Pub Date : 2026-05-01Epub Date: 2026-02-11DOI: 10.1016/j.corsci.2026.113705
Chenkai Xu , Zhe Zhang , Valeryia Kasneryk , Dongmei Zeng , Jiaqi Hu , Shangbin Wen , Qiang Wang , You Zhang
The critical need for smart coatings integrating real-time corrosion diagnostics and self-repair remains unmet due to the monofunctionality of conventional barrier systems. Within this study a hierarchical composite coating consisting of vertically aligned ZnO nanorod arrays, a ZIF-8 film, and a silane sol-gel layer was developed, which combines multiscale functionalities through interfacial confinement design. Fluorescence transitions from sol-gel layer to ZnO layer (475–550 nm) enable real-time monitoring of corrosion progress. The ZIF-8 layer presented in the coating serves two roles: as nanocontainers, it encapsulates external corrosion inhibitor 2-mercaptobenzothiazole, and it acts as an intrinsic inhibitor through its 2-methylimidazole ligands, enabling in this way synergistic self-healing properties. Scanning Kelvin Probe analysis confirms the self-repair mechanism, demonstrating a 500 mV reduction in potential disparity between damaged and intact regions. The coating with multifunctional architecture developed in the frame of the current study establishes a paradigm for smart corrosion protection systems by combining molecular-scale response with macroscopic durability.
{"title":"Early-stage corrosion sensing via sequential fluorescence from sol-gel and ZnO layers: Self-healing ZIF-8 film-based composite coatings for aluminum alloys","authors":"Chenkai Xu , Zhe Zhang , Valeryia Kasneryk , Dongmei Zeng , Jiaqi Hu , Shangbin Wen , Qiang Wang , You Zhang","doi":"10.1016/j.corsci.2026.113705","DOIUrl":"10.1016/j.corsci.2026.113705","url":null,"abstract":"<div><div>The critical need for smart coatings integrating real-time corrosion diagnostics and self-repair remains unmet due to the monofunctionality of conventional barrier systems. Within this study a hierarchical composite coating consisting of vertically aligned ZnO nanorod arrays, a ZIF-8 film, and a silane sol-gel layer was developed, which combines multiscale functionalities through interfacial confinement design. Fluorescence transitions from sol-gel layer to ZnO layer (475–550 nm) enable real-time monitoring of corrosion progress. The ZIF-8 layer presented in the coating serves two roles: as nanocontainers, it encapsulates external corrosion inhibitor 2-mercaptobenzothiazole, and it acts as an intrinsic inhibitor through its 2-methylimidazole ligands, enabling in this way synergistic self-healing properties. Scanning Kelvin Probe analysis confirms the self-repair mechanism, demonstrating a 500 mV reduction in potential disparity between damaged and intact regions. The coating with multifunctional architecture developed in the frame of the current study establishes a paradigm for smart corrosion protection systems by combining molecular-scale response with macroscopic durability.</div></div>","PeriodicalId":290,"journal":{"name":"Corrosion Science","volume":"263 ","pages":"Article 113705"},"PeriodicalIF":7.4,"publicationDate":"2026-05-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146172586","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 : 2026-05-01Epub Date: 2026-02-08DOI: 10.1016/j.corsci.2026.113703
Wei Li , Junshuai Lv , Jianhua Zhang , Junhao Zhao , Hanzhou Li , Xiaohong Shi , Hejun Li
Ultra-high-temperature ceramic-modified 2.5D needle-punched carbon/carbon (C/C) composites, known for their high-temperature strength and ablation resistance, are promising candidates for the sharp leading edges (SLEs) of advanced aircraft. However, the needle-punched architecture and the associated ceramic networks introduce anisotropy in thermal and oxidation responses. Here, three C/C–HfC–SiC SLEs with distinct preform orientations were fabricated via precursor infiltration and pyrolysis to investigate how the matching between preform orientation and heat flux governs heat transfer, oxidation, and failure modes. The best-aligned configuration exhibited outstanding cyclic ablation resistance, retaining its sharp geometry after five ablation cycles (600 s in total, ∼2700 °C) with a linear recession rate of only 0.03 µm s−1. Thermal-transport analysis revealed its highly efficient heat dissipation, which alleviated tip overheating. The extensive ceramic coverage on its windward surface, together with the continuous oxide scales connected by needle-introduced ceramics, forms a protective ceramic network that preserves the structural integrity of the SLE. These results identify orientation–heat-flux matching as a key factor for durable ablation protection and improved reliability of C/C-based SLEs.
{"title":"Needle-punched preform orientation governs cyclic ablation resistance of C/C–HfC–SiC composite leading edges","authors":"Wei Li , Junshuai Lv , Jianhua Zhang , Junhao Zhao , Hanzhou Li , Xiaohong Shi , Hejun Li","doi":"10.1016/j.corsci.2026.113703","DOIUrl":"10.1016/j.corsci.2026.113703","url":null,"abstract":"<div><div>Ultra-high-temperature ceramic-modified 2.5D needle-punched carbon/carbon (C/C) composites, known for their high-temperature strength and ablation resistance, are promising candidates for the sharp leading edges (SLEs) of advanced aircraft. However, the needle-punched architecture and the associated ceramic networks introduce anisotropy in thermal and oxidation responses. Here, three C/C–HfC–SiC SLEs with distinct preform orientations were fabricated via precursor infiltration and pyrolysis to investigate how the matching between preform orientation and heat flux governs heat transfer, oxidation, and failure modes. The best-aligned configuration exhibited outstanding cyclic ablation resistance, retaining its sharp geometry after five ablation cycles (600 s in total, ∼2700 °C) with a linear recession rate of only 0.03 µm s<sup>−1</sup>. Thermal-transport analysis revealed its highly efficient heat dissipation, which alleviated tip overheating. The extensive ceramic coverage on its windward surface, together with the continuous oxide scales connected by needle-introduced ceramics, forms a protective ceramic network that preserves the structural integrity of the SLE. These results identify orientation–heat-flux matching as a key factor for durable ablation protection and improved reliability of C/C-based SLEs.</div></div>","PeriodicalId":290,"journal":{"name":"Corrosion Science","volume":"263 ","pages":"Article 113703"},"PeriodicalIF":7.4,"publicationDate":"2026-05-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146172590","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 : 2026-05-01Epub Date: 2026-02-08DOI: 10.1016/j.corsci.2026.113704
Yuanhang Wang , Wei Li , Lianjun Fan , Ao Zhang , Hengyi Lv , Xianliang Li , Ri Sun , Sumeng Jiang , Jun Gong , Chao Sun
γ/γ′-NiPt-diffused coating was developed via a combined electroplating and arc ion plating (AIP) technique. Its isothermal oxidation behavior at 1100 ℃ was investigated and compared with that of γ/γ′-Pt-diffused coating. The results revealed that the γ/γ′-NiPt-diffused coating, with a higher Al content and free of refractory elements, exhibited significantly improved oxidation resistance and effectively suppressed recrystallization of the single crystal superalloy. Furthermore, the mechanism by which Pt induces recrystallization in single crystal superalloy was also discussed. The findings provide scientific guidance for the design of γ/γ′ coatings with improved oxidation resistance and coating/substrate compatibility.
{"title":"Mechanistic insights into γ/γ′-NiPt-diffused coating: Improved oxidation resistance and coating/substrate compatibility","authors":"Yuanhang Wang , Wei Li , Lianjun Fan , Ao Zhang , Hengyi Lv , Xianliang Li , Ri Sun , Sumeng Jiang , Jun Gong , Chao Sun","doi":"10.1016/j.corsci.2026.113704","DOIUrl":"10.1016/j.corsci.2026.113704","url":null,"abstract":"<div><div>γ/γ′-NiPt-diffused coating was developed via a combined electroplating and arc ion plating (AIP) technique. Its isothermal oxidation behavior at 1100 ℃ was investigated and compared with that of γ/γ′-Pt-diffused coating. The results revealed that the γ/γ′-NiPt-diffused coating, with a higher Al content and free of refractory elements, exhibited significantly improved oxidation resistance and effectively suppressed recrystallization of the single crystal superalloy. Furthermore, the mechanism by which Pt induces recrystallization in single crystal superalloy was also discussed. The findings provide scientific guidance for the design of γ/γ′ coatings with improved oxidation resistance and coating/substrate compatibility.</div></div>","PeriodicalId":290,"journal":{"name":"Corrosion Science","volume":"263 ","pages":"Article 113704"},"PeriodicalIF":7.4,"publicationDate":"2026-05-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146172587","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 : 2026-05-01Epub Date: 2026-01-22DOI: 10.1016/j.corsci.2026.113640
Ding Guo , Jia Liu , Xiaofan Zhai , Yanan Wang , Fang Guan , Jizhou Duan , Baorong Hou
Environmental analysis was employed to assess the pitting corrosion acceleration mechanism of an anaerobic nitrate-reducer Exiguobacterium acetylicum on Q235 steel (Pitmax=29 μm). The metabolic corrosion process of microbial extracellular electron transfer was re-evaluated through chemical thermodynamic and kinetic calculations. E. acetylicum accelerated cathodic hydrogen depolarization corrosion of steel by coupling hydrogenase with the oxidation-reduction of quinones in the cell membrane to achieve hydrogen cycling on the steel surface. Lithotrophic E. acetylicum promoted hydrogen evolution between ferrite phases on the iron surface, thereby enhancing denitrification and nitrogen removal processes and increasing corrosion loss.
采用环境分析方法，研究厌氧硝酸盐还原剂乙酰Exiguobacterium acetylicum对Q235钢（Pitmax=29 μm）的点蚀加速机理。通过化学热力学和动力学计算，重新评价了微生物胞外电子传递的代谢腐蚀过程。E. acetylicum通过将氢化酶与细胞膜上醌的氧化还原偶联来加速钢的阴极氢去极化腐蚀，实现钢表面的氢循环。Lithotrophic E. acetyum促进了铁表面铁素体相之间的析氢，从而增强了脱氮脱氮过程，增加了腐蚀损失。
{"title":"The anaerobic hydrogen cycling process of Exiguobacterium acetylicum regulated by electron acceptor and redox mediators accelerates the microbiologically influenced corrosion of Q235 steel: An environmental analysis result","authors":"Ding Guo , Jia Liu , Xiaofan Zhai , Yanan Wang , Fang Guan , Jizhou Duan , Baorong Hou","doi":"10.1016/j.corsci.2026.113640","DOIUrl":"10.1016/j.corsci.2026.113640","url":null,"abstract":"<div><div>Environmental analysis was employed to assess the pitting corrosion acceleration mechanism of an anaerobic nitrate-reducer <em>Exiguobacterium acetylicum</em> on Q235 steel (Pit<sub>max</sub>=29 μm). The metabolic corrosion process of microbial extracellular electron transfer was re-evaluated through chemical thermodynamic and kinetic calculations. <em>E. acetylicum</em> accelerated cathodic hydrogen depolarization corrosion of steel by coupling hydrogenase with the oxidation-reduction of quinones in the cell membrane to achieve hydrogen cycling on the steel surface. Lithotrophic <em>E. acetylicum</em> promoted hydrogen evolution between ferrite phases on the iron surface, thereby enhancing denitrification and nitrogen removal processes and increasing corrosion loss.</div></div>","PeriodicalId":290,"journal":{"name":"Corrosion Science","volume":"263 ","pages":"Article 113640"},"PeriodicalIF":7.4,"publicationDate":"2026-05-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146172589","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 : 2026-04-15Epub Date: 2026-01-23DOI: 10.1016/j.corsci.2026.113647
Chenchen Liu , Ao Huang , Shenghao Li , Haitao Chen , Jiarun Wang , Bochen Li , Xinyu Chen , Huazhi Gu
Refractory integrity is critical to the safe and stable operation of high-temperature metallurgical equipment, yet slag corrosion behavior of refractory castables under thermo–chemo–mechanical (TCM) conditions is difficult to characterize by conventional post-mortem methods because transient penetration, interfacial dissolution and reaction-product growth occur simultaneously and evolve with time. In this study, the high-temperature digital image correlation (HT-DIC) was applied and a corrosion severity index (CSI) was proposed and verified for in-situ, full-field and quantitative analysis of slag corrosion of the refractory castables with CSI contour maps and the corresponding full-field average CSI curves, thereby a novel multi-dimensional assessment criterion was established. Compared with the Al2O3–MgO castables, the CeO2/La2O3 containing refractory castables exhibit earlier reaction activation but slower late-stage degradation with corrosion index, penetration index and CSI every 0.5 h. Thus, the in-situ assessment with CSI provides a more accurate guidance for comparing slag corrosion resistance among different refractory castables and revealing corrosion or resistance mechanisms.
{"title":"In-situ assessment of slag corrosion on refractories based on HT-DIC: A novel multi-dimensional index with corrosion severity","authors":"Chenchen Liu , Ao Huang , Shenghao Li , Haitao Chen , Jiarun Wang , Bochen Li , Xinyu Chen , Huazhi Gu","doi":"10.1016/j.corsci.2026.113647","DOIUrl":"10.1016/j.corsci.2026.113647","url":null,"abstract":"<div><div>Refractory integrity is critical to the safe and stable operation of high-temperature metallurgical equipment, yet slag corrosion behavior of refractory castables under thermo–chemo–mechanical (TCM) conditions is difficult to characterize by conventional post-mortem methods because transient penetration, interfacial dissolution and reaction-product growth occur simultaneously and evolve with time. In this study, the high-temperature digital image correlation (HT-DIC) was applied and a corrosion severity index (CSI) was proposed and verified for in-situ, full-field and quantitative analysis of slag corrosion of the refractory castables with CSI contour maps and the corresponding full-field average CSI curves, thereby a novel multi-dimensional assessment criterion was established. Compared with the Al<sub>2</sub>O<sub>3</sub>–MgO castables, the CeO<sub>2</sub>/La<sub>2</sub>O<sub>3</sub> containing refractory castables exhibit earlier reaction activation but slower late-stage degradation with corrosion index, penetration index and CSI every 0.5 h. Thus, the in-situ assessment with CSI provides a more accurate guidance for comparing slag corrosion resistance among different refractory castables and revealing corrosion or resistance mechanisms.</div></div>","PeriodicalId":290,"journal":{"name":"Corrosion Science","volume":"262 ","pages":"Article 113647"},"PeriodicalIF":7.4,"publicationDate":"2026-04-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146075822","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 : 2026-04-15Epub Date: 2026-01-22DOI: 10.1016/j.corsci.2026.113649
Teng Fei Zhang , Ze Zhang , Peng Jin , Mingdi Wen , Qimin Wang , Shihong Zhang
To overcome performance limitations of conventional nitride/oxide PVD coatings, this study employs arc ion plating to fabricate periodic N-rich/O-rich nanomultilayer oxynitride coatings, driven by spatial plasma distribution gradient in vacuum chamber and differential reactivity of nitrogen/oxygen species. The optimized (Al0.41Cr0.53Si0.06)0.50(O0.19N0.81)0.50 coating retains fcc-AlCrON primary phase stability after annealing at 1100 ℃, suppressing Cr-N bond dissociation and formation of w-AlN soft phases. Thermal activation promotes Al diffusion into O-rich sublayers and Cr enrichment in N-rich sublayers, enabling fully coherent interfaces across the Al/O-rich and Cr/N-rich multilayers. During isothermal oxidation at 1000 ℃, a protective three-layered oxide scale forms on the coating surface, consisting of an outer θ-Al2O3 layer, a subsurface fcc-(Cr,Al)2O3 layer, and an oxygen-penetration zone. This structure exhibits the lowest onset temperature for accelerated oxidation and minimal oxidation depth, attributed to multiple synergistic mechanisms: rapid nucleation and growth of protective oxide layer facilitated by initial Al-O and Cr-O bonding networks, a “labyrinth” nano-multilayers that prolongs O2- diffusion pathways, and thermally induced coherent Al/O-rich and Cr/N-rich interfaces that establish energy barriers against O2- inward diffusion and metal cation outward migration. However, excessive oxygen doping promotes amorphization and reduces the modulation ratio, impairing coherent interface formation and degrading oxidation resistance. This work elucidates the critical roles of compositional design and interfacial coherence in tailoring high-temperature performance of oxynitride coatings, providing a strategic pathway for developing advanced protective coatings for extreme environments.
{"title":"Enhanced thermal stability and oxidation resistance by coherent interfaces of oxide/nitride sublayers in self-organized nano-multilayer oxynitride coatings","authors":"Teng Fei Zhang , Ze Zhang , Peng Jin , Mingdi Wen , Qimin Wang , Shihong Zhang","doi":"10.1016/j.corsci.2026.113649","DOIUrl":"10.1016/j.corsci.2026.113649","url":null,"abstract":"<div><div>To overcome performance limitations of conventional nitride/oxide PVD coatings, this study employs arc ion plating to fabricate periodic N-rich/O-rich nanomultilayer oxynitride coatings, driven by spatial plasma distribution gradient in vacuum chamber and differential reactivity of nitrogen/oxygen species. The optimized (Al<sub>0.41</sub>Cr<sub>0.53</sub>Si<sub>0.06</sub>)<sub>0.50</sub>(O<sub>0.19</sub>N<sub>0.81</sub>)<sub>0.50</sub> coating retains fcc-AlCrON primary phase stability after annealing at 1100 ℃, suppressing Cr-N bond dissociation and formation of w-AlN soft phases. Thermal activation promotes Al diffusion into O-rich sublayers and Cr enrichment in N-rich sublayers, enabling fully coherent interfaces across the Al/O-rich and Cr/N-rich multilayers. During isothermal oxidation at 1000 ℃, a protective three-layered oxide scale forms on the coating surface, consisting of an outer θ-Al<sub>2</sub>O<sub>3</sub> layer, a subsurface fcc-(Cr,Al)<sub>2</sub>O<sub>3</sub> layer, and an oxygen-penetration zone. This structure exhibits the lowest onset temperature for accelerated oxidation and minimal oxidation depth, attributed to multiple synergistic mechanisms: rapid nucleation and growth of protective oxide layer facilitated by initial Al-O and Cr-O bonding networks, a “labyrinth” nano-multilayers that prolongs O<sup>2-</sup> diffusion pathways, and thermally induced coherent Al/O-rich and Cr/N-rich interfaces that establish energy barriers against O<sup>2-</sup> inward diffusion and metal cation outward migration. However, excessive oxygen doping promotes amorphization and reduces the modulation ratio, impairing coherent interface formation and degrading oxidation resistance. This work elucidates the critical roles of compositional design and interfacial coherence in tailoring high-temperature performance of oxynitride coatings, providing a strategic pathway for developing advanced protective coatings for extreme environments.</div></div>","PeriodicalId":290,"journal":{"name":"Corrosion Science","volume":"262 ","pages":"Article 113649"},"PeriodicalIF":7.4,"publicationDate":"2026-04-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146075826","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 : 2026-04-15Epub 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":"2026-04-15","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}
Pub Date : 2026-04-15Epub Date: 2026-01-30DOI: 10.1016/j.corsci.2026.113666
Ye Zhang , Zhice Yang , Chaoran Ma , Yong Hua , Limin Chang , Tao Zhang , Fuhui Wang
Micro-scale inclusions play a critical role in determining the corrosion performance of semiconductor-grade 316 L stainless steel, yet their quantitative influence remains insufficiently understood. In this work, an integrated experimental-data-driven framework was established to elucidate the corrosion-promoting effects of sub-2 μm inclusions under electronic specialty gas environments. Inclusion characteristics were experimentally characterised and correlated with corrosion responses, forming the basis for model development and validation. To address data scarcity, statistically verified Gaussian-noise and k-nearest-neighbor-based augmentation strategies were employed. Among eight machine-learning algorithms, a weighted ensemble model exhibited the highest predictive accuracy (R² = 0.95). Model predictions were further validated against independent corrosion experiment datasets rather than internal cross-validation alone. SHAP and partial dependence analyses revealed the importance features that small inclusions (0–2 μm), particularly silicates and spinels, significantly promote corrosion once their total area fraction and number density exceed critical thresholds. Based on these findings, a corrosion-recommendation map focusing on sub-2 μm inclusions was constructed for semiconductor-grade 316 L stainless steel. The results highlight inclusion engineering as an effective pathway to improving corrosion resistance in high-purity electronic specialty gas applications.
{"title":"Linking inclusion characterisics to stainless steel corrosion in semiconductor HCl environments via machine leaning approaches","authors":"Ye Zhang , Zhice Yang , Chaoran Ma , Yong Hua , Limin Chang , Tao Zhang , Fuhui Wang","doi":"10.1016/j.corsci.2026.113666","DOIUrl":"10.1016/j.corsci.2026.113666","url":null,"abstract":"<div><div>Micro-scale inclusions play a critical role in determining the corrosion performance of semiconductor-grade 316 L stainless steel, yet their quantitative influence remains insufficiently understood. In this work, an integrated experimental-data-driven framework was established to elucidate the corrosion-promoting effects of sub-2 μm inclusions under electronic specialty gas environments. Inclusion characteristics were experimentally characterised and correlated with corrosion responses, forming the basis for model development and validation. To address data scarcity, statistically verified Gaussian-noise and k-nearest-neighbor-based augmentation strategies were employed. Among eight machine-learning algorithms, a weighted ensemble model exhibited the highest predictive accuracy (R² = 0.95). Model predictions were further validated against independent corrosion experiment datasets rather than internal cross-validation alone. SHAP and partial dependence analyses revealed the importance features that small inclusions (0–2 μm), particularly silicates and spinels, significantly promote corrosion once their total area fraction and number density exceed critical thresholds. Based on these findings, a corrosion-recommendation map focusing on sub-2 μm inclusions was constructed for semiconductor-grade 316 L stainless steel. The results highlight inclusion engineering as an effective pathway to improving corrosion resistance in high-purity electronic specialty gas applications.</div></div>","PeriodicalId":290,"journal":{"name":"Corrosion Science","volume":"262 ","pages":"Article 113666"},"PeriodicalIF":7.4,"publicationDate":"2026-04-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146185271","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 : 2026-04-15Epub Date: 2026-01-29DOI: 10.1016/j.corsci.2026.113673
Youzhi Wang , Shuimei Fan , Ge Wang , Chuang Qiao , Long Hao , Huaiyu Yang
The electrochemical impedance spectroscopy (EIS) data are usually under-explored in corrosion inhibitors community. In this paper, the distribution of relaxation times (DRT) has been employed to explore the EIS data of carbon steels in inorganic acid corrosion systems with/without organic corrosion inhibitors addition. Theoretically analyses find that the characteristic frequency contained in EIS data correlate highly with the corrosion reaction kinetics and the adsorption behavior of inhibitor molecules at the corrosion electrolyte/metal interface. Based on EIS-DRT method, the time-constant shift (TCS) model has been proposed, and its functionalities have been discussed. Results find that the TCS data evolution upon the inhibitor concentration could indicate the inhibition efficiency, adsorption equilibrium constant () and adsorption-type of the inhibitor molecules. In addition, the proposed TCS model applies in corrosion systems with a different temperature. Therefore, the proposed TCS model could serve as an effective supplement to the traditional methods for adsorption behavior investigation and adsorption mechanism exploration of organic corrosion inhibitor molecules in inorganic acid corrosion systems, and besides it is anticipated that the TCS model could find applications in high-throughput evaluation and screening of effective corrosion inhibitors in practice.
{"title":"Innovative EIS-DRT for the research of organic inhibitors in inorganic acid corrosion system","authors":"Youzhi Wang , Shuimei Fan , Ge Wang , Chuang Qiao , Long Hao , Huaiyu Yang","doi":"10.1016/j.corsci.2026.113673","DOIUrl":"10.1016/j.corsci.2026.113673","url":null,"abstract":"<div><div>The electrochemical impedance spectroscopy (EIS) data are usually under-explored in corrosion inhibitors community. In this paper, the distribution of relaxation times (DRT) has been employed to explore the EIS data of carbon steels in inorganic acid corrosion systems with/without organic corrosion inhibitors addition. Theoretically analyses find that the characteristic frequency contained in EIS data correlate highly with the corrosion reaction kinetics and the adsorption behavior of inhibitor molecules at the corrosion electrolyte/metal interface. Based on EIS-DRT method, the time-constant shift (TCS) model has been proposed, and its functionalities have been discussed. Results find that the TCS data evolution upon the inhibitor concentration could indicate the inhibition efficiency, adsorption equilibrium constant (<span><math><msub><mrow><mi>K</mi></mrow><mrow><mi>ads</mi></mrow></msub></math></span>) and adsorption-type of the inhibitor molecules. In addition, the proposed TCS model applies in corrosion systems with a different temperature. Therefore, the proposed TCS model could serve as an effective supplement to the traditional methods for adsorption behavior investigation and adsorption mechanism exploration of organic corrosion inhibitor molecules in inorganic acid corrosion systems, and besides it is anticipated that the TCS model could find applications in high-throughput evaluation and screening of effective corrosion inhibitors in practice.</div></div>","PeriodicalId":290,"journal":{"name":"Corrosion Science","volume":"262 ","pages":"Article 113673"},"PeriodicalIF":7.4,"publicationDate":"2026-04-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146185265","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 : 2026-04-15Epub Date: 2026-01-30DOI: 10.1016/j.corsci.2026.113670
Guoyu Tong , Liping Wu , Xiuling Shang , Xiaoying Sun , Dongjiu Zhang , Changgang Wang
The corrosion behavior of copper in atmospheric environments is significantly influenced by regional climate. To achieve rapid, in-situ identification and provenance tracing of corrosion status, this study proposes an intelligent analysis method integrating real-field images and explainable machine learning. Departing from planar specimens, this work employs three-dimensional pure copper tubes for greater engineering representativeness. These were exposed outdoors for 2–24 months in three typical environments: Wenchang (marine), Chongqing (urban), and Qingdao (industrial–marine) of China. A dataset of 1500 macroscopic corrosion images was constructed using smartphones, addressing challenges like uneven illumination on curved surfaces. A set of 24 color and texture features was extracted, and six machine learning models were employed for regional classification. The Support Vector Machine (SVM) achieved optimal performance, attaining 99.67 % test accuracy using data mixed from all exposure periods. All models achieved test set accuracies of 96 % or higher, confirming the method's capability to capture regional corrosion visual features that are resistant to temporal variations. Explainability techniques, including feature importance analysis and SLIC superpixel heatmaps, revealed the mean blue and red channel values, blue channel standard deviation, and image entropy as the most critical discriminative features. These features possess clear physical correlations with the chemical composition, spatial distribution, and morphological complexity of corrosion products, constructing an interpretive bridge between macroscopic image features and microscopic corrosion mechanisms. This study validates the feasibility of using smartphones and machine learning for high-accuracy corrosion provenance tracing in complex, real-world scenarios, providing a scientific paradigm and practical foundation for intelligent corrosion diagnosis.
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