Pub Date : 2026-04-15Epub Date: 2026-01-15DOI: 10.1016/j.corsci.2026.113632
Ziyu Li , Dawei Guo , Hongchang Qian , Dawei Zhang , Zhongyu Wu , Qian Qiao , Lap Mou Tam , Chi Tat Kwok
This study investigated the early-stage corrosion behavior of additive friction stir deposition (AFSD)-fabricated AA2024. The AFSD process reduced the grain size and the degree of particle clustering, fragmented the large constituent particles, and promoted the coarsening of the precipitate S-phase. Isolated and clustered particles presented distinct corrosion behavior. Isolated particles experienced localized attack at and around active particles, and a greater corrosion product coverage was found in AFSD made samples since the coarsening of precipitate S-phase provided extra active sites. Rings of corrosion products, typical features of stable pitting corrosion, were both observed on the feedstock and AFSD made alloys. However, stable pitting corrosion was less severe on AFSD fabricated specimen due to the weakening particle clustering.
{"title":"Corrosion behavior of AA2024 aluminum alloy manufactured by solid state additive manufacturing – Additive friction stir deposition","authors":"Ziyu Li , Dawei Guo , Hongchang Qian , Dawei Zhang , Zhongyu Wu , Qian Qiao , Lap Mou Tam , Chi Tat Kwok","doi":"10.1016/j.corsci.2026.113632","DOIUrl":"10.1016/j.corsci.2026.113632","url":null,"abstract":"<div><div>This study investigated the early-stage corrosion behavior of additive friction stir deposition (AFSD)-fabricated AA2024. The AFSD process reduced the grain size and the degree of particle clustering, fragmented the large constituent particles, and promoted the coarsening of the precipitate S-phase. Isolated and clustered particles presented distinct corrosion behavior. Isolated particles experienced localized attack at and around active particles, and a greater corrosion product coverage was found in AFSD made samples since the coarsening of precipitate S-phase provided extra active sites. Rings of corrosion products, typical features of stable pitting corrosion, were both observed on the feedstock and AFSD made alloys. However, stable pitting corrosion was less severe on AFSD fabricated specimen due to the weakening particle clustering.</div></div>","PeriodicalId":290,"journal":{"name":"Corrosion Science","volume":"262 ","pages":"Article 113632"},"PeriodicalIF":7.4,"publicationDate":"2026-04-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146006610","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.2026.113669
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":"2026-04-15","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}
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":"2026-04-15","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 : 2026-04-15Epub 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":"2026-04-15","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 : 2026-04-15Epub 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":"2026-04-15","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 : 2026-04-15Epub Date: 2026-02-03DOI: 10.1016/j.corsci.2026.113687
Wenzhuo Gong , Jiaqi Song , Ya Cai , Canying Cai , Chenglong Lv , Guangwen Zhou
The exceptional high-temperature oxidation resistance of Al-containing high-entropy alloys (HEAs) is often attributed to the formation of a protective α-Al2O3 scale. However, the dynamic, atomic-scale mechanisms governing the stability of this scale—including interfacial void formation and the often-postulated but rarely visualized “self-healing” capacity—remain poorly understood. Herein, we reveal the complex evolution of the triple-layer oxide scale on an Al10CoCrFeNi HEA through combined electron microscopy and diffraction study. We show that interfacial voids are an inherent consequence of the scaling process, originating from two distinct mechanisms: the Kirkendall effect at the interface between the γ-Al2O3/α-Al2O3 and alloy driven by cationic diffusion imbalance and volumetric contraction due to phase transformations at the Co-Cr-Fe-Ni spinel/Cr2O3 interface. Crucially, we provide microstructural evidence consistent with an intrinsic self-healing response. This process is driven by coupled inward diffusion of oxygen and outward diffusion of metal cations, leading to the in-situ formation of transient θ-Al2O3 and Co-Cr-Fe-Ni spinel that partially fill and seal the voids. These results provide atomic-scale insights into the phase evolution, defect formation, and self-repair of oxide scales in HEAs—highlighting pathways to enhance their oxidation resistance in extreme environments.
{"title":"Interfacial void formation and self-healing in oxide scales on Al-containing high-entropy alloy","authors":"Wenzhuo Gong , Jiaqi Song , Ya Cai , Canying Cai , Chenglong Lv , Guangwen Zhou","doi":"10.1016/j.corsci.2026.113687","DOIUrl":"10.1016/j.corsci.2026.113687","url":null,"abstract":"<div><div>The exceptional high-temperature oxidation resistance of Al-containing high-entropy alloys (HEAs) is often attributed to the formation of a protective α-Al<sub>2</sub>O<sub>3</sub> scale. However, the dynamic, atomic-scale mechanisms governing the stability of this scale—including interfacial void formation and the often-postulated but rarely visualized “self-healing” capacity—remain poorly understood. Herein, we reveal the complex evolution of the triple-layer oxide scale on an Al<sub>10</sub>CoCrFeNi HEA through combined electron microscopy and diffraction study. We show that interfacial voids are an inherent consequence of the scaling process, originating from two distinct mechanisms: the Kirkendall effect at the interface between the γ-Al<sub>2</sub>O<sub>3</sub>/α-Al<sub>2</sub>O<sub>3</sub> and alloy driven by cationic diffusion imbalance and volumetric contraction due to phase transformations at the Co-Cr-Fe-Ni spinel/Cr<sub>2</sub>O<sub>3</sub> interface. Crucially, we provide microstructural evidence consistent with an intrinsic self-healing response. This process is driven by coupled inward diffusion of oxygen and outward diffusion of metal cations, leading to the in-situ formation of transient θ-Al<sub>2</sub>O<sub>3</sub> and Co-Cr-Fe-Ni spinel that partially fill and seal the voids. These results provide atomic-scale insights into the phase evolution, defect formation, and self-repair of oxide scales in HEAs—highlighting pathways to enhance their oxidation resistance in extreme environments.</div></div>","PeriodicalId":290,"journal":{"name":"Corrosion Science","volume":"262 ","pages":"Article 113687"},"PeriodicalIF":7.4,"publicationDate":"2026-04-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146185275","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: 2026-02-02DOI: 10.1016/j.corsci.2026.113685
Bo Zhang, Jinhui Cui, Fulong Wang, Yipu Sun, Wei Liu
The early-stage corrosion behavior of 2 wt% Ni (2Ni) low-alloy steel with low Cr additions in a simulated marine atmosphere was investigated. Results indicate that low-Cr content improves the overall corrosion resistance of 2Ni steel during the early-stage corrosion stage through a synergistic mechanism of "microstructural regulation and rust layer optimization". Specifically, low Cr content addition reduces the bainite start temperature, promoting bainite transformation and resulting in refined and homogenized granular bainite. This microstructural evolution helps alleviate residual stress accumulation in 2Ni steel and reduces its corrosion susceptibility. In the initial period before a protective rust layer forms, Cr can exist stably as the Cr2O3 oxide and promotes the transformation of γ-FeOOH to α-FeOOH. Moreover, Cr and Ni are found to co-enrich in the rust layer, where Cr further promotes the formation of more beneficial NiFe2O4. These changes collectively optimize the rust layer structure and phase composition, increase the charge transfer resistance at the rust/matrix interface, and enhance the early-stage corrosion resistance of 2Ni steel.
研究了低Cr含量的2 wt% Ni （2Ni）低合金钢在模拟海洋大气中的早期腐蚀行为。结果表明：在腐蚀初期，低cr含量通过“组织调控和锈层优化”的协同机制提高了2Ni钢的整体耐蚀性；具体来说，低Cr含量的加入降低了贝氏体的起始温度，促进了贝氏体的转变，形成了细化和均匀化的粒状贝氏体。这种微观组织的演变有助于减轻2Ni钢的残余应力积累，降低其腐蚀敏感性。在保护锈层形成前的初始阶段，Cr能以Cr2O3氧化物的形式稳定存在，并促进γ-FeOOH向α-FeOOH的转变。此外，Cr和Ni在锈层中共富集，Cr进一步促进了更有利的NiFe2O4的形成。这些变化共同优化了锈层结构和相组成，增加了锈/基体界面处的电荷转移阻力，增强了2Ni钢的早期耐蚀性。
{"title":"Evolution of the early-stage corrosion behavior of 2 % Ni low-alloy steel in simulated marine atmosphere: Regulation by low chromium content","authors":"Bo Zhang, Jinhui Cui, Fulong Wang, Yipu Sun, Wei Liu","doi":"10.1016/j.corsci.2026.113685","DOIUrl":"10.1016/j.corsci.2026.113685","url":null,"abstract":"<div><div>The early-stage corrosion behavior of 2 wt% Ni (2Ni) low-alloy steel with low Cr additions in a simulated marine atmosphere was investigated. Results indicate that low-Cr content improves the overall corrosion resistance of 2Ni steel during the early-stage corrosion stage through a synergistic mechanism of \"microstructural regulation and rust layer optimization\". Specifically, low Cr content addition reduces the bainite start temperature, promoting bainite transformation and resulting in refined and homogenized granular bainite. This microstructural evolution helps alleviate residual stress accumulation in 2Ni steel and reduces its corrosion susceptibility. In the initial period before a protective rust layer forms, Cr can exist stably as the Cr<sub>2</sub>O<sub>3</sub> oxide and promotes the transformation of γ-FeOOH to α-FeOOH. Moreover, Cr and Ni are found to co-enrich in the rust layer, where Cr further promotes the formation of more beneficial NiFe<sub>2</sub>O<sub>4</sub>. These changes collectively optimize the rust layer structure and phase composition, increase the charge transfer resistance at the rust/matrix interface, and enhance the early-stage corrosion resistance of 2Ni steel.</div></div>","PeriodicalId":290,"journal":{"name":"Corrosion Science","volume":"262 ","pages":"Article 113685"},"PeriodicalIF":7.4,"publicationDate":"2026-04-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146185276","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: 2026-01-20DOI: 10.1016/j.corsci.2026.113643
Yingpeng Zhang , Zheng Wang , Yalan Zhang , Lei Li , Peng Guo , Aiying Wang
Stainless steel components often face corrosion and tribocorrosion in various halide environments, as seen in applications like seawater plunger pumps, chemical agitators, and valves. Chloride (Cl-) and bromide (Br-) ions both degrade the corrosion and tribocorrosion resistance of stainless steel, yet their relative aggressiveness remains debated. Therefore, this study systematically compared the damage behavior of stainless steel in different halide environments using combined electrochemical and tribological techniques. Electrochemical corrosion analysis revealed Cl- exhibited greater propensity than Br- to displace oxygen within the Cr2O3 passive film and had a stronger penetration ability (smaller radius), rendering stainless steel more susceptible to pitting corrosion in Cl- solutions. Resultant pits were larger, deeper, and more densely distributed. However, accumulated corrosion products such as FexOy inhibited Cl- penetration, yielding a lower Icorr in Cl- (3.58 ×10−9 A/cm2) versus Br- solutions (8.87 ×10−9 A/cm2). Under tribocorrosion, copious Cl--derived corrosion products acted as abrasive third bodies, exacerbating material loss versus Br- environments, while wear-induced surface activation concurrently accelerated corrosion rates. This synergistic wear-corrosion interaction significantly elevated degradation, with corrosion-enhanced wear dominating material removal. Thus, while Cl- more readily disrupted the Cr2O3 passive film, static corrosion products conferred protection via a “corrosion-product barrier” effect; under tribocorrosion, however, these protective oxides transformed into abrasive particles, amplifying degradation through mechano-electrochemical synergy.
不锈钢部件在各种卤化物环境中经常面临腐蚀和摩擦腐蚀，如海水柱塞泵，化学搅拌器和阀门等应用。氯离子（Cl-）和溴离子（Br-）都会降低不锈钢的耐腐蚀性和耐摩擦腐蚀性，但它们的相对侵蚀性仍存在争议。因此，本研究采用电化学和摩擦学相结合的方法系统地比较了不锈钢在不同卤化物环境下的损伤行为。电化学腐蚀分析表明Cl-比Br-更倾向于取代Cr2O3钝化膜内的氧，并且具有更强的渗透能力（更小的半径），使得不锈钢在Cl-溶液中更容易发生点蚀。合成坑更大、更深、分布更密。然而，累积的腐蚀产物，如FexOy，抑制了Cl-的渗透，使Cl-溶液的Icorr（3.58 ×10−9 a /cm2）低于Br-溶液（8.87 ×10−9 a /cm2）。在摩擦腐蚀中，大量Cl衍生的腐蚀产物作为磨料的第三体，与Br环境相比，加剧了材料的损失，而磨损引起的表面活化同时加速了腐蚀速率。这种协同磨损-腐蚀相互作用显著提高了降解，腐蚀增强磨损主导了材料的去除。因此，虽然Cl-更容易破坏Cr2O3钝化膜，但静态腐蚀产物通过“腐蚀产物屏障”效应提供保护；然而，在摩擦腐蚀下，这些保护性氧化物转化为磨料颗粒，通过机械-电化学协同作用放大降解。
{"title":"Unraveling corrosion and tribocorrosion mechanisms of stainless steel in chloride/bromide media: The dual role of corrosion products","authors":"Yingpeng Zhang , Zheng Wang , Yalan Zhang , Lei Li , Peng Guo , Aiying Wang","doi":"10.1016/j.corsci.2026.113643","DOIUrl":"10.1016/j.corsci.2026.113643","url":null,"abstract":"<div><div>Stainless steel components often face corrosion and tribocorrosion in various halide environments, as seen in applications like seawater plunger pumps, chemical agitators, and valves. Chloride (Cl<sup>-</sup>) and bromide (Br<sup>-</sup>) ions both degrade the corrosion and tribocorrosion resistance of stainless steel, yet their relative aggressiveness remains debated. Therefore, this study systematically compared the damage behavior of stainless steel in different halide environments using combined electrochemical and tribological techniques. Electrochemical corrosion analysis revealed Cl<sup>-</sup> exhibited greater propensity than Br<sup>-</sup> to displace oxygen within the Cr<sub>2</sub>O<sub>3</sub> passive film and had a stronger penetration ability (smaller radius), rendering stainless steel more susceptible to pitting corrosion in Cl<sup>-</sup> solutions. Resultant pits were larger, deeper, and more densely distributed. However, accumulated corrosion products such as Fe<sub>x</sub>O<sub>y</sub> inhibited Cl<sup>-</sup> penetration, yielding a lower <em>I</em><sub>corr</sub> in Cl<sup>-</sup> (3.58 ×10<sup>−9</sup> A/cm<sup>2</sup>) versus Br<sup>-</sup> solutions (8.87 ×10<sup>−9</sup> A/cm<sup>2</sup>). Under tribocorrosion, copious Cl<sup>-</sup>-derived corrosion products acted as abrasive third bodies, exacerbating material loss versus Br<sup>-</sup> environments, while wear-induced surface activation concurrently accelerated corrosion rates. This synergistic wear-corrosion interaction significantly elevated degradation, with corrosion-enhanced wear dominating material removal. Thus, while Cl<sup>-</sup> more readily disrupted the Cr<sub>2</sub>O<sub>3</sub> passive film, static corrosion products conferred protection via a “corrosion-product barrier” effect; under tribocorrosion, however, these protective oxides transformed into abrasive particles, amplifying degradation through mechano-electrochemical synergy.</div></div>","PeriodicalId":290,"journal":{"name":"Corrosion Science","volume":"262 ","pages":"Article 113643"},"PeriodicalIF":7.4,"publicationDate":"2026-04-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146006611","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":"2026-04-15","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}
Pub Date : 2026-04-15Epub Date: 2026-01-15DOI: 10.1016/j.corsci.2026.113633
Zhong Li , Yuzhou Chen , Xiaolong Li , Xiaohu Zhang , Zhiyong Liu , Hongchi ma , Jiaxing Cai , Yi Fan , Daiwei Guo , Zehua Li , Xiaogang Li , Jike Yang
This study investigates the impact of sulfate-reducing bacteria (SRB) biofilm distribution on the stress corrosion cracking (SCC) behavior of X80 steel in an anaerobic environment. U-bend X80 specimens, with stress distributions calculated through Finite Element Modeling (FEM) simulation, were immersed in culture media with varying biofilm distributions. The weight-loss tests, electrochemical tests, and analyses of biogenic H₂S and H₂ gases, as well as SCC crack morphology, were used to investigate the MISCC behavior of different biofilm distributions. The results show that a smaller biofilm distribution causes more severe microbiologically induced corrosion (MIC) because of a higher SRB cell count, following the extracellular electron transfer MIC (EET-MIC) mechanism, which leads to increased weight loss and blunter SCC cracks. Conversely, a larger biofilm distribution results in less weight loss and sharper SCC cracks over the 14 days. Higher levels of biogenic H₂S and H₂ were associated with more active microbiologically induced stress corrosion cracking (MISCC), resulting in deeper, more pronounced cracks in environments with more extensive biofilm distribution. The study suggests that a combined mechanism involving bio-electrochemical activity and biogenic hydrogen sulfide production drives the SCC process. This research provides insights into the biofilm-dependent MISCC interaction, offering guidance for selecting pipeline materials and developing mitigation strategies in environments where SRB activity is present.
{"title":"The mechanism of microbiologically induced stress corrosion cracking of X80 steel under different Desulfovibrio vulgaris biofilm distributions","authors":"Zhong Li , Yuzhou Chen , Xiaolong Li , Xiaohu Zhang , Zhiyong Liu , Hongchi ma , Jiaxing Cai , Yi Fan , Daiwei Guo , Zehua Li , Xiaogang Li , Jike Yang","doi":"10.1016/j.corsci.2026.113633","DOIUrl":"10.1016/j.corsci.2026.113633","url":null,"abstract":"<div><div>This study investigates the impact of sulfate-reducing bacteria (SRB) biofilm distribution on the stress corrosion cracking (SCC) behavior of X80 steel in an anaerobic environment. U-bend X80 specimens, with stress distributions calculated through Finite Element Modeling (FEM) simulation, were immersed in culture media with varying biofilm distributions. The weight-loss tests, electrochemical tests, and analyses of biogenic H₂S and H₂ gases, as well as SCC crack morphology, were used to investigate the MISCC behavior of different biofilm distributions. The results show that a smaller biofilm distribution causes more severe microbiologically induced corrosion (MIC) because of a higher SRB cell count, following the extracellular electron transfer MIC (EET-MIC) mechanism, which leads to increased weight loss and blunter SCC cracks. Conversely, a larger biofilm distribution results in less weight loss and sharper SCC cracks over the 14 days. Higher levels of biogenic H₂S and H₂ were associated with more active microbiologically induced stress corrosion cracking (MISCC), resulting in deeper, more pronounced cracks in environments with more extensive biofilm distribution. The study suggests that a combined mechanism involving bio-electrochemical activity and biogenic hydrogen sulfide production drives the SCC process. This research provides insights into the biofilm-dependent MISCC interaction, offering guidance for selecting pipeline materials and developing mitigation strategies in environments where SRB activity is present.</div></div>","PeriodicalId":290,"journal":{"name":"Corrosion Science","volume":"262 ","pages":"Article 113633"},"PeriodicalIF":7.4,"publicationDate":"2026-04-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146036903","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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