the actual service environment of hypersonic vehicles features ultra-high temperatures and low pressure. To address this gap, we analyzed the residual mechanical properties, surface morphology, and pore-structure evolution of C/SiC composites after exposure to different temperatures, pressures, and loads. Mechanical testing, SEM, and in-situ CT were jointly employed. The results show that, when the temperature increases from 1200 °C to 1400 °C, the average residual strength and modulus exhibit increases of approximately 4 % and 18 %, respectively. Increasing pressure from 5 kPa to 15 kPa and 25 kPa leads to progressive reductions in residual strength by about 8 % and 30 %, while the residual modulus increases modestly by approximately 3 % and 12 %, indicating distinct controlling mechanisms. Notably, at 1200 °C and 5 kPa, an oxygen-diffusion shielding effect was observed: low loads enhance residual strength and modulus by closing pores and suppressing oxygen diffusion, whereas high loads reopen pores and accelerate crack-tip oxidation. In-situ CT analysis further reveals that porosity and fractal dimension decrease at low stress levels before increasing again with increasing stress. Based on these observations, an oxygen-diffusion shielding model that incorporates pore closure and fractal characteristics and a coupled thermo-mechanical-oxidation predictive expression was developed. It accurately captures the three-dimensional dependence of degradation on temperature, pressure, and load, and successfully predicts experimental results at 1400 °C under different loading conditions.</div></div>","PeriodicalId":290,"journal":{"name":"Corrosion Science","volume":"262 ","pages":"Article 113665"},"PeriodicalIF":7.4,"publicationDate":"2026-01-26","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146075757","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2026-01-26DOI: 10.1016/j.corsci.2026.113669
Shu Zhu , Guohao Liu , Peng Zhou , Bingxing Wang , Bin Wang , Yong Tian , Huijun Liu
The effect of Ru addition on regulating the microstructure and electrochemical stability of Ti-0.5Ni-0.3Ta alloy. Ru increases the α/β phase interfaces providing more nucleation sites for passive film. Furthermore, Ru reduces the diffusion flux of oxygen vacancies and replaces Ti atoms with Ru atoms to eliminate cation vacancies in the passive film. However, hydrolysis of Ru ions during passive film formation hinders heterogeneous nucleation. Additionally, Ru increases the potential difference between the α and β phases worsening the micro-galvanic corrosion. Ti-0.5Ni-0.3Ta-0.2Ru alloy has the best corrosion resistance, with a steady-state current density (0.15 μA/cm²) far below the DOE2025 standard (1 μA/cm²).
{"title":"Dural roles of Ru on the corrosion resistance of Ti-0.5Ni-0.3Ta titanium alloy in the simulated environment for proton exchange membrane fuel cells: Passive film growth and micro-galvanic corrosion","authors":"Shu Zhu , Guohao Liu , Peng Zhou , Bingxing Wang , Bin Wang , Yong Tian , Huijun Liu","doi":"10.1016/j.corsci.2026.113669","DOIUrl":"10.1016/j.corsci.2026.113669","url":null,"abstract":"<div><div>The effect of Ru addition on regulating the microstructure and electrochemical stability of Ti-0.5Ni-0.3Ta alloy. Ru increases the α/β phase interfaces providing more nucleation sites for passive film. Furthermore, Ru reduces the diffusion flux of oxygen vacancies and replaces Ti atoms with Ru atoms to eliminate cation vacancies in the passive film. However, hydrolysis of Ru ions during passive film formation hinders heterogeneous nucleation. Additionally, Ru increases the potential difference between the α and β phases worsening the micro-galvanic corrosion. Ti-0.5Ni-0.3Ta-0.2Ru alloy has the best corrosion resistance, with a steady-state current density (0.15 μA/cm²) far below the DOE2025 standard (1 μA/cm²).</div></div>","PeriodicalId":290,"journal":{"name":"Corrosion Science","volume":"262 ","pages":"Article 113669"},"PeriodicalIF":7.4,"publicationDate":"2026-01-26","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146075761","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2026-01-26DOI: 10.1016/j.corsci.2026.113663
Ren Yu , Yao Wang , Jiasheng Dong , Yu Chang , Min Li , Lei Wang
The coupling effect of corrosion and creep on failure mechanism of K411 nickel-based superalloy under a simulated turbine blade service conditions (900 °C/165 MPa with 2 vol% SO2) was investigated. The results show that the creep rupture time in coupling environment decreased around 73 % comparing with that of normal creep. The presence of SO2 in the environment leads to the formation of voids, which serve as rapid diffusion pathways for nitrogen. Subsequently, nitrogen transport was enhanced by applied stress through dislocation-pipe diffusion mechanisms. This coupling effect promotes extensive formation of needle-like and cross-shaped TiN precipitates. The TiN precipitation consumes main γ'-forming elements Ti, generating γ'-free zone beneath corrosion scale measuring approximately 34 ± 3.2 μm in width (increased around 143 %). At the TiN/substrate interfaces, strain incompatibility leads to void nucleation, which was further interconnected and transformed into crack. These cracks then combined with voids initiated by sulphides, leading to surface crack formation and premature failure. The coupling effect of corrosion and creep accelerates nitrogen permeation, which constitutes the fundamental mechanism of the significant rupture time reduction.
{"title":"Failure mechanism of K411 superalloy under the coupling effect of corrosion and creep","authors":"Ren Yu , Yao Wang , Jiasheng Dong , Yu Chang , Min Li , Lei Wang","doi":"10.1016/j.corsci.2026.113663","DOIUrl":"10.1016/j.corsci.2026.113663","url":null,"abstract":"<div><div>The coupling effect of corrosion and creep on failure mechanism of K411 nickel-based superalloy under a simulated turbine blade service conditions (900 °C/165 MPa with 2 vol% SO<sub>2</sub>) was investigated. The results show that the creep rupture time in coupling environment decreased around 73 % comparing with that of normal creep. The presence of SO<sub>2</sub> in the environment leads to the formation of voids, which serve as rapid diffusion pathways for nitrogen. Subsequently, nitrogen transport was enhanced by applied stress through dislocation-pipe diffusion mechanisms. This coupling effect promotes extensive formation of needle-like and cross-shaped TiN precipitates. The TiN precipitation consumes main γ'-forming elements Ti, generating γ'-free zone beneath corrosion scale measuring approximately 34 ± 3.2 μm in width (increased around 143 %). At the TiN/substrate interfaces, strain incompatibility leads to void nucleation, which was further interconnected and transformed into crack. These cracks then combined with voids initiated by sulphides, leading to surface crack formation and premature failure. The coupling effect of corrosion and creep accelerates nitrogen permeation, which constitutes the fundamental mechanism of the significant rupture time reduction.</div></div>","PeriodicalId":290,"journal":{"name":"Corrosion Science","volume":"262 ","pages":"Article 113663"},"PeriodicalIF":7.4,"publicationDate":"2026-01-26","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146075755","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
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