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.
{"title":"Unveiling the critical conditions for ignition and flame-retardant mechanisms of NiCrAl/YSZ coatings applied for protection of titanium alloys","authors":"Jianjun Li , Yang Wang , Congzheng Wang , Shujing Wang , Weijie Wang , Pengfei Jin , Zichong Zu , Yuqi Zhang , Guangyu He , Cheng Zhang , Jinfeng Huang","doi":"10.1016/j.corsci.2025.113566","DOIUrl":"10.1016/j.corsci.2025.113566","url":null,"abstract":"<div><div>To advance the uses of ZrO<sub>2</sub>/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 ZrO<sub>2</sub> coatings within a thickness range of 100–350 μm. Moreover, an advanced <em>F-K</em> 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 ZrO<sub>2</sub> 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 ZrO<sub>2</sub> coating forms a layered TiO-ZrTiO<sub>4</sub> 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 Ti<sub>3</sub>NiAl<sub>2</sub>O, NiAl<sub>2</sub>O<sub>4</sub>, 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.</div></div>","PeriodicalId":290,"journal":{"name":"Corrosion Science","volume":"260 ","pages":"Article 113566"},"PeriodicalIF":7.4,"publicationDate":"2025-12-17","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145787256","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 : 2025-12-16DOI: 10.1016/j.corsci.2025.113563
Zhen Zeng , Xingyu Feng , Wen Wang , Jintao Lu , Jibo Tan , En-Hou Han , Wenjun Kuang
The FeAl coating demonstrates exceptional corrosion resistance in 550 °C Lead-Bismuth Eutectic (LBE) even at an ultra-low oxygen concentration of 10⁻⁹ wt% by forming a protective nanoscale alumina film. However, the leaching of Fe through alumina scale leads to the precipitation of η-Fe₂Al₅ phase in sub-surface region, especially along grain boundaries, which is considered the primary degradation mechanism of the coating in LBE. Approximately 10 % of the grain boundaries also formed intergranular pores. Scratching promotes the aging process of coating as it induces severe plastic deformation. Notably, recrystallization occurs in surface region, along with increased density and extent of precipitates in the deformation zone. Furthermore, the intergranular pores in the coating surface are effectively suppressed in the scratched area.
{"title":"Effect of scratching on the corrosion-assisted aging of slurry aluminide coating on 316LN stainless steel in oxygen-poor lead-bismuth eutectic at 550 °C","authors":"Zhen Zeng , Xingyu Feng , Wen Wang , Jintao Lu , Jibo Tan , En-Hou Han , Wenjun Kuang","doi":"10.1016/j.corsci.2025.113563","DOIUrl":"10.1016/j.corsci.2025.113563","url":null,"abstract":"<div><div>The FeAl coating demonstrates exceptional corrosion resistance in 550 °C Lead-Bismuth Eutectic (LBE) even at an ultra-low oxygen concentration of 10⁻⁹ wt% by forming a protective nanoscale alumina film. However, the leaching of Fe through alumina scale leads to the precipitation of η-Fe₂Al₅ phase in sub-surface region, especially along grain boundaries, which is considered the primary degradation mechanism of the coating in LBE. Approximately 10 % of the grain boundaries also formed intergranular pores. Scratching promotes the aging process of coating as it induces severe plastic deformation. Notably, recrystallization occurs in surface region, along with increased density and extent of precipitates in the deformation zone. Furthermore, the intergranular pores in the coating surface are effectively suppressed in the scratched area.</div></div>","PeriodicalId":290,"journal":{"name":"Corrosion Science","volume":"260 ","pages":"Article 113563"},"PeriodicalIF":7.4,"publicationDate":"2025-12-16","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145787145","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 : 2025-12-16DOI: 10.1016/j.corsci.2025.113565
Dongju Kim , Youho Lee
A mechanistic model to quantitatively predict steam oxidation-induced degradation of chromium (Cr) coatings on zirconium (Zr) alloys and corresponding rapid oxidation was developed and validated by comprehensively modeling each kinetic process responsible for degradation. The model was validated against isothermal oxidation data in the 1100–1300 °C range, in terms of layer thicknesses, oxidation weight gain, and oxygen distribution profiles in the Zr matrix. The developed model consists of four interconnected sub-models: (1) Transient Cr-coating thickness model. (2) Cr-coating grain boundary density model. (3) ZrO2 oxygen path in the Cr-coating grain boundary model. (4) Cr₂O₃ reduction and oxygen ingress model. At each time step, the model calculates both the Cr-coating thickness and the depth of ZrO₂ paths. When the ZrO₂ path depth exceeds the Cr-coating thickness, the simulation transitions to the Cr₂O₃ layer reduction phase. Once through‑oxide voids form, direct steam ingress and oxygen diffusion along the ZrO₂ paths are initiated; the resulting oxygen flux is imposed as boundary condition for transient oxygen diffusion in the Zr matrix. To capture spatial heterogeneity in microstructural evolution, the system is divided into regions based on grain boundary density, each simulated independently within a Monte Carlo framework. This probabilistic simulation explains the two-stage transition: statistical variations cause a slight initial rate increase from premature failures, while a macroscopic acceleration requires a statistically significant simultaneous failure of regions. The resulting model provides a robust tool for safety assessment, enabling quantitative prediction of cladding oxidation and embrittlement under the prolonged high-temperature steam conditions of various accident scenarios.
{"title":"An integral mechanistic model for the degradation and protection loss of Cr-coated zirconium alloys in steam oxidation environments","authors":"Dongju Kim , Youho Lee","doi":"10.1016/j.corsci.2025.113565","DOIUrl":"10.1016/j.corsci.2025.113565","url":null,"abstract":"<div><div>A mechanistic model to quantitatively predict steam oxidation-induced degradation of chromium (Cr) coatings on zirconium (Zr) alloys and corresponding rapid oxidation was developed and validated by comprehensively modeling each kinetic process responsible for degradation. The model was validated against isothermal oxidation data in the 1100–1300 °C range, in terms of layer thicknesses, oxidation weight gain, and oxygen distribution profiles in the Zr matrix. The developed model consists of four interconnected sub-models: (1) Transient Cr-coating thickness model. (2) Cr-coating grain boundary density model. (3) ZrO<sub>2</sub> oxygen path in the Cr-coating grain boundary model. (4) Cr₂O₃ reduction and oxygen ingress model. At each time step, the model calculates both the Cr-coating thickness and the depth of ZrO₂ paths. When the ZrO₂ path depth exceeds the Cr-coating thickness, the simulation transitions to the Cr₂O₃ layer reduction phase. Once through‑oxide voids form, direct steam ingress and oxygen diffusion along the ZrO₂ paths are initiated; the resulting oxygen flux is imposed as boundary condition for transient oxygen diffusion in the Zr matrix. To capture spatial heterogeneity in microstructural evolution, the system is divided into regions based on grain boundary density, each simulated independently within a Monte Carlo framework. This probabilistic simulation explains the two-stage transition: statistical variations cause a slight initial rate increase from premature failures, while a macroscopic acceleration requires a statistically significant simultaneous failure of regions. The resulting model provides a robust tool for safety assessment, enabling quantitative prediction of cladding oxidation and embrittlement under the prolonged high-temperature steam conditions of various accident scenarios.</div></div>","PeriodicalId":290,"journal":{"name":"Corrosion Science","volume":"260 ","pages":"Article 113565"},"PeriodicalIF":7.4,"publicationDate":"2025-12-16","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145837406","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 : 2025-12-16DOI: 10.1016/j.corsci.2025.113564
Jinhang Li , Weichen Xu , Rongling Zhang , Liang Fan , Jingying Li , Jizhou Duan , Baorong Hou
Large temperature difference is typical in highlands and mountainous regions, where routine maintenance, monitoring and inspection are costly and difficult. The development of oxide film on HRB400E steel rebars from the initial to mature stages in simulated concrete pore solution has been thoroughly investigated. The electrochemical, compositional and morphological studies of the oxide film have been carried out at temperatures from −7 °C to 30 °C. High temperature disfavors the protectiveness of the oxide film, and the corrosion resistance decreases with the increasing temperature. Three plateaus have been observed during the development of OCP starting from a bare surface at 20 °C and 30 °C but not at lower temperatures. The plateaus have been ascribed to the nucleation, growth of Fe(OH)2 crystals and further oxidation to Fe(III) species. Thick, porous, inhomogeneous and clustered structure was observed at 30 °C, but thin and compact oxide film formed at 10 °C, 0 °C and −7 °C. It is suggested that high temperatures tend to lower the quality of the oxide film in a self-repair process.
{"title":"Oxide film formed on steel rebars in simulated concrete pore solution under large temperature difference – Typical in highlands and mountainous regions","authors":"Jinhang Li , Weichen Xu , Rongling Zhang , Liang Fan , Jingying Li , Jizhou Duan , Baorong Hou","doi":"10.1016/j.corsci.2025.113564","DOIUrl":"10.1016/j.corsci.2025.113564","url":null,"abstract":"<div><div>Large temperature difference is typical in highlands and mountainous regions, where routine maintenance, monitoring and inspection are costly and difficult. The development of oxide film on HRB400E steel rebars from the initial to mature stages in simulated concrete pore solution has been thoroughly investigated. The electrochemical, compositional and morphological studies of the oxide film have been carried out at temperatures from −7 °C to 30 °C. High temperature disfavors the protectiveness of the oxide film, and the corrosion resistance decreases with the increasing temperature. Three plateaus have been observed during the development of OCP starting from a bare surface at 20 °C and 30 °C but not at lower temperatures. The plateaus have been ascribed to the nucleation, growth of Fe(OH)<sub>2</sub> crystals and further oxidation to Fe(III) species. Thick, porous, inhomogeneous and clustered structure was observed at 30 °C, but thin and compact oxide film formed at 10 °C, 0 °C and −7 °C. It is suggested that high temperatures tend to lower the quality of the oxide film in a self-repair process.</div></div>","PeriodicalId":290,"journal":{"name":"Corrosion Science","volume":"260 ","pages":"Article 113564"},"PeriodicalIF":7.4,"publicationDate":"2025-12-16","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145787252","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}