Corrosion Resistance Of Alloy Research Articles

Optimization of tribological properties and corrosion resistance of MAO coatings on LY12 aluminum alloy by co-doping with graphite particles and in situ formation of zinc phosphate

Micro-arc oxidation (MAO) coatings can enhance the wear and corrosion resistance of aluminum alloys, but the high coefficient of friction and surface pores can lead to failure in the field. In this study, zinc acetate and graphite particles are introduced to the electrolyte to form corrosion-resistant and lubricating MAO coatings on the LY12 aluminum alloy. Zinc phosphate nanocrystals formed in situ are uniformly distributed in the amorphous coating, while the extrinsic graphite is mainly located in the amorphous structure. Compared to the aluminum alloy substrate, the friction coefficient of the optimal MAO coating decreases to ∼0.2, and the wear rate decreases by nearly 10 times. Zinc phosphate nanocrystals generated in situ in the coatings release Zn2+ during corrosion attack to cover the vulnerable weak corrosion areas around the pores. The corrosion resistance is improved significantly, as manifested by the increase of the corrosion potential from −1.290 V to −0.811 V and the decrease of the corrosion current density from 3.172 × 10−6 A cm−2 to 4.320 × 10−10 A cm−2. The co-doped MAO coatings have better wear and corrosion resistance and are more suitable than the LY12 alloy in many engineering applications.

Thermal properties and microstructure of Al–Sn alloys

The Al–Sn alloys feature excellent wear and corrosion resistance, along with good mechanical properties. They are mostly used as bearing materials. However, the application of these alloys as phase change materials (PCMs) for thermal energy storage (TES) has recently been suggested. To assess the adequacy of these alloys in a given area, a detailed evaluation of their thermal properties is required. In the present study, Al–Sn alloys with 11.7, 22.4, 32.8, 41.1, and 53.4 at.% Sn were produced by melting of pure metals. The melt was continuously stirred to avoid segregation, after which casting was carried out in a stainless steel mold. The obtained ingots had a homogeneous microstructure without the appearance of cracks and pores. The thermal diffusivities of the solid Al–Sn alloys in the temperature interval 25–150 °C were measured using the light flash method. The densities at room temperature were measured by the Archimedes method, and the specific heat capacities at different temperatures were calculated using the calculation of phase diagrams (CALPHAD) method. Then the thermal conductivities for studied Al–Sn alloys were obtained by the specific conversion equation. The phase transition temperatures and related heat effects were studied using differential scanning calorimetry (DSC). Variations of thermal conductivity with composition and temperature were determined as well as variation of latent heat of fusion with alloy composition. Moreover, the microstructures and phase compositions of the alloys were examined using scanning electron microscopy (SEM) combined with energy dispersive spectrometry (EDS). The present research results provide important information on the thermal properties and microstructure of the Al–Sn alloys for designing new PCM for thermal energy storage.

Exploring the role of Fe in the wear and corrosion resistance of Ti-based alloys produced with conventional powder metallurgy

In this study, the Ti-6Al-XFe alloy was produced by conventional powder metallurgy at varying Fe contents (3.5, 7.0, 10.5, 14.0, 17.5, and 21.0 wt%) to investigate its potential as a substitute for Nb and V. The primary aim was to assess the impact of Fe content on the mechanical, tribological, and electrochemical properties of the alloys, focusing on their suitability for biomedical implants. XRD and SEM analyses revealed a decrease in the α-Ti phase and an increase in the β-Ti and FeTi phases with higher Fe content. The lowest porosity (0.8 %) and highest hardness (348.4 Hv0.2) were observed in the Ti-6Al-17.5Fe alloy. Tensile and flexural strengths peaked at 238.3 MPa and 680 MPa, respectively, in the 17.5Fe alloy. The Ti-6Al-14.0Fe alloy showed the smallest change in specific wear rate (0.274 × 10−6 mm3/N·m) under dry conditions, while the Ti-6Al-7.0Fe alloy had the smallest change (0.565 × 10−6 mm3/N·m) under wet conditions. The 7.0Fe alloy demonstrated the highest corrosion resistance, with the lowest Icorr (1.02 × 10−8 mm3/N·m) and corrosion rate (14.02 × 10−3 mpy), and the highest charge transfer resistance in EIS analysis.

Influence of Equal Channel Angular Pressing Processing on the Microstructure, Hardness and Corrosion Resistance of Al-Si Alloy

In this study, the impact of heat treatment and Equal Channel Angular Pressing (ECAP) processing routes on refining the microstructure, hardness, and corrosion resistance of Al-7.5% S alloy in a 3.5% NaCl solution was examined. The alloy underwent T5 and T6 heat treatments, followed by ECAP processing via routes A and Bc in a mold with a channel angle of 120° at room temperature. The results indicate that dendritic α-Al grains transformed to globular and fiber shapes after processing routes Bc and A, respectively. Both processing routes fragmented coarse and brittle Si particles into smaller sizes in the eutectic phase. The use of a combination of heat treatment and the Equal Channel Angular Pressing (ECAP) process significantly improved the hardness and corrosion resistance of the samples. The hardness of the heat-treated samples increased considerably from 68 to 116 and 129 HV after three and four passes, respectively. Reducing the area ratio between the noble silicon particles and the less noble eutectic aluminum phase greatly enhances the resistance of alloy to pitting corrosion.

Multifunctional zinc-nickel alloy enabling high-performance aqueous zinc ion batteries

Aqueous zinc ion batteries are considered to be the new type of secondary batteries that have the potential to replace lithium-ion batteries as the most widely used in the future due to their green environment, high specific capacity and abundant zinc resources. However, due to the contact between the zinc anode and electrolyte, the generation of by-products and corrosion phenomena are not completely avoided, which can easily lead to problems such as short cycle life and poor electrochemical performance of the battery. In this study, uniform zinc-nickel alloy (ZnNi) was prepared by melting method. The element nickel has excellent corrosion resistance and is widely used to improve the corrosion resistance of metal alloys, so the introduction of nickel effectively enhances the corrosion resistance of ZnNi alloys. In addition, metallic nickel shows strong attraction to Zn2+, which can promote the uniform distribution and deposition of Zn2+ and inhibit the dendrites growth to prolong the battery life. Notably, the ZnNi-assembled symmetric cell exhibited excellent cycling performance compared with the Zn//Zn cell (100 h), with a cycle life of up to 1000 h at 2 mA cm−2. In addition, the capacity retention rate of the ZnNi//MnO2 full cell was still as high as 90.6 % after 1000 cycles. The preparation of the ZnNi alloy anode may provide a new idea for future alloying strategies.

In-situ incorporation of polydopamine surface modified bioactive glass nanoparticles into a plasma electrolytic oxidation coating on biodegradable AZ31 Mg alloy: A study of bioactivity and corrosion performance

Magnesium alloys are promising candidates for next-generation biodegradable biomaterials. However, their poor corrosion resistance has limited their medical applications. In this study, to improve the bioactivity performance and control the degradation rate of an AZ31 Mg alloy, anodic oxide coatings containing bioactive glass (BG) were created on the alloy using plasma electrolytic oxidation (PEO). First, BG nanoparticles were synthesized through the sol-gel method and surface-modified with polydopamine (BG/PDA). These nanoparticles were then dispersed in an alkaline phosphate electrolyte and incorporated into the coatings grown using unipolar and bipolar waveforms. According to EDS results, incorporation of BG/PDA nanoparticles was higher when the bipolar waveform was applied. Electrochemical impedance spectroscopy revealed that the coatings significantly enhanced the corrosion resistance of the AZ31 Mg alloy, with the BG/PDA nanoparticle-containing coatings demonstrating the lowest degradation rate during long-term immersion. These coatings achieved the highest faradic resistance of ∼ 12 kΩ.cm² after 28 days of immersion. The incorporation of BG and BG/PDA nanoparticles enhanced the bioactivity performance of the coatings, facilitating hydroxyapatite formation on the coating surface. Based on the results, the newly developed BG-coated alloy shows promising potential for biomedical applications.

Effect of High Deformation without Preheating on Microstructure and Corrosion of Pure Mg

In this study, the relationship between the extrusion ratio and the corrosion resistance of pure Mg deformed using extrusion with an oscillating die (KoBo) without preheating of the initial billet was investigated. The materials investigated in this study were extruded at high deformation ratios, R1 5:1, R2 7:1, and R3 10:1, resulting in significant grain refinement from the very coarse grains formed in the initial billet to a few µm in the KoBo-extruded samples at room temperature, which is not typical for hexagonal structures. Our research clearly shows that KoBo extrusion improves the corrosion performance of pure Mg, but there is no straightforward dependence between the extrusion ratios and corrosion resistance improvement. Although it was expected that the smallest grain size should provide the highest corrosion resistance, the dislocation density accumulated in the grain interiors during deformation at the highest extrusion ratio, R3 10:1, supports dissolution reactions. This, in turn, provides the answers for the greater grain size observed after deformation at R2 7:1, where dynamic recovery prevailed over dynamic recrystallization. This situation led to the annihilation of dislocation, leading to better corrosion resistance of the respective alloy. Therefore, the alloy with the greatest grain size has the best corrosion resistance.

Effects of heat treatment on the microstructure and corrosion behavior of manganese aluminum bronzes

Abstract Due to a much lower nickel content, manganese aluminum bronzes (MAB) are a cost-effective alternative to nickel aluminum bronzes (NAB). When the material is processed, different microstructures are observable in the material which have an impact on the corrosion resistance of MAB alloys. MAB samples were annealed at 900 °C and quenched in water. After that, annealing treatments at 600, 500, 400 and 300 °C for up to 24 h were performed and the samples were again quenched in water. Metallographic sections were prepared from all samples and potentiostatic corrosion tests at different potentials were performed in synthetic seawater. It was found that the sample annealed at 900 °C and quenched in water as well as those samples which underwent a second annealing treatment at low temperatures for shorter times exhibited a greater corrosion tendency than those undergoing a second annealing treatment at higher temperatures. X-ray diffraction measurements revealed that phase transformations and changes in grain size occurred during the annealing treatments. The increase in corrosion resistance as a result of annealing at higher temperatures is probably due to the strong intergrowth of the phases that are formed.

Mechanism of alteration in passivity of additively manufactured Ni-Fe-Cr Alloy 718 caused by minor carbon variation

Unlike conventional alloys, where carbon content typically promotes carbide compound formation and reduces localized corrosion resistance, the impact of carbon in additively manufactured materials remains largely unexplored due to rapid cooling rates inhibiting carbide formation. This study addresses the novel question of whether reducing carbon content benefits corrosion performance and its underlying mechanisms in Ni-Fe-Cr-based alloy 718. Employing high-resolution techniques and microcapillary electrochemical methods, it was revealed that higher carbon content increases dislocation density at cell boundaries. This increased dislocation density facilitates the enhanced ejection of nickel and iron from the protective chromium oxide layer on the surface, leading to the formation of a defective outer Ni-Fe oxide layer. This compromised layer subsequently diminishes the alloy's corrosion resistance, particularly under tensile stress conditions.

Role of scandium addition to microstructure, corrosion resistance, and mechanical properties of AA7085/ZrB2+Al2O3 composites

The effect of varying amounts of scandium (Sc) on the mechanical performance and corrosion resistance of aluminum alloy (AA7085) composites reinforced with Zirconium diboride (ZrB2) and Aluminum oxide (Al2O3) nanoparticles was investigated. The specimens were made using an in-situ process with varying amounts of Sc up to 0.5 wt%, and their microstructural behavior, corrosion, and mechanical properties were explored in detail. Phase structural analysis revealed the successful incorporation of ZrB2 and Al2O3 into the matrix through in-situ synthesis, ranging from 30 to 61.7 nm. In addition, HRTEM and XRD analysis displays the Al3Zr prominence observed with 0.1 wt% Sc content, transforming to Al3(Sc, Zr) in the 0.3 wt% Sc composite, and finally becoming Al3Sc with 0.5 wt% Sc. Corrosion analysis revealed that the 0.3 wt% Sc composite exhibited fine Al3(Sc, Zr) precipitate phases that enhanced corrosion properties. The Sc addition leads to a significant improvement in the mechanical properties of AA7085/ZrB2+Al2O3 composites. The ultimate tensile strength of 678 ± 5 MPa for 0.5 wt% Sc under the hot rolled and T6 aged condition was achieved. The optimum content of Sc in AA7085/ZrB2+Al2O3 composites has identified both corrosion and mechanical properties enhancement at 0.3 wt% and 0.5 wt%, respectively.

DIELECTRIC BARRIER DISCHARGE BASED PLASMA DEVICE FOR COLD STERILIZATION IN WATER WITH ADDITIONAL ULTRASONIC CAVITATION

A prototype of plasma sterilizer based on dielectric barrier discharge (DBD) with additional ultrasonic cavitation for cold sterilization has been developed. It provides sterilization of reusable small dental instruments, and components made from corrosion-resistant metals and alloys (stainless steel, titanium, etc.), as well as surgical instruments, implants, small drills, plastic sundries, ozone resistant medical rubbers (silicone, etc.), polymers, epoxy resins and glass. The sterilizer is well suited for dentistry and can be used in medical, sanatorium, outpatient and other medical institutions, as well as in military field surgery. The volume of the sterilization bath is 2.5 l. The ozone concentration at the output of the ozone generator is 35…52 mg/l, the ozone concentration in the sterilizer chamber is 6.5…8 mg/l, depending on the water temperature and its volume in the bath. The dependence of the increase of ozone concentration in water on time at different oxygen flow rates is monitored.

Design of ZIF-8-based PVB composite coating on AZ31B Mg alloy surface with superhydrophobic, wear, corrosion protection and durability

Magnesium (Mg) alloys are susceptible to being attacked by corrosive ions in practical application environments, which limits their widespread application as the most promising engineering material. Herein, the superhydrophobic composite coating PVB/STA/ZIF-8@SiO2 (PSZS) has been designed on the surface of Mg alloy by using a drop coating method to improve its corrosion resistance. In this study, we provide an approachable decoration strategy for hydrophobic and hierarchical modification of zeolite imidazolate frameworks (ZIF-8) with stearic acid (STA) and SiO2, and combined with polyvinyl butyral (PVB) to form a composite coating with excellent performance on the substrate surface. Notably, the PSZS composite coating exhibited superhydrophobic and the contact angle is greater than 150° after 300 cm of mechanical friction. The electrochemical testing of the PSZS composite coating indicated that it greatly protected the Mg alloys from corrosion. Moreover, the PSZS coating displayed highly effective corrosion resistance even after being immersed in 3.5 wt% NaCl aqueous solution for 7 days. Overall, the PSZS composite coating with the advantages of corrosion resistance, corrosion durability, superhydrophobic, abrasion resistance and simple preparation process broadens the horizons of Mg alloy corrosion resistance research.

Zinc-doped phosphate coatings for enhanced corrosion resistance, antibacterial properties, and biocompatibility of AZ91D Mg alloy

Magnesium and its alloys have been foreseen as promising bone-implant owing to good biocompatibility, high strength, mechanical properties, and biodegradability to replace the conventional bio-metals (Titanium, stainless-steel, Co-Cr alloys) in orthopedic applications. However, high corrosion rate and high degradation rates adversely effects like abrupt evolution of H2 gas and localized alkalization in a physiological environment limit its medical applications. To overcome these issues, phosphate-based surface coating is developed on Mg-alloy to resist the high biodegradation and corrosion rate utilizing magnesium substrate as source of magnesium ion through a single-step hydrothermal process. Controlling the fast corrosion rate and localized alkalization would reduce the antibacterial character of magnesium-based implants therefore, the simple phosphate-based coatings has been induced by doping it with zinc ions due to its physiological tolerance and excellent antibacterial efficacy. The doping of zinc ions may provide a sustained drug-free antibacterial characteristic for potential application in orthopedics. The synthesized phosphate-based coating was characterized using advanced techniques like Scanning Electron Microscopy, X-ray Diffraction, and wettability test, followed by comprehensive electrochemical testing to assess its corrosion behavior. The in vitro immersion test in simulated body fluid (SBF) indicates that deposition of phosphate and zinc doped phosphate coatings reduces the degradation rate consequently minimized the fast dissolution of Mg2+ ions and OH- in physiological environment. Additionally, cytotoxicity and biocompatibility were evaluated using Alamar Blue and live/dead assays on the MC3T3-E1 mouse osteoblast cell line. These assays demonstrated good cell viability, indicating the coatings possess favorable cytocompatibility and support cellular metabolic activity.

Analysis, Assessment, and Mitigation of Stress Corrosion Cracking in Austenitic Stainless Steels in the Oil and Gas Sector: A Review

This comprehensive review examines the phenomena of stress corrosion cracking (SCC) and chloride-induced stress corrosion cracking (Cl-SCC) in materials commonly used in the oil and gas industry, with a focus on austenitic stainless steels. The study reveals that SCC initiation can occur at temperatures as low as 20 °C, while Cl-SCC propagation rates significantly increase above 60 °C, reaching up to 0.1 mm/day in environments with high chloride concentrations. Experimental methods such as Slow Strain Rate Tests (SSRTs), Small Punch Tests (SPTs), and Constant-Load Tests (CLTs) were employed to quantify the impacts of temperature, chloride concentration, and pH on SCC susceptibility. The results highlight the critical role of these factors in determining the susceptibility of materials to SCC. The review emphasizes the importance of implementing various mitigation strategies to prevent SCC, including the use of corrosion-resistant alloys, protective coatings, cathodic protection, and corrosion inhibitors. Additionally, regular monitoring using advanced sensor technologies capable of detecting early signs of SCC is crucial for preventing the onset of SCC. The study concludes with practical recommendations for enhancing infrastructure resilience through meticulous material selection, comprehensive environmental monitoring, and proactive maintenance strategies, aimed at safeguarding operational integrity and ensuring environmental compliance. The review underscores the significance of considering the interplay between mechanical stresses and corrosive environments in the selection and application of materials in the oil and gas industry. Low pH levels and high temperatures facilitate the rapid progression of SCC, with experimental results indicating that stainless steel forms passive films with more defects under these conditions, reducing corrosion resistance. This interplay highlights the need for a comprehensive understanding of the complex interactions between materials, environments, and mechanical stresses to ensure the long-term integrity of critical infrastructure.

Enhancing corrosion resistance of AZ31B magnesium alloy substrate in 3.5 % NaCl solution with Al-Si coating prepared by cold metal transfer-based wire arc additive manufacturing

In this study, we explored an innovative approach to enhance the corrosion resistance of AZ31B magnesium alloy in 3.5 wt% NaCl solution by applying an Al-Si coating using cold metal transfer (CMT)-based wire arc additive manufacturing (WAAM) technology. The findings indicate that the Al-Si coating improved the alloy’s corrosion performance, with a more noble self-corrosion potential (- 0.97 VSCE) and lower self-corrosion current density (3.68 μA/cm2) compared to untreated AZ31B. Long-term immersion tests demonstrated that AZ31B suffered from severe localized corrosion, while Al-Si coating maintained a uniform corrosion profile. Analysis of the corrosion products showed that the Al-Si coating primarily comprised oxidized Mg and hydroxide Al, with minimal oxidized Al and Si, in contrast to the mainly metallic and hydroxide Mg on AZ31B. By reducing the electrochemical activity and enhancing the stability of corrosion products, the Al-Si coating significantly improved the corrosion resistance of AZ31B substrate. This study suggests a promising avenue for advancing the durability of magnesium alloys in corrosive environments.

Effect of two-step anodizing on corrosion and adhesion resistance of A5052 aluminum alloy

Effect of two-step anodizing on corrosion and adhesion resistance of A5052 aluminum alloy

Influence of Cu and Si on the microstructure and properties of CoCrFeNiCu1-xSix alloys

The effect of Cu and Si on the microstructure and properties of CoCrFeNiCu1-xSix alloys (x = 0, 0.2, 0.5, 0.8 and 1) was studied in this work. The results indicate that as the x value increased from 0 to 1, the phase compositions of CoCrFeNiCu1-xSix alloys evolved from FCC + Cu-rich phases to FCC + Cu-rich + NiSi-rich phases to FCC + BCC + NiSi-rich phases. Therefore, the decrease in Cu content led to the decreasing Cu-rich phase content, whereas Si addition not only favored the formation of intermetallic compounds, but also promoted the phase transition from FCC to BCC. Due to the competition between BCC phase suppressing corrosion and Cu-rich + NiSi-rich phases inducing galvanic corrosion, the corrosion resistance of CoCrFeNiCu1-xSix alloys improved with the increasing x value. The microstructure change also resulted in an improvement in hardness and wear resistance, and a deterioration in fracture toughness of CoCrFeNiCu1-xSix alloys. Moreover, the main wear mechanism evolved from adhesive wear and abrasive wear to slight abrasive wear. Comparison among five alloys indicates that Cu0.2Si0.8 alloy exhibited the excellent comprehensive properties, revealed by the corrosion current density of 4.81 × 10−8 A/cm2, the hardness value of 510.5 HV, the fracture toughness of 8.57 MPa·m1/2 and the wear rate of 0.88 mm3·N−1 · m−1.

Effect of Si on the corrosion resistance of AlZrNbTi lightweight refractory high-entropy alloys in acidic environment

This study investigated the effect of Si content on the corrosion behavior of AlZrNbTiSix (x=0, 0.3, 0.6, 1.0 at%) lightweight refractory high-entropy alloys in a 1 M HNO3 solution. The results showed a transformation in the microstructures of AlZrNbTiSix from a single BCC phase (x=0) to a BCC matrix phase with Zr5Al3 hexagonal precipitated phases (x=0.3, 0.6, 1.0). AlZrNbTiSi0.6 exhibited the best corrosion resistance, attributed to the addition of Si promoting the growth of continuous and dense oxides. Microgalvanic corrosion affected the formation of the oxide film, triggering an excessive amount of Si worsening the stability of the passive film.

In-situ N-doping to improve wear and corrosion resistance of a complex-concentrated alloy manufactured by directed energy deposition

In this study, the effects of in-situ N-doping on wear and corrosion resistance of a complex-concentrated alloy (CCA) prepared by directed energy deposition have been studied. After the addition of N, the wear resistance of the CCA is significantly improved (wear rate: decreasing from ∼2.92 × 10−4 mm3/N•m to ∼0.68 × 10−4 mm3/N•m). Attributed to grain refinement and solution strengthening brought by N-doping, the resistance of the matrix to plastic deformation and delamination is enhanced effectively. Besides, the in-situ N-doping helps to reduce corrosion sites and promote the formation of protective films to improve electrochemical corrosion resistance. Therefore, in-situ N-doping is an effective method to improve the wear resistance and corrosion resistance of superalloy.

Exploring the Kinetics of Oxygen Reduction Reaction in Relation to Pitting Corrosion Resistance in Fe-Cr Alloys

Pitting corrosion, a major concern in materials science and engineering, threatens critical metallic structures and components. Its implications reach across daily life and industries such as energy, transportation, and infrastructure, potentially causing environmental harm, economic losses, and even loss of life. This complex process is influenced by factors including material composition, local environment, and mechanical stresses.1 Once initiated, pit propagation rates are largely dependent on the magnitude of the supporting cathodic current available from the oxygen reduction reaction (ORR) occurring on the external passive film.2 In Fe-Cr alloys, the ORR occurs on this film, undergoing a mixed diffusion and kinetic-controlled process. The number of electrons involved and the corrosion rate are determined by the thermodynamically stable state of the passive film.This research studies the ORR kinetics on FeCr alloys fabricated by arc-melting, using both computational and experimental methods. The rotating disc electrode technique was employed across various Fe:Cr alloys in alkaline and neutral electrolytes. The Koutecky-Levich analysis showed a dominant four-electron ORR pathway in all tested Fe-Cr alloys, with the ORR significantly inhibited by higher proportions of Cr2O3 in the film, suggesting a correlation with high chromium content. Experimental ORR overpotentials, when combined with theoretical potential-pH (Pourbaix) diagrams, helped discern the likely characteristics of the passive films on the alloys. It was deduced that the catalytic properties of potential passive films increased in the order Cr2O3 < Fe3O4 < Fe2O3 < FeCr2O4. These findings, excellently aligned with density functional theory (DFT) modelling, underscore the role of increased chromium levels in slowing pitting progression by suppressing the ORR.In summary, this research offers distinctive insights into the correlation between the kinetics of the ORR and the resistance to localized corrosion in Fe-Cr alloys, which enhances our understanding of the underlying mechanisms of pitting corrosion. Keywords FeCr alloy, pitting corrosion, ORR, rotating disc electrode, DFT Reference [1] B. Zhang, J. Wang, B. Wu, X. W. Guo, Y. J. Wang, D. Chen, Y. C. Zhang, K. Du, E. E. Oguzie, and X. L. Ma, Nat. Commun. (2018) 9, 2559.[2] G. T. Burstein, P. C. Pistorius, and S. P. Mattin, Corros. Sci. (1993) 35, 57.