Pub Date : 2025-12-23DOI: 10.1016/j.corsci.2025.113576
Ting Chen , Jia-Chu Yang , Xu Wang , Xiao-Ze Ma , Le Shi , Xin-Xin Zhang , Wen-Tie Yang , Ze-Hua Dong
Photocathodic protection (PCP) has attracted significant attention in the field of metal corrosion and protection due to its environmentally friendly and sustainable qualities. In this study, a ZnO/CdS heterojunction composite photoanode was successfully fabricated by depositing CdS nanoparticles onto ZnO nanorods using a spin-coating-assisted modified Successive Ionic Layer Adsorption and Reaction (SILAR) technique. Thanks to the SILAR technique, CdS was uniformly distributed across the ZnO surface, thereby extending the composite's light absorption edge to 554 nm. The photoanode exhibited promising, durable PCP performance on stainless steel and carbon steel in seawater. When paired with SUS304 stainless steel, it achieved a photocurrent density of 762.3 μA/cm² (29 times higher than pristine ZnO) and shifted the potential of SUS304 to −1.20 V vs. Ag/AgCl. Furthermore, it successfully polarized carbon steel to below −1.10 V, sufficient for effective cathodic protection. Density functional theory (DFT) calculations imply that the Z-scheme heterojunction efficiently promotes the separation of photogenerated electron-hole pairs, contributing to the excellent photoelectrochemical performance of ZnO/CdS and offering a promising outlook for marine environments structure protection.
{"title":"ZnO/CdS photocathodic protection for steel in marine environments: Impact of heterojunction on photoelectrochemical efficiency","authors":"Ting Chen , Jia-Chu Yang , Xu Wang , Xiao-Ze Ma , Le Shi , Xin-Xin Zhang , Wen-Tie Yang , Ze-Hua Dong","doi":"10.1016/j.corsci.2025.113576","DOIUrl":"10.1016/j.corsci.2025.113576","url":null,"abstract":"<div><div>Photocathodic protection (PCP) has attracted significant attention in the field of metal corrosion and protection due to its environmentally friendly and sustainable qualities. In this study, a ZnO/CdS heterojunction composite photoanode was successfully fabricated by depositing CdS nanoparticles onto ZnO nanorods using a spin-coating-assisted modified Successive Ionic Layer Adsorption and Reaction (SILAR) technique. Thanks to the SILAR technique, CdS was uniformly distributed across the ZnO surface, thereby extending the composite's light absorption edge to 554 nm. The photoanode exhibited promising, durable PCP performance on stainless steel and carbon steel in seawater. When paired with SUS304 stainless steel, it achieved a photocurrent density of 762.3 μA/cm² (29 times higher than pristine ZnO) and shifted the potential of SUS304 to −1.20 V <em>vs.</em> Ag/AgCl. Furthermore, it successfully polarized carbon steel to below −1.10 V, sufficient for effective cathodic protection. Density functional theory (DFT) calculations imply that the Z-scheme heterojunction efficiently promotes the separation of photogenerated electron-hole pairs, contributing to the excellent photoelectrochemical performance of ZnO/CdS and offering a promising outlook for marine environments structure protection.</div></div>","PeriodicalId":290,"journal":{"name":"Corrosion Science","volume":"260 ","pages":"Article 113576"},"PeriodicalIF":7.4,"publicationDate":"2025-12-23","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145836891","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}
Corrosion-related failures are critical for electronics reliability in various technological sectors, with a wide range of systems shifting towards the use of high voltage and power. Miniaturization and high voltage between closely spaced connectors induce a higher risk of dendrite formation due to electrochemical migration (ECM) when connected by a condensed water film. Shorting caused by ECM dendrites is a prominent failure mechanism in electronics, which at higher voltage could even lead to incidents of fire. Dendrite growth occurs by metal dissolution and electric field assisted deposition, while dendrite composition and shorting characteristics are determined by the kinetics of growth, controlled by the current. To study the kinetic factors related to dendrite growth, a galvanostatic approach with applied current in the range of 0.5 µA to 5 mA was employed on a simple test PCB consisting of two copper pads. Electrochemical testing was supplemented by chemical analysis of dissolved species in a micro-volume of solution using ICP-OES, while characteristics of dendrite as a function of current levels were analyzed using XPS, SEM-EDS and TEM. Dendrite growth and pH gradient increased with current levels. Dendrite composition varied depending on the current levels, while it was suggested that hydrolysis reactions rate determined local pH and dendrite morphology rather than the level of copper dissolution (Total charge QT/Charge consumed by Cu dissolution QCu>1 for low and high current levels with shorting). A complementary potentiostatic test verified this understanding of charge consumed (QT/ QCu>1 at 2 V and 48 V applied voltage, without dendritic shorting).
{"title":"Investigation of kinetics of ECM dendrite growth during corrosion in electronics","authors":"Jyothsna Murli Rao, Anish Rao Lakkaraju, Feng Li, Kapil Kumar Gupta, Rajan Ambat","doi":"10.1016/j.corsci.2025.113575","DOIUrl":"10.1016/j.corsci.2025.113575","url":null,"abstract":"<div><div>Corrosion-related failures are critical for electronics reliability in various technological sectors, with a wide range of systems shifting towards the use of high voltage and power. Miniaturization and high voltage between closely spaced connectors induce a higher risk of dendrite formation due to electrochemical migration (ECM) when connected by a condensed water film. Shorting caused by ECM dendrites is a prominent failure mechanism in electronics, which at higher voltage could even lead to incidents of fire. Dendrite growth occurs by metal dissolution and electric field assisted deposition, while dendrite composition and shorting characteristics are determined by the kinetics of growth, controlled by the current. To study the kinetic factors related to dendrite growth, a galvanostatic approach with applied current in the range of 0.5 µA to 5 mA was employed on a simple test PCB consisting of two copper pads. Electrochemical testing was supplemented by chemical analysis of dissolved species in a micro-volume of solution using ICP-OES, while characteristics of dendrite as a function of current levels were analyzed using XPS, SEM-EDS and TEM. Dendrite growth and pH gradient increased with current levels. Dendrite composition varied depending on the current levels, while it was suggested that hydrolysis reactions rate determined local pH and dendrite morphology rather than the level of copper dissolution (Total charge Q<sub>T</sub>/Charge consumed by Cu dissolution Q<sub>Cu</sub>>1 for low and high current levels with shorting). A complementary potentiostatic test verified this understanding of charge consumed (Q<sub>T</sub>/ Q<sub>Cu</sub>>1 at 2 V and 48 V applied voltage, without dendritic shorting).</div></div>","PeriodicalId":290,"journal":{"name":"Corrosion Science","volume":"260 ","pages":"Article 113575"},"PeriodicalIF":7.4,"publicationDate":"2025-12-23","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145837401","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 : 2025-12-22DOI: 10.1016/j.corsci.2025.113571
Yahuan Zhao , Zhao Shen , Ziye Dong , Kun Zhang , Jiaqi Li , Jie Yang , Yifei Shen , Yangxin Li , Kai Chen , Shixin Gao , Kun Zhang , Xiaoqin Zeng
Two Cr coatings with distinct grain morphologies were deposited on Zr alloy claddings by physical vapor deposition to investigate their corrosion behavior in oxygenated water. Long-term autoclave tests at 360 °C and 20 MPa up to 6000 h showed that the columnar-grained coating degraded much faster than the coarse near-elliptical one. Dense grain boundaries in the columnar structure accelerated diffusion of Cr and oxygen, forming porous and unstable Cr2O3 and enabling continuous dissolution. In contrast, the coarse-grained coating exhibited slower degradation due to its lower grain boundary density. These results reveal that hydrothermal corrosion of Cr coatings is governed by grain boundary–controlled mass transport and Cr2O3 instability, emphasizing the importance of grain morphology optimization for durable accident tolerant fuel claddings.
{"title":"Grain boundary–controlled dissolution of Cr coatings on Zr alloy cladding in oxygenated high-temperature water","authors":"Yahuan Zhao , Zhao Shen , Ziye Dong , Kun Zhang , Jiaqi Li , Jie Yang , Yifei Shen , Yangxin Li , Kai Chen , Shixin Gao , Kun Zhang , Xiaoqin Zeng","doi":"10.1016/j.corsci.2025.113571","DOIUrl":"10.1016/j.corsci.2025.113571","url":null,"abstract":"<div><div>Two Cr coatings with distinct grain morphologies were deposited on Zr alloy claddings by physical vapor deposition to investigate their corrosion behavior in oxygenated water. Long-term autoclave tests at 360 °C and 20 MPa up to 6000 h showed that the columnar-grained coating degraded much faster than the coarse near-elliptical one. Dense grain boundaries in the columnar structure accelerated diffusion of Cr and oxygen, forming porous and unstable Cr<sub>2</sub>O<sub>3</sub> and enabling continuous dissolution. In contrast, the coarse-grained coating exhibited slower degradation due to its lower grain boundary density. These results reveal that hydrothermal corrosion of Cr coatings is governed by grain boundary–controlled mass transport and Cr<sub>2</sub>O<sub>3</sub> instability, emphasizing the importance of grain morphology optimization for durable accident tolerant fuel claddings.</div></div>","PeriodicalId":290,"journal":{"name":"Corrosion Science","volume":"260 ","pages":"Article 113571"},"PeriodicalIF":7.4,"publicationDate":"2025-12-22","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145837407","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 : 2025-12-22DOI: 10.1016/j.corsci.2025.113572
Guangguang Xiang , Jinghong Ma , Dezhi Zeng , Yanli Zhou , Hongpeng Zheng
Adhesion mechanisms at the coating/metal interface play a critical role in the durability of coated systems. Current study introduces a novel strategy utilizing a “wetting-adsorption” thermodynamic contour diagram to probe interfacial interactions in silane-modified waterborne epoxy coatings on metals. Predictive assessments of interfacial interactions, adhesion strength, and corrosion resistance were conducted using the contour diagram, density functional theory (DFT) calculations, and molecular dynamics (MD) simulations, with experimental validation via adhesion, hydrophobicity, electrochemical impedance spectroscopy (EIS), and salt spray tests. Results demonstrate that the contour diagram reliably forecasts long-term coating durability (adhesion retention and corrosion resistance) after immersion, aligning with measured adhesion loss and corrosion resistance. In contrast, DFT calculations and MD simulations accurately predict initial bonding strength, correlating with pre-immersion adhesion tests. A key divergence emerges for KH560-EP and KH570-EP coatings: although DFT calculations and MD simulations initially rank KH570-EP higher, long-term durability consistently favors the contour diagram’s prediction that KH560-EP performed better. Therefore, addressing conflicting predictions requires an integrated strategy that prioritizes the contour diagram for long-term durability assessment and leverages DFT calculations and MD simulations for initial bonding analysis, thereby achieving an optimized coating design through their synergistic integration.
{"title":"Density functional theory, molecular dynamics and thermodynamics analyses of silane-modified waterborne Epoxy/Q235 steel interfaces: Adhesion and anti-corrosion","authors":"Guangguang Xiang , Jinghong Ma , Dezhi Zeng , Yanli Zhou , Hongpeng Zheng","doi":"10.1016/j.corsci.2025.113572","DOIUrl":"10.1016/j.corsci.2025.113572","url":null,"abstract":"<div><div>Adhesion mechanisms at the coating/metal interface play a critical role in the durability of coated systems. Current study introduces a novel strategy utilizing a “wetting-adsorption” thermodynamic contour diagram to probe interfacial interactions in silane-modified waterborne epoxy coatings on metals. Predictive assessments of interfacial interactions, adhesion strength, and corrosion resistance were conducted using the contour diagram, density functional theory (DFT) calculations, and molecular dynamics (MD) simulations, with experimental validation via adhesion, hydrophobicity, electrochemical impedance spectroscopy (EIS), and salt spray tests. Results demonstrate that the contour diagram reliably forecasts long-term coating durability (adhesion retention and corrosion resistance) after immersion, aligning with measured adhesion loss and corrosion resistance. In contrast, DFT calculations and MD simulations accurately predict initial bonding strength, correlating with pre-immersion adhesion tests. A key divergence emerges for KH560-EP and KH570-EP coatings: although DFT calculations and MD simulations initially rank KH570-EP higher, long-term durability consistently favors the contour diagram’s prediction that KH560-EP performed better. Therefore, addressing conflicting predictions requires an integrated strategy that prioritizes the contour diagram for long-term durability assessment and leverages DFT calculations and MD simulations for initial bonding analysis, thereby achieving an optimized coating design through their synergistic integration.</div></div>","PeriodicalId":290,"journal":{"name":"Corrosion Science","volume":"260 ","pages":"Article 113572"},"PeriodicalIF":7.4,"publicationDate":"2025-12-22","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145837410","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 : 2025-12-22DOI: 10.1016/j.corsci.2025.113573
Yuanyuan Ji , Yuheng Wu , Weimin Qin , Weixian Jin , Wenbin Hu , Xinjie Yao , Hongqiang Fan , Da-Hai Xia , Bernard Tribollet
Localized corrosion caused by oxide film breakdown significantly shortens the service life of aluminum alloys in marine environments. However, there are few detailed data available for longer-term field exposures of Al-Mg alloys, especially for the properties of the oxide film. Here, the surface films formed on an unsensitized and a sensitized 5083 Al-Mg alloy samples after 2 years of exposure in the splash zone and the tidal zone are investigated. Pitting corrosion was observed on the samples exposed to the splash zone, whereas the samples in the tidal zone exhibited a characteristic of uniform corrosion. A near-surface deformed layer (NSDL) composed of nanocrystalline grains was found to inhibit intergranular corrosion (IGC) in the sensitized Al-Mg alloy. From the high splash zone to the tidal zone, the corrosion resistance of the surface film that consists of an outer loose corrosion products layer and an inner oxide film decreased. Longer drying time and sufficient oxygen supply in the high splash zone facilitated the formation of a complete oxide film with high Al2O3 content. Under prolonged wetting time and limited oxygen supply in the tidal zone, a defective oxide film enriched in Mg and Si formed on the alloy surface. Our findings provide insights into the corrosion evolution mechanism and oxide film formation of Al-Mg alloys in marine splash and tidal zones.
{"title":"Improved corrosion resistance of AA5083 after 2 years of exposure in seawater splash and tidal zones: Formation of a protective surface film","authors":"Yuanyuan Ji , Yuheng Wu , Weimin Qin , Weixian Jin , Wenbin Hu , Xinjie Yao , Hongqiang Fan , Da-Hai Xia , Bernard Tribollet","doi":"10.1016/j.corsci.2025.113573","DOIUrl":"10.1016/j.corsci.2025.113573","url":null,"abstract":"<div><div>Localized corrosion caused by oxide film breakdown significantly shortens the service life of aluminum alloys in marine environments. However, there are few detailed data available for longer-term field exposures of Al-Mg alloys, especially for the properties of the oxide film. Here, the surface films formed on an unsensitized and a sensitized 5083 Al-Mg alloy samples after 2 years of exposure in the splash zone and the tidal zone are investigated. Pitting corrosion was observed on the samples exposed to the splash zone, whereas the samples in the tidal zone exhibited a characteristic of uniform corrosion. A near-surface deformed layer (NSDL) composed of nanocrystalline grains was found to inhibit intergranular corrosion (IGC) in the sensitized Al-Mg alloy. From the high splash zone to the tidal zone, the corrosion resistance of the surface film that consists of an outer loose corrosion products layer and an inner oxide film decreased. Longer drying time and sufficient oxygen supply in the high splash zone facilitated the formation of a complete oxide film with high Al<sub>2</sub>O<sub>3</sub> content. Under prolonged wetting time and limited oxygen supply in the tidal zone, a defective oxide film enriched in Mg and Si formed on the alloy surface. Our findings provide insights into the corrosion evolution mechanism and oxide film formation of Al-Mg alloys in marine splash and tidal zones.</div></div>","PeriodicalId":290,"journal":{"name":"Corrosion Science","volume":"260 ","pages":"Article 113573"},"PeriodicalIF":7.4,"publicationDate":"2025-12-22","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145837409","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}
This work investigates the correlation between natural atmospheric exposure and laboratory-accelerated corrosion behavior of Q420qENH weathering steel. In both environments, the mass-gain kinetics were found to follow the relationship ΔW=A·tⁿ. On this kinetic analysis, a time-conversion model was established: lntatm= 0.72129 lntacc-2.01994. The model indicates that 20 days of alternating wet-dry testing is equivalent to approximately one year of natural exposure, thereby providing a quantitative basis for predicting service life in engineering applications. Regarding corrosion products and morphology, natural exposure resulted in the formation of a denser inner rust layer with stronger adhesion to the substrate. However, it also led to more pronounced surface undulation and dust deposition. In contrast, the alternating wet-dry tests produced a smoother surface and a more uniform distribution of corrosion products, albeit with a higher density of pores and microcracks. Evaluation of the stabilization treatment revealed that it promotes the enrichment of Cu and Cr and accelerates the formation of α-FeOOH within the rust layer. This process contributes to grain refinement in the rust layer and facilitates the healing of micro-defects. These findings establish a theoretical basis for evaluating the performance and engineering application of stabilization-treated weathering steel, while also offering valuable insights for designing accelerated corrosion tests and assessing the service life of various steel grades in diverse corrosive environments.
{"title":"Laboratory-to-field equivalence of corrosion in stabilized-treated Q420qENH weathering steel","authors":"Guiyi Zhou , Tieming Guo , Junwei Miao , Yaobing Wei , Zefen Liang , Xueli Nan , Ruihua Zhang","doi":"10.1016/j.corsci.2025.113570","DOIUrl":"10.1016/j.corsci.2025.113570","url":null,"abstract":"<div><div>This work investigates the correlation between natural atmospheric exposure and laboratory-accelerated corrosion behavior of Q420qENH weathering steel. In both environments, the mass-gain kinetics were found to follow the relationship ΔW=A·tⁿ. On this kinetic analysis, a time-conversion model was established: lnt<sub>atm</sub>= 0.72129 lnt<sub>acc</sub>-2.01994. The model indicates that 20 days of alternating wet-dry testing is equivalent to approximately one year of natural exposure, thereby providing a quantitative basis for predicting service life in engineering applications. Regarding corrosion products and morphology, natural exposure resulted in the formation of a denser inner rust layer with stronger adhesion to the substrate. However, it also led to more pronounced surface undulation and dust deposition. In contrast, the alternating wet-dry tests produced a smoother surface and a more uniform distribution of corrosion products, albeit with a higher density of pores and microcracks. Evaluation of the stabilization treatment revealed that it promotes the enrichment of Cu and Cr and accelerates the formation of α-FeOOH within the rust layer. This process contributes to grain refinement in the rust layer and facilitates the healing of micro-defects. These findings establish a theoretical basis for evaluating the performance and engineering application of stabilization-treated weathering steel, while also offering valuable insights for designing accelerated corrosion tests and assessing the service life of various steel grades in diverse corrosive environments.</div></div>","PeriodicalId":290,"journal":{"name":"Corrosion Science","volume":"260 ","pages":"Article 113570"},"PeriodicalIF":7.4,"publicationDate":"2025-12-21","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145837010","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 : 2025-12-20DOI: 10.1016/j.corsci.2025.113569
Junting An, Keren Zhang, Haobin Zhou, Mi Zhou, Xiaoyong Zhang, Hui Zhao
This study investigates the formation mechanism of a double-continuous (Ti,Ta)O2/TiN protective oxide layer during high-temperature oxidation of TiAl-Ta alloys, combining experimental characterization with first-principles calculations. The results demonstrate that cyclic heat treatment produces fine-grained coherent boundaries in the alloy. This unique microstructure enables Ta to promote in-situ formation of a thermally grown oxide layer, consisting of a TiN sublayer and a (Ti,Ta)O2 outer layer. Based on this, 12 different arrangement forms of the TiO2/TiN interface were constructed, and the most stable structure was identified through first-principles calculations. The calculations revealed that the interfacial energy of TiO2(110)/TiN(001) interface was strongly influenced by the distance and density of O–N bonds. Further investigation demonstrated that substituting Ta for Ti in the TiO2 lattice reduced the total energy of the system. The system reaches its minimum energy state when Ta is doped at the TiO2 (110)/TiN(001) interface, which exhibits high resistance to peeling. Finally, the formation mechanism of the (Ti,Ta)O2/TiN protective film and the thickening of the TiN layer were discussed.
{"title":"Formation mechanisms of in-situ (Ti,Ta)O2/TiN protective layer in oxidized TiAl-Ta alloys: First-principles and experiments study","authors":"Junting An, Keren Zhang, Haobin Zhou, Mi Zhou, Xiaoyong Zhang, Hui Zhao","doi":"10.1016/j.corsci.2025.113569","DOIUrl":"10.1016/j.corsci.2025.113569","url":null,"abstract":"<div><div>This study investigates the formation mechanism of a double-continuous (Ti,Ta)O<sub>2</sub>/TiN protective oxide layer during high-temperature oxidation of TiAl-Ta alloys, combining experimental characterization with first-principles calculations. The results demonstrate that cyclic heat treatment produces fine-grained coherent boundaries in the alloy. This unique microstructure enables Ta to promote in-situ formation of a thermally grown oxide layer, consisting of a TiN sublayer and a (Ti,Ta)O<sub>2</sub> outer layer. Based on this, 12 different arrangement forms of the TiO<sub>2</sub>/TiN interface were constructed, and the most stable structure was identified through first-principles calculations. The calculations revealed that the interfacial energy of TiO<sub>2</sub>(110)/TiN(001) interface was strongly influenced by the distance and density of O–N bonds. Further investigation demonstrated that substituting Ta for Ti in the TiO<sub>2</sub> lattice reduced the total energy of the system. The system reaches its minimum energy state when Ta is doped at the TiO<sub>2</sub> (110)/TiN(001) interface, which exhibits high resistance to peeling. Finally, the formation mechanism of the (Ti,Ta)O<sub>2</sub>/TiN protective film and the thickening of the TiN layer were discussed.</div></div>","PeriodicalId":290,"journal":{"name":"Corrosion Science","volume":"260 ","pages":"Article 113569"},"PeriodicalIF":7.4,"publicationDate":"2025-12-20","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145837405","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 : 2025-12-19DOI: 10.1016/j.corsci.2025.113567
Yifan Wang , Debin Wang , Jin Gao , Zhaoxin Meng , Jianxin Hou , Jianqiang Wang , Xianpeng Wang
Face-centered cubic (FCC) multi-principal element alloys (MPEAs) exhibit exceptional combinations of high strength and ductility, yet they remain susceptible to localized corrosion in operational environments. Enhancing their corrosion resistance is thus critical for broader engineering applications. Given the paucity of existing corrosion data and the expansive compositional landscape of FCC MPEAs, we introduce a hybrid framework that leverages Wasserstein Generative Adversarial Networks with Gradient Penalty for data augmentation, coupled with machine learning models and Bayesian optimization for alloy composition refinement. Experimental validation demonstrates that the optimized alloy composition, Fe20.1Cr35.04Ni20.1Al4.66Co20.1, achieves a pitting potential of 1065 mVSCE, representing a 20 % improvement over the top-performing composition in the dataset. This superior corrosion resistance stems from Cr oxide enrichment, which refines the semiconductor properties of the passive film. By integrating data augmentation with machine learning-driven modeling, our approach establishes a generalizable framework for designing corrosion-resistant MPEAs.
{"title":"Accelerated discovery of corrosion-resistant multi-principal element alloys via data-augmented machine learning","authors":"Yifan Wang , Debin Wang , Jin Gao , Zhaoxin Meng , Jianxin Hou , Jianqiang Wang , Xianpeng Wang","doi":"10.1016/j.corsci.2025.113567","DOIUrl":"10.1016/j.corsci.2025.113567","url":null,"abstract":"<div><div>Face-centered cubic (FCC) multi-principal element alloys (MPEAs) exhibit exceptional combinations of high strength and ductility, yet they remain susceptible to localized corrosion in operational environments. Enhancing their corrosion resistance is thus critical for broader engineering applications. Given the paucity of existing corrosion data and the expansive compositional landscape of FCC MPEAs, we introduce a hybrid framework that leverages Wasserstein Generative Adversarial Networks with Gradient Penalty for data augmentation, coupled with machine learning models and Bayesian optimization for alloy composition refinement. Experimental validation demonstrates that the optimized alloy composition, Fe<sub>20.1</sub>Cr<sub>35.04</sub>Ni<sub>20.1</sub>Al<sub>4.66</sub>Co<sub>20.1</sub>, achieves a pitting potential of 1065 mV<sub>SCE</sub>, representing a 20 % improvement over the top-performing composition in the dataset. This superior corrosion resistance stems from Cr oxide enrichment, which refines the semiconductor properties of the passive film. By integrating data augmentation with machine learning-driven modeling, our approach establishes a generalizable framework for designing corrosion-resistant MPEAs.</div></div>","PeriodicalId":290,"journal":{"name":"Corrosion Science","volume":"260 ","pages":"Article 113567"},"PeriodicalIF":7.4,"publicationDate":"2025-12-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145787255","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 : 2025-12-18DOI: 10.1016/j.corsci.2025.113555
Chengshuang Zhou , Haolin Wu , Huijie Chen , Xiaoping Yan , Yuxuan Qian , Kaiyu Zhang , Lin Zhang , Juan Shang
Hydrogen energy is crucial for the transition to a low-carbon economy, but high-pressure hydrogen can cause severe embrittlement in pipeline steels. The presence of CO₂ impurities in hydrogen-blended natural gas may significantly influence the hydrogen embrittlement (HE) behavior. This work systematically investigates the influence of CO₂ partial pressure on the hydrogen embrittlement of pure iron in high-pressure environments using slow strain rate tensile (SSRT) and fatigue crack growth rate (FCGR) tests, hydrogen permeation experiments, and first-principles molecular dynamics (FPMD) simulations. The results show that, compared to pure hydrogen, as CO₂ concentration increases, the elongation of pure iron first decreases then increases, while FCGR increases then decreases, with the most significant HE promotion occurring at 0.2 MPa CO₂. The consistency between SSRT and FCGR outcomes can be explained by the dual role of CO₂ in hydrogen permeation. At low CO₂ concentrations, CO₂ promotes the migration of hydrogen atoms toward the subsurface, which enhances hydrogen embrittlement; at high CO₂ concentrations, CO₂ occupies more metal surface adsorption sites, inhibiting hydrogen adsorption and coordination on the metal surface, thereby inhibiting hydrogen embrittlement.
{"title":"The influence of CO2 partial pressure on the hydrogen embrittlement behavior of pure iron in high-pressure hydrogen environment","authors":"Chengshuang Zhou , Haolin Wu , Huijie Chen , Xiaoping Yan , Yuxuan Qian , Kaiyu Zhang , Lin Zhang , Juan Shang","doi":"10.1016/j.corsci.2025.113555","DOIUrl":"10.1016/j.corsci.2025.113555","url":null,"abstract":"<div><div>Hydrogen energy is crucial for the transition to a low-carbon economy, but high-pressure hydrogen can cause severe embrittlement in pipeline steels. The presence of CO₂ impurities in hydrogen-blended natural gas may significantly influence the hydrogen embrittlement (HE) behavior. This work systematically investigates the influence of CO₂ partial pressure on the hydrogen embrittlement of pure iron in high-pressure environments using slow strain rate tensile (SSRT) and fatigue crack growth rate (FCGR) tests, hydrogen permeation experiments, and first-principles molecular dynamics (FPMD) simulations. The results show that, compared to pure hydrogen, as CO₂ concentration increases, the elongation of pure iron first decreases then increases, while FCGR increases then decreases, with the most significant HE promotion occurring at 0.2 MPa CO₂. The consistency between SSRT and FCGR outcomes can be explained by the dual role of CO₂ in hydrogen permeation. At low CO₂ concentrations, CO₂ promotes the migration of hydrogen atoms toward the subsurface, which enhances hydrogen embrittlement; at high CO₂ concentrations, CO₂ occupies more metal surface adsorption sites, inhibiting hydrogen adsorption and coordination on the metal surface, thereby inhibiting hydrogen embrittlement.</div></div>","PeriodicalId":290,"journal":{"name":"Corrosion Science","volume":"260 ","pages":"Article 113555"},"PeriodicalIF":7.4,"publicationDate":"2025-12-18","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145837408","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 : 2025-12-17DOI: 10.1016/j.corsci.2025.113566
Jianjun Li , Yang Wang , Congzheng Wang , Shujing Wang , Weijie Wang , Pengfei Jin , Zichong Zu , Yuqi Zhang , Guangyu He , Cheng Zhang , Jinfeng Huang
To advance the uses of ZrO2/NiCrAl coatings for flame-retardant protection, the effects of such coatings on critical ignition conditions of TC4 titanium alloy were systematically investigated by using an oxygen-enriched ignition test. The findings reveal that NiCrAl coating demonstrate superior ignition critical conditions, such as ignition temperature and critical pressure, compared to ZrO2 coatings within a thickness range of 100–350 μm. Moreover, an advanced F-K model was introduced to quantitatively describe the relationship between coating parameters (such as compositions and thickness) and the ignition critical conditions. Furthermore, the fitting results revealed that the activation energy for ignition of ZrO2 and NiCrAl coatings as 111.395 kJ/mol and 116.074 kJ/mol, respectively, notably exceeding the substrate's 89.130 kJ/mol. The improved flame retardancy can be related to the ZrO2 coating forms a layered TiO-ZrTiO4 structure during combustion, which impedes the Ti/O chain reaction and lowers exothermic reaction efficiency. Conversely, the NiCrAl coating develops a dense multi-layered network of Ti3NiAl2O, NiAl2O4, and β-Ti(Cr). This structure obstructs oxygen diffusion and severs the contact between the Ti and O, thus effectively suppressing the sustained Ti/O chain reaction. These findings provide a data and theoretical basis for the optimizing design and flame-retardant application of NiCrAl/YSZ coatings.
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