Pub Date : 2026-04-01Epub Date: 2026-01-03DOI: 10.1016/j.corsci.2026.113595
Wang Diao , Junwei Wang , Li Lu , Bo Li , Leyang Dai , Jun Cheng , Haifeng Liao , Xiangning Wang , Zhenjie Wang , Zhilong Xu
The anti-tribocorrosion mechanisms of CoCrFeNiTix (x = 0.0, 0.1, 0.3, 0.5, 1.0) in simulated seawater were investigated quantitatively. At low Ti content (Ti0.1), corrosion-promoted wear (ΔWc) is pronounced due to rapid repassivation, resulting in a high tribocorrosion rate. At higher Ti contents (Ti0.5 and Ti1.0), the Laves phase (L-phase) delaminates after the R phase (HCP structure similar to Ni3Fe) is corroded, also leading to a high tribocorrosion rate. The Ti0.3 alloy exhibits outstanding tribocorrosion resistance (4.35 × 10−6 mm³/(N·m)) due to the anodic protection by the R phase. Improving wear resistance and reducing the L phase are beneficial for enhancing its tribocorrosion resistance.
{"title":"Tribocorrosion resistance of high entropy alloy CoCrFeNiTix in simulated seawater","authors":"Wang Diao , Junwei Wang , Li Lu , Bo Li , Leyang Dai , Jun Cheng , Haifeng Liao , Xiangning Wang , Zhenjie Wang , Zhilong Xu","doi":"10.1016/j.corsci.2026.113595","DOIUrl":"10.1016/j.corsci.2026.113595","url":null,"abstract":"<div><div>The anti-tribocorrosion mechanisms of CoCrFeNiTi<sub>x</sub> (<em>x</em> = 0.0, 0.1, 0.3, 0.5, 1.0) in simulated seawater were investigated quantitatively. At low Ti content (Ti<sub>0.1</sub>), corrosion-promoted wear (Δ<em>W</em><sub>c</sub>) is pronounced due to rapid repassivation, resulting in a high tribocorrosion rate. At higher Ti contents (Ti<sub>0.5</sub> and Ti<sub>1.0</sub>), the Laves phase (<span>L</span>-phase) delaminates after the R phase (HCP structure similar to Ni<sub>3</sub>Fe) is corroded, also leading to a high tribocorrosion rate. The Ti<sub>0.3</sub> alloy exhibits outstanding tribocorrosion resistance (4.35 × 10<sup>−6</sup> mm³/(N·m)) due to the anodic protection by the R phase. Improving wear resistance and reducing the L phase are beneficial for enhancing its tribocorrosion resistance.</div></div>","PeriodicalId":290,"journal":{"name":"Corrosion Science","volume":"261 ","pages":"Article 113595"},"PeriodicalIF":7.4,"publicationDate":"2026-04-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145897958","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 study modifies the texture and precipitation phases of titanium-free maraging steel by adjusting the heat treatment process, thereby enhancing its resistance to hydrogen embrittlement and toughness without compromising the steel's strength. The results revealed three key advancements: (i) ω-precipitates and reversed austenite acted as hydrogen traps, delaying hydrogen diffusion; the subsequent formation of the Laves phase further enhanced this effect, significantly reducing the hydrogen diffusion coefficient by 71.3 %; (ii) incomplete recrystallization of austenite before quenching inhibited the formation of martensite variants, resulting in a pronounced < 110 > //RD fiber texture that effectively altered the crack propagation path—a texture mechanism previously overlooked in hydrogen embrittlement studies; (iii) analysis of the crack path and thermal desorption spectra of SLLA-480 demonstrated that reversed austenite served as a hydrogen trap, inhibiting hydrogen diffusion, while dispersed reversed austenite had limited capacity to impede crack propagation in high-strength maraging steel. Due to these synergistic mechanisms, the SLLA-480 process reduced hydrogen embrittlement sensitivity by 17 % without compromising strength. This work deepens our understanding of the hydrogen embrittlement mechanism in maraging steel and proposes a microstructure design strategy based on the synergistic control of nanoprecipitates and crystal texture—a strategy particularly important for titanium-free maraging steel systems.
{"title":"Texture and nano-precipitates synergistically suppress hydrogen embrittlement susceptibility in titanium-free maraging steel","authors":"Xin Liu , Kaiyu Zhang , Wanliang Zhang , Jinrong Wu , Kehang Wu , Chengshuang Zhou , Lin Zhang , Jinyang Zheng","doi":"10.1016/j.corsci.2026.113599","DOIUrl":"10.1016/j.corsci.2026.113599","url":null,"abstract":"<div><div>This study modifies the texture and precipitation phases of titanium-free maraging steel by adjusting the heat treatment process, thereby enhancing its resistance to hydrogen embrittlement and toughness without compromising the steel's strength. The results revealed three key advancements: (i) ω-precipitates and reversed austenite acted as hydrogen traps, delaying hydrogen diffusion; the subsequent formation of the Laves phase further enhanced this effect, significantly reducing the hydrogen diffusion coefficient by 71.3 %; (ii) incomplete recrystallization of austenite before quenching inhibited the formation of martensite variants, resulting in a pronounced < 110 > //RD fiber texture that effectively altered the crack propagation path—a texture mechanism previously overlooked in hydrogen embrittlement studies; (iii) analysis of the crack path and thermal desorption spectra of SLLA-480 demonstrated that reversed austenite served as a hydrogen trap, inhibiting hydrogen diffusion, while dispersed reversed austenite had limited capacity to impede crack propagation in high-strength maraging steel. Due to these synergistic mechanisms, the SLLA-480 process reduced hydrogen embrittlement sensitivity by 17 % without compromising strength. This work deepens our understanding of the hydrogen embrittlement mechanism in maraging steel and proposes a microstructure design strategy based on the synergistic control of nanoprecipitates and crystal texture—a strategy particularly important for titanium-free maraging steel systems.</div></div>","PeriodicalId":290,"journal":{"name":"Corrosion Science","volume":"261 ","pages":"Article 113599"},"PeriodicalIF":7.4,"publicationDate":"2026-04-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145923718","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 : 2026-04-01Epub Date: 2026-01-05DOI: 10.1016/j.corsci.2026.113602
Jun Fan , Hongwei Yao , Kai Xu , Gang Liu , Jibin Pu
Corrosion is the primary challenge for metallic materials serving in marine environments, and the pursuit of lower corrosion rate and more stable passivation remains perpetual. However, these two key properties are difficult to simultaneously optimize for traditional metallic materials. Oxygen, typically treated as an impurity during the smelting process of metallic materials, requires strict control. In contrast, oxygen in marine environments can promote the formation of dense passive films on metal surfaces. In this work, in-situ incorporation of oxygen into a novel CrNbTiZr multi-principal element coating was implemented to achieve the synergistic regulation of corrosion rate and passivation behavior. In NaCl solution, the self-corrosion current density of the coating was reduced by approximately two orders of magnitude compared to traditional 304 stainless steel and its passivation potential even outperformed that of titanium alloys. The excellent corrosion resistance originates from the microstructural transformation of CrNbTiZr from BCC to amorphous state induced by controlled oxygen content. The collapsed BCC phase enables more uniform distribution of Nb/Ti passivating elements within the amorphous phase. Additionally, the formation of local (covalent) bonds between oxygen and metal atoms reduces the element dissolution rate, facilitating the formation of a uniform-thickness and dense double-layer passive film across different phases on the surface of the coating. The high-quality passive film and dense intrinsic structure of coatings significantly enhance the resistance of Cl⁻ attack, endowing the coating with potential applications in marine engineering. This work highlights the beneficial effect of in-situ oxygen incorporation on the corrosion resistance of metallic materials, providing a new strategy for the design of metallic materials with high corrosion resistance in harsh environments.
{"title":"Robust corrosion resistance enabled by in-situ oxygen-tailored microstructure of CrNbTiZr multi-principal element coating","authors":"Jun Fan , Hongwei Yao , Kai Xu , Gang Liu , Jibin Pu","doi":"10.1016/j.corsci.2026.113602","DOIUrl":"10.1016/j.corsci.2026.113602","url":null,"abstract":"<div><div>Corrosion is the primary challenge for metallic materials serving in marine environments, and the pursuit of lower corrosion rate and more stable passivation remains perpetual. However, these two key properties are difficult to simultaneously optimize for traditional metallic materials. Oxygen, typically treated as an impurity during the smelting process of metallic materials, requires strict control. In contrast, oxygen in marine environments can promote the formation of dense passive films on metal surfaces. In this work, in-situ incorporation of oxygen into a novel CrNbTiZr multi-principal element coating was implemented to achieve the synergistic regulation of corrosion rate and passivation behavior. In NaCl solution, the self-corrosion current density of the coating was reduced by approximately two orders of magnitude compared to traditional 304 stainless steel and its passivation potential even outperformed that of titanium alloys. The excellent corrosion resistance originates from the microstructural transformation of CrNbTiZr from BCC to amorphous state induced by controlled oxygen content. The collapsed BCC phase enables more uniform distribution of Nb/Ti passivating elements within the amorphous phase. Additionally, the formation of local (covalent) bonds between oxygen and metal atoms reduces the element dissolution rate, facilitating the formation of a uniform-thickness and dense double-layer passive film across different phases on the surface of the coating. The high-quality passive film and dense intrinsic structure of coatings significantly enhance the resistance of Cl⁻ attack, endowing the coating with potential applications in marine engineering. This work highlights the beneficial effect of in-situ oxygen incorporation on the corrosion resistance of metallic materials, providing a new strategy for the design of metallic materials with high corrosion resistance in harsh environments.</div></div>","PeriodicalId":290,"journal":{"name":"Corrosion Science","volume":"261 ","pages":"Article 113602"},"PeriodicalIF":7.4,"publicationDate":"2026-04-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145923653","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 : 2026-04-01Epub Date: 2026-01-05DOI: 10.1016/j.corsci.2026.113596
Lili Liu , Haiyang Jiang , Quan Shan , Junlei Zhang , Xiang Chen , Zulai Li , Dawei Wang , Guangsheng Huang
This study systematically investigated, through a combination of experimental characterization and first-principles calculations, the influence of pre-deformation modes on the microstructural evolution and corrosion behavior of AM60 magnesium alloy. The results indicated that basal slip was the dominant mechanism during pre-tension, leading to significant dislocation multiplication. In contrast, pre-compression activated extensive twinning, which resulted in grain refinement and a reorientation of the grain c-axis by ∼86.5°. Mechanical testing indicated that pre-deformation improved the alloy's strength at the expense of ductility; the yield strength increased by ∼50 MPa, and the elongation reduced by ∼1.6 % (pre-tension) and ∼5.2 % (pre-compression). Corrosion results revealed that the corrosion rates of the pre-tensioned and pre-compressed samples increased to 2.01 and 1.19 times that of the initial state, respectively. The high-density dislocations generated by pre-tension formed preferential corrosion channels, which promoted cracking of the surface product film, thereby accelerating localized corrosion. Conversely, the twins introduced by pre-compression refined the grain structure, which effectively alleviated the tensile stress within the product film and facilitated the formation of a dense protective layer. First-principles calculations further revealed the dual role of extension twins. Although their high interfacial energy (90.4 mJ/m2) decreased atomic stability, the high-density twin distribution in the pre-compressed specimen reduced its surface energy (1.431 J/cm2) compared to the pre-tensioned specimen (1.465 J/cm2), while simultaneously diminishing the energy differences among grains. The synergistic effect between surface energy optimization and grain refinement collectively contributes to the superior corrosion resistance of pre-compressed specimens over pre-tensioned ones.
{"title":"The influence of pre-compression/tension induced deformation mechanisms on the corrosion behavior of AM60 Mg alloy","authors":"Lili Liu , Haiyang Jiang , Quan Shan , Junlei Zhang , Xiang Chen , Zulai Li , Dawei Wang , Guangsheng Huang","doi":"10.1016/j.corsci.2026.113596","DOIUrl":"10.1016/j.corsci.2026.113596","url":null,"abstract":"<div><div>This study systematically investigated, through a combination of experimental characterization and first-principles calculations, the influence of pre-deformation modes on the microstructural evolution and corrosion behavior of AM60 magnesium alloy. The results indicated that basal slip was the dominant mechanism during pre-tension, leading to significant dislocation multiplication. In contrast, pre-compression activated extensive twinning, which resulted in grain refinement and a reorientation of the grain c-axis by ∼86.5°. Mechanical testing indicated that pre-deformation improved the alloy's strength at the expense of ductility; the yield strength increased by ∼50 MPa, and the elongation reduced by ∼1.6 % (pre-tension) and ∼5.2 % (pre-compression). Corrosion results revealed that the corrosion rates of the pre-tensioned and pre-compressed samples increased to 2.01 and 1.19 times that of the initial state, respectively. The high-density dislocations generated by pre-tension formed preferential corrosion channels, which promoted cracking of the surface product film, thereby accelerating localized corrosion. Conversely, the twins introduced by pre-compression refined the grain structure, which effectively alleviated the tensile stress within the product film and facilitated the formation of a dense protective layer. First-principles calculations further revealed the dual role of <span><math><mrow><mspace></mspace><mo>{</mo><mn>10</mn><mover><mrow><mn>1</mn></mrow><mo>̅</mo></mover><mn>2</mn><mo>}</mo></mrow></math></span> extension twins. Although their high interfacial energy (90.4 mJ/m<sup>2</sup>) decreased atomic stability, the high-density twin distribution in the pre-compressed specimen reduced its surface energy (1.431 J/cm<sup>2</sup>) compared to the pre-tensioned specimen (1.465 J/cm<sup>2</sup>), while simultaneously diminishing the energy differences among grains. The synergistic effect between surface energy optimization and grain refinement collectively contributes to the superior corrosion resistance of pre-compressed specimens over pre-tensioned ones.</div></div>","PeriodicalId":290,"journal":{"name":"Corrosion Science","volume":"261 ","pages":"Article 113596"},"PeriodicalIF":7.4,"publicationDate":"2026-04-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145923729","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 : 2026-04-01Epub Date: 2026-01-19DOI: 10.1016/j.corsci.2026.113641
Xu-dong Li, Zi-wen Zhao, Muhammad Arslan Hafeez, Cheng Zhang, Lin Liu
Austenitic stainless steels (SS) frequently suffer severe corrosion degradation under mechanical stress, yet the atomic-scale mechanisms governing this ubiquitous phenomenon remain poorly understood. Here, we present a multi-scale study combining electrochemical analysis, x-ray photoelectron spectroscopy (XPS), aberration-corrected transmission electron microscopy (TEM), density functional theory (DFT) and ab initio molecular dynamics (AIMD) simulations to investigate the effect of elastic tensile stress on the passive film stability of a laser-desensitized 316L SS. It is found that increasing tensile stress dramatically degrades corrosion resistance, as evidenced by lower film resistance and intensified metastable pitting. XPS results confirm that degradation of corrosion resistance is linked to the promotion of detrimental Fe-oxides and a reduction in protective Cr2O3 content in the passive film. In addition, TEM analysis indicates that high tensile stress thickens the passive film by ∼18.6 % and transforms it into a vulnerable Fe-enriched and Cr-depleted structure. Theoretical simulations with both DFT and AIMD reveal that the outward diffusion of Fe driven by tensile elastic stress is thermodynamically favoured and kinetically accelerated. This work provides a novel understanding of stress-induced deterioration of the corrosion resistance of austenitic SS.
{"title":"Mechanisms of stress-induced deterioration of corrosion resistance of the laser-desensitized 316L stainless steel","authors":"Xu-dong Li, Zi-wen Zhao, Muhammad Arslan Hafeez, Cheng Zhang, Lin Liu","doi":"10.1016/j.corsci.2026.113641","DOIUrl":"10.1016/j.corsci.2026.113641","url":null,"abstract":"<div><div>Austenitic stainless steels (SS) frequently suffer severe corrosion degradation under mechanical stress, yet the atomic-scale mechanisms governing this ubiquitous phenomenon remain poorly understood. Here, we present a multi-scale study combining electrochemical analysis, x-ray photoelectron spectroscopy (XPS), aberration-corrected transmission electron microscopy (TEM), density functional theory (DFT) and ab initio molecular dynamics (AIMD) simulations to investigate the effect of elastic tensile stress on the passive film stability of a laser-desensitized 316L SS. It is found that increasing tensile stress dramatically degrades corrosion resistance, as evidenced by lower film resistance and intensified metastable pitting. XPS results confirm that degradation of corrosion resistance is linked to the promotion of detrimental Fe-oxides and a reduction in protective Cr<sub>2</sub>O<sub>3</sub> content in the passive film. In addition, TEM analysis indicates that high tensile stress thickens the passive film by ∼18.6 % and transforms it into a vulnerable Fe-enriched and Cr-depleted structure. Theoretical simulations with both DFT and AIMD reveal that the outward diffusion of Fe driven by tensile elastic stress is thermodynamically favoured and kinetically accelerated. This work provides a novel understanding of stress-induced deterioration of the corrosion resistance of austenitic SS.</div></div>","PeriodicalId":290,"journal":{"name":"Corrosion Science","volume":"261 ","pages":"Article 113641"},"PeriodicalIF":7.4,"publicationDate":"2026-04-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146023972","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 : 2026-04-01Epub Date: 2026-01-15DOI: 10.1016/j.corsci.2026.113629
Vincenzo Bongiorno , Niek Hijnen , Xiaorong Zhou
Large Language Models (LLMs) were applied to automate the interpretation of electrochemical impedance spectroscopy (EIS) data, enabling classification and parameter estimation without the need for a task specific machine learning training. The approach achieved classification accuracies up to 96 % and produced fitting results comparable to those obtained with specifically trained neural networks. The methodology reduces reliance on labelled data and manual intervention. While demonstrated in the context of organic coatings, the framework provides a scalable AI-based workflow that could, in principle, be extended to conceptually similar tasks in materials and corrosion research, subject to dedicated validation.
{"title":"Exploring the use of large language models for EIS: A feasibility study on organic coatings for corrosion protection","authors":"Vincenzo Bongiorno , Niek Hijnen , Xiaorong Zhou","doi":"10.1016/j.corsci.2026.113629","DOIUrl":"10.1016/j.corsci.2026.113629","url":null,"abstract":"<div><div>Large Language Models (LLMs) were applied to automate the interpretation of electrochemical impedance spectroscopy (EIS) data, enabling classification and parameter estimation without the need for a task specific machine learning training. The approach achieved classification accuracies up to 96 % and produced fitting results comparable to those obtained with specifically trained neural networks. The methodology reduces reliance on labelled data and manual intervention. While demonstrated in the context of organic coatings, the framework provides a scalable AI-based workflow that could, in principle, be extended to conceptually similar tasks in materials and corrosion research, subject to dedicated validation.</div></div>","PeriodicalId":290,"journal":{"name":"Corrosion Science","volume":"261 ","pages":"Article 113629"},"PeriodicalIF":7.4,"publicationDate":"2026-04-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146023973","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 : 2026-04-01Epub Date: 2025-12-27DOI: 10.1016/j.corsci.2025.113587
Farzad Jafarihonar , Alessandro Ruozzi , Hanna Kinnunen , Leena Hupa , Emil Vainio
This study investigates the risk of low-temperature corrosion on carbon steel tube surfaces located at the clean side of the flue gas channel downstream of a selective catalytic reduction (SCR) unit in a full-scale bubbling fluidized bed (BFB) boiler, where the HCl(g) concentration is typically very low (<5 ppmv). Short- and long-term corrosion probe measurements, along with online deposit monitoring, were carried out in the flue gas channel to determine the causes of corrosion and establish safe material temperatures. To further investigate the results, laboratory tests were conducted in a quartz-tube furnace under simulated flue gas conditions. The results demonstrated that corrosion rates increased once the material surface temperature fell below 90 °C, with particularly severe attack evident at 80 and 70 °C. Notably, a considerable amount of chlorine was present in the corrosion products, indicating a high risk of chlorine-induced corrosion at cold-end surfaces, even at very low HCl(g) concentrations. Two potential corrosion mechanisms were identified, namely the absorption of HCl(g) into surface-adsorbed water monolayers above the water dew point, and the presence of corrosive NH4Cl(s,aq) on tube surfaces. HCl-induced corrosion was found to be the most likely mechanism. According to this mechanism, corrosion can occur even without bulk water condensation, and it depends on the local relative humidity (RH) at the steel surface. The findings collectively suggest that carbon steel surfaces on the clean side of the flue gas path should be maintained above approximately 90 °C (with an appropriate safety margin, depending on flue gas H2O(g) concentration) to mitigate the observed HCl-induced corrosion. A similar corrosion mechanism may also affect the dirty side of the flue gas path at similarly low temperatures.
{"title":"New insights into HCl-induced low-temperature corrosion in biomass- and waste-fired boilers","authors":"Farzad Jafarihonar , Alessandro Ruozzi , Hanna Kinnunen , Leena Hupa , Emil Vainio","doi":"10.1016/j.corsci.2025.113587","DOIUrl":"10.1016/j.corsci.2025.113587","url":null,"abstract":"<div><div>This study investigates the risk of low-temperature corrosion on carbon steel tube surfaces located at the clean side of the flue gas channel downstream of a selective catalytic reduction (SCR) unit in a full-scale bubbling fluidized bed (BFB) boiler, where the HCl(g) concentration is typically very low (<5 ppm<sub>v</sub>). Short- and long-term corrosion probe measurements, along with online deposit monitoring, were carried out in the flue gas channel to determine the causes of corrosion and establish safe material temperatures. To further investigate the results, laboratory tests were conducted in a quartz-tube furnace under simulated flue gas conditions. The results demonstrated that corrosion rates increased once the material surface temperature fell below 90 °C, with particularly severe attack evident at 80 and 70 °C. Notably, a considerable amount of chlorine was present in the corrosion products, indicating a high risk of chlorine-induced corrosion at cold-end surfaces, even at very low HCl(g) concentrations. Two potential corrosion mechanisms were identified, namely the absorption of HCl(g) into surface-adsorbed water monolayers above the water dew point, and the presence of corrosive NH<sub>4</sub>Cl(s,aq) on tube surfaces. HCl-induced corrosion was found to be the most likely mechanism. According to this mechanism, corrosion can occur even without bulk water condensation, and it depends on the local relative humidity (RH) at the steel surface. The findings collectively suggest that carbon steel surfaces on the clean side of the flue gas path should be maintained above approximately 90 °C (with an appropriate safety margin, depending on flue gas H<sub>2</sub>O(g) concentration) to mitigate the observed HCl-induced corrosion. A similar corrosion mechanism may also affect the dirty side of the flue gas path at similarly low temperatures.</div></div>","PeriodicalId":290,"journal":{"name":"Corrosion Science","volume":"261 ","pages":"Article 113587"},"PeriodicalIF":7.4,"publicationDate":"2026-04-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145923724","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 : 2026-04-01Epub Date: 2026-01-12DOI: 10.1016/j.corsci.2026.113627
Xiaohong Chen, Taoqiang Ling, Danchu Wang, Dan Zhou, Pengcheng Zhou, Wenpo Li
The porous, loose rust layer on bronze artifacts induces continuous corrosion of the bronze substrate, ultimately causing perforation and pulverization. Conventional sealing methods have limitations like poor aging resistance, environmental harm, and damage to artifacts’ original appearance, creating an urgent need for environmentally benign, long-lasting, non-destructive sealing materials. In this work, silane coupling agent (KH550) and polyaspartic acid (PASP) were hydrothermally modified to prepare corrosion inhibitor N@KH550. Via simple immersion, N@KH550 can penetrate the bronze corrosion layer to the copper matrix and self-assemble into a dense protective film. Its siloxane and carbonyl/amido-containing compounds form the dense composite film through physical adsorption (van der Waals forces, hydrogen bonds), metal ion complexation, and Si-O-Si condensation, effectively blocking corrosive media ingress. At 298 K, 30 min pre-filming yielded 94.52 % corrosion inhibition efficiency for bronze samples, showing high efficacy; even at 333 K, efficiency remained over 90 %, indicating good thermal stability. Critically, it does not affect bronze patina morphology or color, meeting cultural heritage conservation requirements. This study is expected to provide new theoretical and technical support for bronze preservation, advancing cultural heritage conservation.
{"title":"Non-destructive conservation and thermally stable self-assembled films for bronze: Evaluation of synergistic protection mechanisms","authors":"Xiaohong Chen, Taoqiang Ling, Danchu Wang, Dan Zhou, Pengcheng Zhou, Wenpo Li","doi":"10.1016/j.corsci.2026.113627","DOIUrl":"10.1016/j.corsci.2026.113627","url":null,"abstract":"<div><div>The porous, loose rust layer on bronze artifacts induces continuous corrosion of the bronze substrate, ultimately causing perforation and pulverization. Conventional sealing methods have limitations like poor aging resistance, environmental harm, and damage to artifacts’ original appearance, creating an urgent need for environmentally benign, long-lasting, non-destructive sealing materials. In this work, silane coupling agent (KH550) and polyaspartic acid (PASP) were hydrothermally modified to prepare corrosion inhibitor N@KH550. Via simple immersion, N@KH550 can penetrate the bronze corrosion layer to the copper matrix and self-assemble into a dense protective film. Its siloxane and carbonyl/amido-containing compounds form the dense composite film through physical adsorption (van der Waals forces, hydrogen bonds), metal ion complexation, and Si-O-Si condensation, effectively blocking corrosive media ingress. At 298 K, 30 min pre-filming yielded 94.52 % corrosion inhibition efficiency for bronze samples, showing high efficacy; even at 333 K, efficiency remained over 90 %, indicating good thermal stability. Critically, it does not affect bronze patina morphology or color, meeting cultural heritage conservation requirements. This study is expected to provide new theoretical and technical support for bronze preservation, advancing cultural heritage conservation.</div></div>","PeriodicalId":290,"journal":{"name":"Corrosion Science","volume":"261 ","pages":"Article 113627"},"PeriodicalIF":7.4,"publicationDate":"2026-04-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145974633","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 : 2026-03-01Epub Date: 2025-11-23DOI: 10.1016/j.corsci.2025.113499
Yujia Zhang , Zhixiang Zhang , Xuemeng Zhang , Keke Wu , Ralf Riedel , Dou Hu , Yang Xu , Lianwei Wu , Jia Sun
Ultra-high-temperature ceramic coatings are critical for thermal protection systems in hypersonic vehicles. However, their compositional optimization is constrained by the inefficiency of traditional trial-and-error method. In this study, a machine learning-driven design strategy is proposed for the ZrC-TaC-SiC ternary system (denoted ZnTmSt, n, m, t = 0–100) to enhance ablation resistance. A random forest regression model was constructed using 170 literature data to predict surface ablation temperature, mass ablation rate, and linear ablation rate across the full compositional space of the ZrC-TaC-SiC ternary system. Four optimized formulations (Z60T30S10, Z60T10S30, Z80T15S5, Z80T5S15), each exhibiting stable mass and linear ablation rates in the order of 10−4 g/s and 10−4 mm/s, respectively, were selected through the model and fabricated via supersonic atmospheric plasma spraying. Oxyacetylene ablation test results confirmed the reliability of the model, with prediction errors for linear ablation rate within the order of 10−5 mm/s. Microstructural characterization revealed that high-TaC content (15–30 wt%) led to excessive formation of Zr6Ta2O17 during ablation, resulting in reduced thermal stability of the oxide scale and discontinuities in structure. Moreover, non-uniform sintering caused an increase in porosity. Interestingly, the low-TaC (5 wt%) Z80T5S15 sample achieved a dense and continuous oxide layer by a proper Zr/Ta content ratio in oxide phase, exhibiting excellent ablation resistance. This study establishes a machine-learning–assisted strategy combined with experimental validation, which can provide a new paradigm for intelligent design and performance prediction of ultra-high-temperature ceramic coatings.
超高温陶瓷涂层是高超声速飞行器热防护系统的关键。然而，传统的试错法效率低下，限制了它们的成分优化。本研究提出了一种机器学习驱动的ZrC-TaC-SiC三元体系（表示ZnTmSt， n, m, t = 0-100）抗烧蚀性设计策略。利用170篇文献数据构建随机森林回归模型，对ZrC-TaC-SiC三元体系的表面烧蚀温度、质量烧蚀率和线性烧蚀率进行了预测。通过模型优选出质量稳定、烧蚀率为10−4 g/s、线性烧蚀率为10−4 mm/s的四种优化配方Z60T30S10、Z60T10S30、Z80T15S5、Z80T5S15，并采用超声速大气等离子喷涂工艺制备。氧乙炔烧蚀试验结果证实了该模型的可靠性，线性烧蚀速率的预测误差在10 ~ 5 mm/s量级。显微组织表征表明，高tac含量（15-30 wt%）导致Zr6Ta2O17在烧蚀过程中过量形成，导致氧化层热稳定性降低，结构不连续。此外，不均匀烧结导致孔隙率增加。有趣的是，低tac(5 wt%) Z80T5S15样品通过适当的氧化相Zr/Ta含量比获得了致密连续的氧化层，表现出优异的抗烧蚀性能。本研究建立了一种结合实验验证的机器学习辅助策略，为超高温陶瓷涂层的智能设计和性能预测提供了新的范例。
{"title":"Machine learning guided design and ablation behavior of ZrC-TaC-SiC ternary coatings","authors":"Yujia Zhang , Zhixiang Zhang , Xuemeng Zhang , Keke Wu , Ralf Riedel , Dou Hu , Yang Xu , Lianwei Wu , Jia Sun","doi":"10.1016/j.corsci.2025.113499","DOIUrl":"10.1016/j.corsci.2025.113499","url":null,"abstract":"<div><div>Ultra-high-temperature ceramic coatings are critical for thermal protection systems in hypersonic vehicles. However, their compositional optimization is constrained by the inefficiency of traditional trial-and-error method. In this study, a machine learning-driven design strategy is proposed for the ZrC-TaC-SiC ternary system (denoted Z<em>n</em>T<em>m</em>S<em>t</em>, <em>n</em>, <em>m</em>, <em>t</em> = 0–100) to enhance ablation resistance. A random forest regression model was constructed using 170 literature data to predict surface ablation temperature, mass ablation rate, and linear ablation rate across the full compositional space of the ZrC-TaC-SiC ternary system. Four optimized formulations (Z60T30S10, Z60T10S30, Z80T15S5, Z80T5S15), each exhibiting stable mass and linear ablation rates in the order of 10<sup>−4</sup> g/s and 10<sup>−4</sup> mm/s, respectively, were selected through the model and fabricated via supersonic atmospheric plasma spraying. Oxyacetylene ablation test results confirmed the reliability of the model, with prediction errors for linear ablation rate within the order of 10<sup>−5</sup> mm/s. Microstructural characterization revealed that high-TaC content (15–30 wt%) led to excessive formation of Zr<sub>6</sub>Ta<sub>2</sub>O<sub>17</sub> during ablation, resulting in reduced thermal stability of the oxide scale and discontinuities in structure. Moreover, non-uniform sintering caused an increase in porosity. Interestingly, the low-TaC (5 wt%) Z80T5S15 sample achieved a dense and continuous oxide layer by a proper Zr/Ta content ratio in oxide phase, exhibiting excellent ablation resistance. This study establishes a machine-learning–assisted strategy combined with experimental validation, which can provide a new paradigm for intelligent design and performance prediction of ultra-high-temperature ceramic coatings.</div></div>","PeriodicalId":290,"journal":{"name":"Corrosion Science","volume":"260 ","pages":"Article 113499"},"PeriodicalIF":7.4,"publicationDate":"2026-03-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145683003","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 study investigates the interplay between parasitic corrosion and transport-limiting passivation in alkaline aluminum–air batteries using aluminum–magnesium–bismuth–indium anodes processed across a deformation-temperature gradient (cryogenic→ room temperature → dynamic recovery → near-recrystallization). A temperature-driven microstructure–film–performance coupling is identified. As deformation temperature increases, the fraction of dynamically recrystallized grains rises (∼0.7 % to ∼7.1 %), dislocation density decreases (∼2.21 ×10 ¹⁴ to ∼1.66 ×10 ¹⁴·m⁻²), and texture shifts from beta-fiber to alpha-fiber/copper. These changes alter interfacial film kinetics: from activation-controlled dissolution with sparse nuclei (cryogenic) to semi-permeable Al(OH)₃/Al₂O₃ films (room-temperature/recovery), and ultimately to dense, continuous discharge product layers (near-recrystallization). This shift reduces corrosion depth (∼586 µm to ∼333 µm), as semi-permeable films suppress localized corrosion, while dense films hinder ion exchange, redirect hydroxide ions along grain boundaries, and promote boundary-guided cracking and exfoliation corrosion (∼613 µm). Electrochemical data show that charge-transfer resistance decreases and then increases with temperature, while film/diffusion resistance increases monotonically, indicating densification and transport limitation. The room-temperature/recovery window minimizes the combined penalty of charge-transfer and diffusion polarizations, suppressing self-corrosion/intergranular corrosion, and enabling higher, more stable voltages and peak energy output (∼2618 mWh·g⁻¹, ∼86.56 % utilization). These results highlight deformation temperature as a key factor in tuning microstructure-controlled film growth, which governs corrosion pathways and discharge performance.
{"title":"Effect of deformation temperature on the coupled corrosion – Discharge mechanisms of aluminum-air battery anodes","authors":"Wen-hua Zhang, Jun-hua Cheng, Kui-cong Ma, Yu Liu, Zheng-bing Xiao, Hong-bang Shao, Yuan-chun Huang","doi":"10.1016/j.corsci.2025.113532","DOIUrl":"10.1016/j.corsci.2025.113532","url":null,"abstract":"<div><div>This study investigates the interplay between parasitic corrosion and transport-limiting passivation in alkaline aluminum–air batteries using aluminum–magnesium–bismuth–indium anodes processed across a deformation-temperature gradient (cryogenic→ room temperature → dynamic recovery → near-recrystallization). A temperature-driven microstructure–film–performance coupling is identified. As deformation temperature increases, the fraction of dynamically recrystallized grains rises (∼0.7 % to ∼7.1 %), dislocation density decreases (∼2.21 ×10 ¹⁴ to ∼1.66 ×10 ¹⁴·m⁻²), and texture shifts from beta-fiber to alpha-fiber/copper. These changes alter interfacial film kinetics: from activation-controlled dissolution with sparse nuclei (cryogenic) to semi-permeable Al(OH)₃/Al₂O₃ films (room-temperature/recovery), and ultimately to dense, continuous discharge product layers (near-recrystallization). This shift reduces corrosion depth (∼586 µm to ∼333 µm), as semi-permeable films suppress localized corrosion, while dense films hinder ion exchange, redirect hydroxide ions along grain boundaries, and promote boundary-guided cracking and exfoliation corrosion (∼613 µm). Electrochemical data show that charge-transfer resistance decreases and then increases with temperature, while film/diffusion resistance increases monotonically, indicating densification and transport limitation. The room-temperature/recovery window minimizes the combined penalty of charge-transfer and diffusion polarizations, suppressing self-corrosion/intergranular corrosion, and enabling higher, more stable voltages and peak energy output (∼2618 mWh·g⁻¹, ∼86.56 % utilization). These results highlight deformation temperature as a key factor in tuning microstructure-controlled film growth, which governs corrosion pathways and discharge performance.</div></div>","PeriodicalId":290,"journal":{"name":"Corrosion Science","volume":"260 ","pages":"Article 113532"},"PeriodicalIF":7.4,"publicationDate":"2026-03-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145683000","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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