Pub Date : 2026-01-24DOI: 10.1016/j.corsci.2026.113661
Jian Wang, Xueyan Shan, Min Du, Ting Xu, Zhiyu Tian, Chengjiao Jiao
This study addressed the challenge of corrosion induced by sulfate-reducing bacteria (SRB) in oilfield produced water and proposed the use of the beneficial bacterium Bacillus sp. for corrosion control. The potential mechanisms through which Bacillus sp. inhibited SRB-induced corrosion were investigated, including competitive exclusion, production of microbial metabolites and biomineralization. The Bacillus sp. significantly inhibited SRB growth and reduced the production of corrosive sulfides. The microbial metabolites produced included numerous amino acid-based corrosion inhibitors and antimicrobial agents. Furthermore, the formation of biomineralized film effectively slowed down the corrosion process of SRB and possessed a certain self-repairing ability.
{"title":"Inhibition of SRB-induced corrosion of X65 steel by Bacillus sp.: Microbial competition and biomineralized film formation","authors":"Jian Wang, Xueyan Shan, Min Du, Ting Xu, Zhiyu Tian, Chengjiao Jiao","doi":"10.1016/j.corsci.2026.113661","DOIUrl":"10.1016/j.corsci.2026.113661","url":null,"abstract":"<div><div>This study addressed the challenge of corrosion induced by sulfate-reducing bacteria (SRB) in oilfield produced water and proposed the use of the beneficial bacterium <em>Bacillus</em> sp. for corrosion control. The potential mechanisms through which <em>Bacillus</em> sp. inhibited SRB-induced corrosion were investigated, including competitive exclusion, production of microbial metabolites and biomineralization. The <em>Bacillus</em> sp. significantly inhibited SRB growth and reduced the production of corrosive sulfides. The microbial metabolites produced included numerous amino acid-based corrosion inhibitors and antimicrobial agents. Furthermore, the formation of biomineralized film effectively slowed down the corrosion process of SRB and possessed a certain self-repairing ability.</div></div>","PeriodicalId":290,"journal":{"name":"Corrosion Science","volume":"262 ","pages":"Article 113661"},"PeriodicalIF":7.4,"publicationDate":"2026-01-24","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146075759","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 : 2026-01-24DOI: 10.1016/j.corsci.2026.113648
Shan Jiang , Jian-ping Cao , Zhi-yong Liu , Ning Cai , Xue-tao Li
The reduction behavior of corrosion products formed on low alloy steels and oxygen reduction behavior are investigated in this study using ex- and in-situ electrochemical-phase analysis methods. The role of Ni in the cathodic reaction is also elucidated. The reduction of the corrosion products and oxygen is inhibited by the enrichment of Ni in the rust layer formed on Ni-containing steels. The reduction of amorphous substance and maghemite is not inhibited by the enrichment of Ni in the rust layer, while the oxidation behavior of the corrosion products is inhibited, leading to a reduction in the amount of reducible corrosion products. Therefore, the reduction of corrosion products formed on the Ni-containing steels is inhibited by decreasing the amount of reducible corrosion products. The effect of Ni on the reduction of corrosion products is therefore an indirect inhibitory process.
{"title":"Influence of Ni on the cathodic reaction of corrosion products formed on low alloy steel under wet-dry cycling","authors":"Shan Jiang , Jian-ping Cao , Zhi-yong Liu , Ning Cai , Xue-tao Li","doi":"10.1016/j.corsci.2026.113648","DOIUrl":"10.1016/j.corsci.2026.113648","url":null,"abstract":"<div><div>The reduction behavior of corrosion products formed on low alloy steels and oxygen reduction behavior are investigated in this study using ex- and in-situ electrochemical-phase analysis methods. The role of Ni in the cathodic reaction is also elucidated. The reduction of the corrosion products and oxygen is inhibited by the enrichment of Ni in the rust layer formed on Ni-containing steels. The reduction of amorphous substance and maghemite is not inhibited by the enrichment of Ni in the rust layer, while the oxidation behavior of the corrosion products is inhibited, leading to a reduction in the amount of reducible corrosion products. Therefore, the reduction of corrosion products formed on the Ni-containing steels is inhibited by decreasing the amount of reducible corrosion products. The effect of Ni on the reduction of corrosion products is therefore an indirect inhibitory process.</div></div>","PeriodicalId":290,"journal":{"name":"Corrosion Science","volume":"262 ","pages":"Article 113648"},"PeriodicalIF":7.4,"publicationDate":"2026-01-24","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146075823","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 : 2026-01-23DOI: 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":"2026-01-23","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 : 2026-01-23DOI: 10.1016/j.corsci.2026.113651
Roger Castellote-Alvarez , David San-Martin , Cesar Fernandez-Jimenez , Jose A. Jimenez , Christopher Petersson , Esteban Urones-Garrote , Peter Szakalos , Isaac Toda-Caraballo
This study presents the design, characterization and evaluation of corrosion resistance and mechanical integrity of a novel Co-free face-centered cubic (FCC) non-equiatomic Fe33.5Ni43.5Cr11Mn6Al6 High-Entropy Alloy (HEA) for structural applications in Generation IV Lead-cooled Fast Reactors (LFRs). The alloy was engineered to form a protective Al-rich oxide scale. Liquid Metal Corrosion (LMC) tests were conducted in stagnant liquid Pb at 550 °C and 650 °C for 1150 h, under controlled oxygen concentrations ranging from 7.4·10−6 to 8.6·10−6 wt% at 550 °C, and from 4.5·10−5 to 3.6·10−4 wt% at 650 °C. Liquid Metal Embrittlement (LME) susceptibility was assessed via Slow Strain Rate Testing (SSRT) between 350 °C to 600 °C. LMC test results revealed bilayer oxide scale formation, with an inner amorphous alumina scale acting as an effective diffusion barrier and a complex outer Mn(Al,Fe,Cr)2O4 spinel prone to detachment. The alloy exhibited self-healing behavior, regenerating protective oxides in areas where Pb penetration took place. No signs of LME were observed up to 400 °C, with embrittlement onset occurring at 500 °C. Despite its high Ni content, which is typically detrimental in liquid Pb due to the its high solubility at elevated temperatures, leading to accelerated degradation, combined with low oxygen availability that hinders protective oxide formation and microstructural heterogeneities (oxide inclusions and local grain size variations), the alloy maintained excellent corrosion resistance and mechanical integrity. These results underscore the exceptional corrosion resistance of this non-equiatomic Fe33.5Ni43.5Cr11Mn6Al6 HEA, positioning it as a highly promising candidate for high-temperature nuclear applications in Pb-cooled systems.
{"title":"Corrosion behavior in liquid lead of a novel FCC non-equiatomic high-entropy alloy capable of forming an alumina protective oxide scale","authors":"Roger Castellote-Alvarez , David San-Martin , Cesar Fernandez-Jimenez , Jose A. Jimenez , Christopher Petersson , Esteban Urones-Garrote , Peter Szakalos , Isaac Toda-Caraballo","doi":"10.1016/j.corsci.2026.113651","DOIUrl":"10.1016/j.corsci.2026.113651","url":null,"abstract":"<div><div>This study presents the design, characterization and evaluation of corrosion resistance and mechanical integrity of a novel Co-free face-centered cubic (FCC) non-equiatomic Fe<sub>33.5</sub>Ni<sub>43.5</sub>Cr<sub>11</sub>Mn<sub>6</sub>Al<sub>6</sub> High-Entropy Alloy (HEA) for structural applications in Generation IV Lead-cooled Fast Reactors (LFRs). The alloy was engineered to form a protective Al-rich oxide scale. Liquid Metal Corrosion (LMC) tests were conducted in stagnant liquid Pb at 550 °C and 650 °C for 1150 h, under controlled oxygen concentrations ranging from 7.4·10<sup>−6</sup> to 8.6·10<sup>−6</sup> wt% at 550 °C, and from 4.5·10<sup>−5</sup> to 3.6·10<sup>−4</sup> wt% at 650 °C. Liquid Metal Embrittlement (LME) susceptibility was assessed via Slow Strain Rate Testing (SSRT) between 350 °C to 600 °C. LMC test results revealed bilayer oxide scale formation, with an inner amorphous alumina scale acting as an effective diffusion barrier and a complex outer Mn(Al,Fe,Cr)<sub>2</sub>O<sub>4</sub> spinel prone to detachment. The alloy exhibited self-healing behavior, regenerating protective oxides in areas where Pb penetration took place. No signs of LME were observed up to 400 °C, with embrittlement onset occurring at 500 °C. Despite its high Ni content, which is typically detrimental in liquid Pb due to the its high solubility at elevated temperatures, leading to accelerated degradation, combined with low oxygen availability that hinders protective oxide formation and microstructural heterogeneities (oxide inclusions and local grain size variations), the alloy maintained excellent corrosion resistance and mechanical integrity. These results underscore the exceptional corrosion resistance of this non-equiatomic Fe<sub>33.5</sub>Ni<sub>43.5</sub>Cr<sub>11</sub>Mn<sub>6</sub>Al<sub>6</sub> HEA, positioning it as a highly promising candidate for high-temperature nuclear applications in Pb-cooled systems.</div></div>","PeriodicalId":290,"journal":{"name":"Corrosion Science","volume":"262 ","pages":"Article 113651"},"PeriodicalIF":7.4,"publicationDate":"2026-01-23","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146075766","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 : 2026-01-23DOI: 10.1016/j.corsci.2026.113652
Jiawei He , Dawei Wang , Dan Qi , Linyang Zhang , Wei Cheng , Qifei Peng , Pinliang Jiang , Boyang Liu , Peng Chen , Cheng Wang , Min Zha
Formation kinetics of corrosion product film in Mg-Y-Al alloys is deliberately controlled via Y addition. An optimized Y content (3.5 wt%) promotes rapid Mg(OH)2 nucleation via Y(OH)3-assisted heterogeneous nucleation yet restrains its growth rate, forming a dense and protective film. This rapid generation is paramount during SCC, enabling swift film repair after rupture to hinder Cl⁻/H ingress, thereby mitigating the corrosion-hydrogen-stress synergy. This leads to a low corrosion rate (∼0.1 mm y⁻¹) and reduced SCC susceptibility (near zero strength loss and ∼10 % ductility loss). This work demonstrates that regulating film formation kinetics critically enhances corrosion and SCC resistance.
通过添加Y来控制Mg-Y-Al合金腐蚀产物膜的形成动力学。优化后的Y含量（3.5 wt%）通过Y(OH)3辅助的非均相成核促进了Mg(OH)2的快速成核，但抑制了其生长速度，形成致密的保护膜。在SCC过程中，这种快速生成是最重要的，可以在破裂后迅速修复膜，阻止Cl - H的进入，从而减轻腐蚀-氢应力的协同作用。这导致低腐蚀速率（~ 0.1 mm y⁻¹）和降低SCC敏感性（接近零强度损失和~ 10 %延性损失）。这项工作表明，调节成膜动力学可以提高腐蚀和抗SCC能力。
{"title":"RE-mediated dynamic film reconstruction for concurrent corrosion and stress corrosion cracking resistance","authors":"Jiawei He , Dawei Wang , Dan Qi , Linyang Zhang , Wei Cheng , Qifei Peng , Pinliang Jiang , Boyang Liu , Peng Chen , Cheng Wang , Min Zha","doi":"10.1016/j.corsci.2026.113652","DOIUrl":"10.1016/j.corsci.2026.113652","url":null,"abstract":"<div><div>Formation kinetics of corrosion product film in Mg-Y-Al alloys is deliberately controlled via Y addition. An optimized Y content (3.5 wt%) promotes rapid Mg(OH)<sub>2</sub> nucleation via Y(OH)<sub>3</sub>-assisted heterogeneous nucleation yet restrains its growth rate, forming a dense and protective film. This rapid generation is paramount during SCC, enabling swift film repair after rupture to hinder Cl⁻/H ingress, thereby mitigating the corrosion-hydrogen-stress synergy. This leads to a low corrosion rate (∼0.1 mm y⁻¹) and reduced SCC susceptibility (near zero strength loss and ∼10 % ductility loss). This work demonstrates that regulating film formation kinetics critically enhances corrosion and SCC resistance.</div></div>","PeriodicalId":290,"journal":{"name":"Corrosion Science","volume":"262 ","pages":"Article 113652"},"PeriodicalIF":7.4,"publicationDate":"2026-01-23","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146075760","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 : 2026-01-22DOI: 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":"2026-01-22","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 : 2026-01-22DOI: 10.1016/j.corsci.2026.113645
Shengyuan Wang , Ruochong Liu , Haoyu Zhang , Ge Zhou , Xiao-Bo Chen , Lijia Chen
Ti-4Al-6Mo-2V-5Cr-2Zr alloy with different microstructures was prepared through two heat treatment processes (STA 1 and STA 2), and its corrosion fatigue behavior in a 3.5 % NaCl solution was investigated. STA 1 forms a hierarchical nanostructure (HN) containing coarse grain boundary α (GB α), primary α (αp), and nanoscale secondary α (αs) with significant elemental segregation. In contrast, STA 2 forms a lamellar structure (LM) composed of fine, needle-like αs with uniform element distribution. Results indicate that LM has better corrosion resistance, its passive film resistance (4.328 ×106 Ω·cm2) is higher than that of HN (1.101 ×106 Ω·cm2, 6.9 nm). In a 3.5 % NaCl solution, STA 1 shows significant corrosion fatigue behavior, whereas STA 2 does not exhibit any signs of corrosion fatigue. The deformation in HN mainly occurs within the coarse α phase, and the high dislocation density can lead to localized stress concentrations, thereby damaging the passivation film and initiating corrosion fatigue cracks.
{"title":"Corrosion fatigue behavior of Ti-4Al-6Mo-2V-5Cr-2Zr alloy with different microstructures in 3.5 % NaCl solution","authors":"Shengyuan Wang , Ruochong Liu , Haoyu Zhang , Ge Zhou , Xiao-Bo Chen , Lijia Chen","doi":"10.1016/j.corsci.2026.113645","DOIUrl":"10.1016/j.corsci.2026.113645","url":null,"abstract":"<div><div>Ti-4Al-6Mo-2V-5Cr-2Zr alloy with different microstructures was prepared through two heat treatment processes (STA 1 and STA 2), and its corrosion fatigue behavior in a 3.5 % NaCl solution was investigated. STA 1 forms a hierarchical nanostructure (HN) containing coarse grain boundary α (GB α), primary α (α<sub>p</sub>), and nanoscale secondary α (α<sub>s</sub>) with significant elemental segregation. In contrast, STA 2 forms a lamellar structure (LM) composed of fine, needle-like α<sub>s</sub> with uniform element distribution. Results indicate that LM has better corrosion resistance, its passive film resistance (4.328 ×10<sup>6</sup> Ω·cm<sup>2</sup>) is higher than that of HN (1.101 ×10<sup>6</sup> Ω·cm<sup>2</sup>, 6.9 nm). In a 3.5 % NaCl solution, STA 1 shows significant corrosion fatigue behavior, whereas STA 2 does not exhibit any signs of corrosion fatigue. The deformation in HN mainly occurs within the coarse α phase, and the high dislocation density can lead to localized stress concentrations, thereby damaging the passivation film and initiating corrosion fatigue cracks.</div></div>","PeriodicalId":290,"journal":{"name":"Corrosion Science","volume":"262 ","pages":"Article 113645"},"PeriodicalIF":7.4,"publicationDate":"2026-01-22","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146036905","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}
In order to develop advanced and clean molten salt electrolysis technologies for electrometallurgy and CO2 conversion, stable inert anodes in chloride molten salt are crucial, but also serious challenge. Precious metals exhibit the best corrosion resistance, but it is impossible to directly used due to extremely high cost for conventional bulk or plate structure. Herein, a novel coated RuO2-IrO2 inert anode with double-layer structure was proposed in chloride molten salt. IrO2 as intermediate layer and RuO2 as top layer are step by step coated on a titanium current collector. Dense RuO2-IrO2 coating with good adhesion with titanium substrate is formed via thermal treatment. RuO2-IrO2 coating is chemically and electrochemically stable in typical CaCl2-NaCl molten salt. Coated RuO2-IrO2 inert anode can achieve long-term and stable electrolysis for 100 h in chloride molten salt under harsh and fluctuating conditions. It is confirmed that excellent stability is ascribed to in-situ formation of complex perovskite oxide with high-valence Ir(VI) and Ru(VI). For CO2 electrolysis as a representative case, coated RuO2-IrO2 inert anode exhibits good stability and deliver a high current efficiency of 89.8 %. High-purity carbon is easily obtained. This study highlights a surface-engineered strategy to design robust and cost-effective inert anodes for molten salt electrochemical metallurgy and related high-temperature electrochemical processes in harsh chloride molten salt.
{"title":"Coated RuO2-IrO2 inert anode on a titanium current collector for electrolysis in chloride molten salt","authors":"Yadong Jia, Mingyong Wang, Kaiyi Shi, Haoyang Liu, Le Niu, Jianbang Ge, Shuqiang Jiao","doi":"10.1016/j.corsci.2026.113650","DOIUrl":"10.1016/j.corsci.2026.113650","url":null,"abstract":"<div><div>In order to develop advanced and clean molten salt electrolysis technologies for electrometallurgy and CO<sub>2</sub> conversion, stable inert anodes in chloride molten salt are crucial, but also serious challenge. Precious metals exhibit the best corrosion resistance, but it is impossible to directly used due to extremely high cost for conventional bulk or plate structure. Herein, a novel coated RuO<sub>2</sub>-IrO<sub>2</sub> inert anode with double-layer structure was proposed in chloride molten salt. IrO<sub>2</sub> as intermediate layer and RuO<sub>2</sub> as top layer are step by step coated on a titanium current collector. Dense RuO<sub>2</sub>-IrO<sub>2</sub> coating with good adhesion with titanium substrate is formed via thermal treatment. RuO<sub>2</sub>-IrO<sub>2</sub> coating is chemically and electrochemically stable in typical CaCl<sub>2</sub>-NaCl molten salt. Coated RuO<sub>2</sub>-IrO<sub>2</sub> inert anode can achieve long-term and stable electrolysis for 100 h in chloride molten salt under harsh and fluctuating conditions. It is confirmed that excellent stability is ascribed to in-situ formation of complex perovskite oxide with high-valence Ir(VI) and Ru(VI). For CO<sub>2</sub> electrolysis as a representative case, coated RuO<sub>2</sub>-IrO<sub>2</sub> inert anode exhibits good stability and deliver a high current efficiency of 89.8 %. High-purity carbon is easily obtained. This study highlights a surface-engineered strategy to design robust and cost-effective inert anodes for molten salt electrochemical metallurgy and related high-temperature electrochemical processes in harsh chloride molten salt.</div></div>","PeriodicalId":290,"journal":{"name":"Corrosion Science","volume":"262 ","pages":"Article 113650"},"PeriodicalIF":7.4,"publicationDate":"2026-01-22","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146036904","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 resistance of FeCrAl alloy APMT (Fe-21Cr-5Al-3Mo) in flowing lead-bismuth eutectic (LBE) was investigated by corrosion tests performed at 723 K using a non-isothermal forced convection loop. The oxygen concentration in flowing LBE was controlled at 1 × 10−6 wt%. No severe corrosion or erosion was detected on the specimens exposed to flowing LBE for 2000 h and 4000 h. Multiple oxide layers consisting of Fe-rich, Cr-rich and Al-rich sub-layers were formed in situ on the surface of APMT during the corrosion tests, which effectively suppressed corrosion and erosion. The oxide layers were intentionally removed by gentle abrasion prior to re-immersion and the specimens were then re-immersed in flowing LBE for an additional 2000 h. The oxide layers were spontaneously re-formed in situ on the abraded surface. This behavior indicates a self-healing capability. The results of micro-scratch tests indicated that the in-situ formed multiple oxide layers exhibited high adhesion strength in the shear direction after the 2000 h corrosion test. The α-Al2O3 layer pre-formed by oxidation in air at 1373 K remained adherent to the APMT specimen during exposure to flowing LBE for 2000 h. The adhesion strength of the α-Al2O3 layer in the shear direction was not degraded after the corrosion test.
{"title":"Reformation of protective oxide layers on artificially abraded surfaces of FeCrAl alloy during 4000 h exposure in flowing lead-bismuth eutectic","authors":"Masatoshi KONDO , Yoshiki KITAMURA , Atsushi KAWARAI , Shigeru SAITO , Hironari OBAYASHI","doi":"10.1016/j.corsci.2026.113646","DOIUrl":"10.1016/j.corsci.2026.113646","url":null,"abstract":"<div><div>The corrosion resistance of FeCrAl alloy APMT (Fe-21Cr-5Al-3Mo) in flowing lead-bismuth eutectic (LBE) was investigated by corrosion tests performed at 723 K using a non-isothermal forced convection loop. The oxygen concentration in flowing LBE was controlled at 1 × 10<sup>−6</sup> wt%. No severe corrosion or erosion was detected on the specimens exposed to flowing LBE for 2000 h and 4000 h. Multiple oxide layers consisting of Fe-rich, Cr-rich and Al-rich sub-layers were formed in situ on the surface of APMT during the corrosion tests, which effectively suppressed corrosion and erosion. The oxide layers were intentionally removed by gentle abrasion prior to re-immersion and the specimens were then re-immersed in flowing LBE for an additional 2000 h. The oxide layers were spontaneously re-formed in situ on the abraded surface. This behavior indicates a self-healing capability. The results of micro-scratch tests indicated that the in-situ formed multiple oxide layers exhibited high adhesion strength in the shear direction after the 2000 h corrosion test. The α-Al<sub>2</sub>O<sub>3</sub> layer pre-formed by oxidation in air at 1373 K remained adherent to the APMT specimen during exposure to flowing LBE for 2000 h. The adhesion strength of the α-Al<sub>2</sub>O<sub>3</sub> layer in the shear direction was not degraded after the corrosion test.</div></div>","PeriodicalId":290,"journal":{"name":"Corrosion Science","volume":"262 ","pages":"Article 113646"},"PeriodicalIF":7.4,"publicationDate":"2026-01-21","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146075764","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 : 2026-01-21DOI: 10.1016/j.corsci.2026.113630
Lichao Xu , Xin Ruan , Fabio Biondini , Qidi Wang
This study investigates the corrosion behaviour of Q345 steel in different directions, considering the characteristics of polycrystalline microstructures. Based on metallographic experimental results, a polycrystalline-structure dimensional upscaling modelling method (2D to 3D) is proposed to construct refined microstructural models. Building on these models, a pit-evolution prediction model is developed to reveal and quantitatively characterize the influence of microstructure on the corrosion process. The proposed polycrystalline modelling method and the baseline corrosion-prediction model are validated through comparisons with metallographic and corrosion experiments, thereby ensuring the reliability of the subsequent extended analyses. On this basis, a systematic comparative study is conducted, supported by cross-validation between numerical simulations and corrosion experiments, to evaluate the directional corrosion behaviour of Q345 steel and to quantitatively assess the anisotropic corrosion characteristics of engineering structural steel. The results indicate that polycrystalline microstructures exert a significant influence on the corrosion process of engineering steels: the corrosion rate along the direction of multilayer grain-boundary stacking is higher than that in other directions. When the corrosion mass-loss ratio reaches approximately 2 %, this directional difference corresponds to a maximum difference of 23.03 % in localized pit depth. Therefore, accurate consideration of polycrystalline microstructures is necessary for reliable corrosion prediction of steel structures. These findings not only provide a reasonable explanation for the frequently observed abnormally rapid edge corrosion in steel components of engineering structures, but also offer a robust tool for refined corrosion prediction and analysis.
{"title":"Anisotropic corrosion study of Q345 steel incorporating experiment-informed polycrystalline modelling","authors":"Lichao Xu , Xin Ruan , Fabio Biondini , Qidi Wang","doi":"10.1016/j.corsci.2026.113630","DOIUrl":"10.1016/j.corsci.2026.113630","url":null,"abstract":"<div><div>This study investigates the corrosion behaviour of Q345 steel in different directions, considering the characteristics of polycrystalline microstructures. Based on metallographic experimental results, a polycrystalline-structure dimensional upscaling modelling method (2D to 3D) is proposed to construct refined microstructural models. Building on these models, a pit-evolution prediction model is developed to reveal and quantitatively characterize the influence of microstructure on the corrosion process. The proposed polycrystalline modelling method and the baseline corrosion-prediction model are validated through comparisons with metallographic and corrosion experiments, thereby ensuring the reliability of the subsequent extended analyses. On this basis, a systematic comparative study is conducted, supported by cross-validation between numerical simulations and corrosion experiments, to evaluate the directional corrosion behaviour of Q345 steel and to quantitatively assess the anisotropic corrosion characteristics of engineering structural steel. The results indicate that polycrystalline microstructures exert a significant influence on the corrosion process of engineering steels: the corrosion rate along the direction of multilayer grain-boundary stacking is higher than that in other directions. When the corrosion mass-loss ratio reaches approximately 2 %, this directional difference corresponds to a maximum difference of 23.03 % in localized pit depth. Therefore, accurate consideration of polycrystalline microstructures is necessary for reliable corrosion prediction of steel structures. These findings not only provide a reasonable explanation for the frequently observed abnormally rapid edge corrosion in steel components of engineering structures, but also offer a robust tool for refined corrosion prediction and analysis.</div></div>","PeriodicalId":290,"journal":{"name":"Corrosion Science","volume":"262 ","pages":"Article 113630"},"PeriodicalIF":7.4,"publicationDate":"2026-01-21","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146075825","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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