Electrochemical Corrosion Research Articles

Corrosion and conductivity damage of AgNW transparent conductive thin films under a simulated sulfur-containing atmosphere and mechanical force

Silver nanowire (AgNW) transparent conductive thin films possess high flexibility, high conductivity, high light transmittance and etc., demonstrating significant advantages in flexible electronics applications. However, in the service occasions, the coupled effect of corrosion and mechanical force easily makes the electrical conductivity of AgNW films deteriorate or even fail, which seriously affects the service reliability of AgNW films. In this work, scanning vibrating electrode technique was firstly used to confirm the existence of electrochemical corrosion on AgNW films. Furthermore, electrochemical measurements (including OCP, PDP and EIS) were carried out for researching the electrochemical corrosion process on AgNW films under different environmental factors and mechanical forces. Their surface morphologies and electrical conductivity were characterized and evaluated by the Scanning Electron Microscopy and square resistance tester respectively. Experimental results indicate that the corrosion-mechanics interaction effect aggravates the damage process of electrical conductivity of AgNW films.

The effect of oxide scale on the corrosion resistance of SUS301L stainless steel welding joints

The effect of thermal oxidates on the corrosion of SUS301L stainless steel welded joint was investigated using electrochemical corrosion test and TEM microstructure observation. Activation dissolution behavior without passive region was found in the potentiodynamic polarization curves on the welding zone and heat affected zone. The activation corrosion is related to the preferential dissolution of the NiFe layer at the interface between chromium oxide and substrate. However, the passive region in the polarization curve reappears after the unstable NiFe dissolves in the salt-frog test. The passivation behavior due to microstructure evolution beneath the thermal oxide film was discussed during the corrosion process.

Effect of discharge thermal action in ECDM on electrochemical behaviours of matrix material and its recast layer in glycol-based solution

The interaction between thermal and electrochemical corrosion in the ECDM process remains unclear. This study clarifies the effect of discharge thermal action on electrochemical corrosion. Real-time temperature curves indicate that the solution temperature in the electrochemical corrosion zone increased significantly due to discharge thermal action. The corrosion resistance of the recast layer’s passive film is superior to that of the matrix due to the enrichment of Cr2O3. As the electrolyte temperature rises, the passive film thickens but shows lower polarization resistances and poorer corrosion resistance due to a loose and weak structure. The matrix material and its recast layer dissolved uniformly, resulting in a considerably flat surface in a glycol-based solution, with enhanced levelling efficiency due to discharge thermal action.

Effect of hot-rolling process on the microstructure, mechanical and corrosion behaviors of dual-phase Co-based entropic alloys

Two compositions from dual-phase Co-based entropic alloys with high corrosion resistance were chosen, and the effect of hot-rolling process on the microstrcture, mechanical property and corrosion resistance was investigated in this work. The processing parameters were designed and optimized by CALPHAD calculations. For the case of hot-rolled alloys, fcc + hcp dual-phase structures were confirmed by different characterization techniques, including XRD, ECCI, and EBSD. After testing various mechanical properties and electrochemical corrosion behaviors at room temperature, the hot-rolled alloys exhibit an outstanding mechanical and corrosion resistance property. The hot-rolling process improves the electrochemical corrosion resistance slightly and promotes hardness as well as strength-ductility greatly. The experimental characterizations provide plentiful information about microstructure, crystallographic orientation, lattice misorientation, grain boundaries, and so on. More details for the strengthening and hardening mechanisms could be obtained from the EBSD analysis. The current work shed lights on the design of new alloy recipe as well as the synthesis of novel grade dual-phase entropic alloys with excellent combination of mechanical properties and corrosion resistance which could be applied in harsh environments.

Corrosion behavior of novel Ti6422 alloy with equiaxed structure and lamellar structure in HCl solution

This study systematically investigated the electrochemical corrosion and static immersion corrosion behavior of the novel Ti6422 (Ti-6Al-4V-2Mo-2Fe) alloy with equiaxed (EM) and lamellar structure (LM) in HCl solution. The differences in corrosion performance between EM and LM samples were analyzed based on the characteristics of the passive film and substrate microstructure. Results indicated that the LM sample contained higher contents of TiO₂, Al₂O₃, and MoO₃ with higher stability compared with the EM sample, and the thickness of passive film was approximately twice that of the EM sample. Additionally, the donor density of LM sample was lower than EM sample. These findings indicate that the passive film on LM samples is thicker, with fewer defects and higher density. Electrochemical corrosion results revealed that the corrosion current of LM samples was lower and the polarization resistance was higher than these of EM samples, both suggesting superior corrosion resistance of LM samples. Immersion corrosion further confirmed that the LM sample had a lower corrosion rate. The enhanced corrosion resistance in LM samples was primarily due to higher content of corrosion-resistant β phase. Conversely, the numerous micro-galvanic cells between αs precipitates and adjacent β phase in EM samples weakened the corrosion resistance. Overall, these results demonstrated that regulating microstructure through heat treatment is an effective strategy for improving corrosion resistance of titanium alloys.

Mitigating anodic corrosion in aluminum–air batteries: Effects of alkali metal cation size on electrochemical performance

Anodic corrosion limits the performance of aluminum–air batteries (AABs) by reducing discharge capacity and hindering energy density. This study proposes a strategy to mitigate anodic corrosion by controlling electrolyte cations to decrease the activity of free water molecules in the anodic corrosion process. Alkali metal cations (Na+, K+, Rb+) are introduced into a 1mol dm−3 KOH solution to examine their solvation properties and effects on free water molecule activity. Results show that larger cations (Na+ < K+ < Rb+) enhance anode discharge capacity by promoting more stable discharge reactions. Raman spectroscopy reveals that as cation radius increases, free water molecule activity decreases due to increased hydration. X-ray photoelectron spectroscopy analysis shows that larger cations favor the formation of corrosion-resistant aluminum compounds like Al2O3 and Al(OH)3, due to their higher concentration in the electric double layer, inhibiting anodic corrosion. This study highlights the critical role of cation solvation in enhancing electrochemical performance and corrosion resistance of AAB anodes.

Uncovering the electrochemical stability and corrosion reaction pathway of Mg (0001) surface: Insight from first-principles calculation

An understanding of the anomalously enhanced hydrogen evolution reaction (HER) of magnesium (Mg) under anodic polarisation in aqueous corrosion is paramount for a predictive theory of its corrosion and metal electrocatalysis. Previous theoretical and experimental studies have proposed that sub-surface hydride phases play a role in this behaviour but the underlying atomic mechanisms remain unclear. By constructing theoretical surface Pourbaix diagrams, based on density functional theory (DFT) calculations, we have identified the atomic structure of a sub-surface hydride phase on the Mg (0001) surface that remains electrochemically stable under significant anodic overpotentials across a wide pH range. Specifically, this stability persists up to 0.38 VSHE under mildly alkaline conditions (e.g., pH = 8), thus providing thermodynamic support for the proposed hydride-enhanced HER under anodic conditions. Reaction barrier analysis establishes that the proposed sub-surface hydride phase could promote anodic HER via a Heyrovsky pathway, based on hydrogen outward diffusion, with an energy barrier of 1.54 eV as the rate-limiting step, showing an anodic characteristic and significantly favouring external anodic polarisation. Furthermore, we have established that the surface adsorption condition, contingent on both the pH and potential, significantly influences the mechanism and kinetics of the initial corrosion of Mg.

Multi-physics coupled simulation and experimental investigation of alternating stray current corrosion of buried gas pipeline adjacent to rail transit system

As the gradual emergence of alternating current (AC) electrified rail transit system in urban areas, buried gas pipeline adjacent to the system will be seriously corroded by induced alternating stray current. These buried gas pipelines are at serious risk of electrochemical corrosion, which leads to safety and environmental threaten. In order to study the distribution of alternating stray current corrosion on pipeline surface on a larger spatial scale, this paper conducted numerical simulation and experimental validation of alternating stray current corrosion of buried gas pipeline. In the numerical simulation model, coupling between different physical fields are realized through the relationship between current density of pipe-to-soil interface, electrolyte, and electrodes. Proposed numerical method based on coupled multi-physics in this paper are in good agreement with experimental results under different influencing factors. A novel evaluation index was proposed to assess the corrosion risk within different zones on the pipeline surface. Results show that corrosion distribution is greatly influenced by spatial interaction between buried pipeline and rail transit system including crossing angle and parallel distance. Besides, alternating stray current corrosion on buried gas pipeline are proved to be both affected by dynamic characteristics due to AC fluctuation and operation mode of locomotive.

Microstructure and corrosion properties of CrMnFeCoNi high entropy alloy coating by temperature field-assisted laser cladding

The CrMnFeCoNi high entropy alloy coatings were prepared on the surface of Q345 steel using a temperature field-assisted laser cladding process, and the effects of the applied temperature field on the cladding coatings were studied. The microstructures and corrosion morphologies of the coatings were observed, and the elemental distribution, hardness, effective elastic modulus, electrochemical corrosion performance, and corrosion products of different coatings were analyzed. The results show that the porosity of the HEA coatings prepared with a temperature field is reduced to below 50 % of the initial level. The microstructure of the coating changed, with the nanoindentation hardness of the coating increasing by up to 0.55 GPa, enhancing the mechanical properties. Among all the coatings, the coating prepared at 250 °C temperature field exhibited the best corrosion resistance, with corrosion potential and current density of −0.27 V and 0.15 μA/cm2, respectively, improving the corrosion potential by 0.1 V and reducing the current density by 1.08 μA/cm2 compared to the sample prepared at room temperature. After incorporating the temperature field, the stability of the passive film on the coating during corrosion improved, and the nucleation rate of pitting decreased. Therefore, incorporating an appropriate temperature field during laser cladding can effectively enhance the overall performance of the CrMnFeCoNi HEA coating.

Mitigating adverse effects of Cu-containing intrauterine devices using a highly biocompatible Cu[sbnd]5Fe alloy

Copper-containing intrauterine devices (Cu-IUD) are adopted by worldwide women for contraception with the advantages of long-term effectiveness, reversibility and affordability. However, adverse effects occur in the initial implantation stage of Cu-IUD in uterine because of the burst release of Cu2+. To minimize the burst release, in this study, we designed a series of Cu–Fe alloys with 0.5 wt%, 1 wt% and 5 wt% Fe and also further produced ultrafine grained (UFG) structure for these alloys via equal-channel angular pressing. The microstructures and properties of the coarse grained (CG) Cu, CG Cu–Fe alloys and UFG Cu–Fe alloys were systematically investigated, including grain structure and phase compositions, metallic ions release behavior, electrochemical corrosion performance, and in vitro cytotoxicity. With careful comparison and selection, we chose the CG Cu–5Fe and UFG Cu–5Fe for in vivo tests using rat model, including tissue biocompatibility, in vivo corrosion behavior, and contraceptive effectiveness. Moreover, the corrosion mechanism of the Cu–5Fe alloy and its improved biocompatibility was discussed. Both CG and UFG Cu–5Fe alloys exhibited dramatic suppression of Cu2+ release in simulated uterine fluid for the long-term immersion process. The in vivo tissue compatibility was significantly improved with both CG and UFG Cu–5Fe alloys implanted in the rats’ uterine while the high contraceptive efficacy was well maintained. Due to the superior biocompatibility, the CG and UFG Cu–5Fe alloys can be the promising candidate material for Cu-IUD. Statement of significanceA highly biocompatible Cu–Fe alloy was designed and fabricated for Cu-containing intrauterine devices (Cu-IUD). With 5 wt% Fe, the burst release of Cu2+ is inhibited due to the formed galvanic cell of Cu and Fe, resulting in earlier release of Fe3+. As Fe is the most abundant essential trace element of human body, it can mitigate the toxic effects of Cu2+, thus significantly improving both in vitro cell compatibility and in vivo tissue compatibility. More importantly, the Cu–5Fe alloy exhibits 100 % contraceptive efficiency as the CG Cu, but with greatly reduced adverse effects to the uterus tissues. An advanced Cu-IUD can be developed using Cu–Fe alloys.

Impact of sulfate to chloride ratio on titanium aluminide coating's high temperature corrosion performance in settings mimicking waste incineration

One major problem with waste incineration is the corrosion of superheater tubes at high temperatures. The presence of sulfate and chloride in this setting poses a severe risk to the boiler's service life. In this work, pack aluminizing was used to create titanium aluminide coating, which was then subjected to five distinct NaCl+Na2SO4 salt combination proportions for 168 h at 600 °C. The outcomes demonstrated that in the presence of solid Na2SO4 deposits, titanium aluminide coating displayed remarkably low corrosion rates. Adding 1/6 NaCl significantly accelerated the rate of corrosion. The electrochemical corrosion resulting from eutectization between NaCl and Na2SO4 was again considerably amplified when the NaCl level was raised to 1/4.

Microstructure and properties of a HIP manufactured B4Cp reinforced highly alloyed Al-Zn-Mg-Cu-Zr aluminum matrix composite

In this study, an aluminum matrix composite with good mechanical property and excellent corrosion resistance, B4C particles (B4Cp) reinforced highly alloyed Al-Zn-Mg-Cu-Zr matrix composite, was successfully fabricated through ball-milling, cold isostatic pressing, vacuum degassing, hot isostatic pressing (HIP), homogenization, hot extrusion, solution treatment, and aging treatment. It was found that the B4C/MgAl2O4/Al was the dominant interface structure, which was coherent and enhanced the bonding between the particles and the matrix considerably, while the B4C/Al2O3/Al was the minor interface structure. The grain boundary was very clean in both T4 and T6 aging states, without aging precipitates and O element segregation. In T4 aging state, the composite exhibited superior properties, with the mass density of 2.84 g·cm-3, the elastic modulus of 119.18 GPa, the yield strength of 576.08 MPa, the ultimate tensile strength of 655.27 MPa, the tensile elongation of 1.48%, and the very low electrochemical corrosion current density of 4.4581×10-8 A·cm-2 in 3.5 wt.% NaCl water solution. The MgAl2O4 and BO3-rich interface phases, the strengthening mechanisms and the anti-corrosion mechanisms of the composite were discussed in detail.

Surface etching-reconstruction effectively suppresses icing in jet fuel pipeline

In extreme weather, icing in aircraft fuel systems poses a serious threat to flight safety. Moisture in fuel can freeze inside pipes at high altitudes, risking engine operation and performance. This study explores the use of superhydrophobic technology to prevent icing. Aerospace-grade aluminum alloy (6061) was chemically etched with FeCl3 to create rough micro and nano structures. The surface was then modified with low surface energy perfluoropolyether (PFPE) to form a superhydrophobic coating. Tests showed that a 1.0 wt% PFPE coating exhibited excellent superhydrophobic and oleophobic properties, with a water contact angle of 154.79° and a jet fuel (RP-3) contact angle of 150.13°. X-ray photoelectron spectroscopy (XPS) and Fourier transform infrared spectroscopy (FT-IR) analyses confirmed the presence of C-F3 and C-F2 bonds. The electrochemical corrosion resistance test shows that the coating has good corrosion resistance and the corrosion resistance rate is 0.61 mm/a. The coating also demonstrated outstanding waterproof performance, resisting grease and stain adhesion under jet fuel immersion. This approach offers a promising solution for surface protection and functional material design. Future research will further optimize its performance and explore broader applications.

Corrosion failure analysis of interfacial bond performance in circular seawater sea-sand concrete encased weathering steel structures

This paper investigated the bond-slip behavior of circular seawater sea-sand concrete encased weathering steel (CSSCEWS) structures after chloride-induced corrosion. Electrochemical corrosion tests and push-out tests were conducted on fifteen designed CSSCEWS specimens. The results revealed that the corrosion ratio and steel section type distinctly influenced the interfacial bond performance. Both the ultimate and residual bond strengths decreased with the increase of the corrosion ratio, and the decline rate slowed down gradually. Compared to the uncorroded specimens, the average damage ratio of the ultimate strength of the specimens with a corrosion ratio of 8% is 25.9%, while the average damage ratio of the residual strength is 49.1%. The bond toughness continuously decreased with prolonged corrosion, while the bond stiffness and energy dissipation index first increased and then decreased. Additionally, formulas for calculating the corroded bond strengths of CSSCEWS specimens were proposed. Considering the strength damage due to corrosion and the stiffness damage due to slip, a three-stage bond-slip constitutive model was proposed. Finally, this model was applied to the nonlinear spring elements in finite element modeling to effectively simulate the interfacial bond behavior during the loading of corroded CSSCEWS specimens.

A robust and high-throughput superhydrophobic-superoleophilic Zn/Ni composite coating prepared on stainless steel mesh for oil-water separation

Frequent oil spills and the discharge of oily wastewater have adverse effects on the environment and ecosystems. Against the backdrop of escalating environmental concerns, developing high-performing and eco-friendly oil-water separation techniques is crucial. In this study, we successfully created a PFOTS-Zn/Ni superhydrophobic-superoleophilic coating, abbreviated as PZNM, by electroplating Zn2+ and Ni2+ on the stainless steel mesh, followed by modification with perfluorooctyltriethoxysilane-ethanol solution. The wettability test results show that the water contact angle (WCA) reaches 161.3°, with a water sliding angle (WSA) of 2°, and the oil contact angle (OCA) is approximately 0°. Subsequently, the PZNM samples were subjected to tests including blade scratching combined with sandpaper abrasion, tape peeling, bending tests, submerging in acidic and alkaline solutions, high-temperature gradient exposure, and electrochemical corrosion to verify their outstanding long-term durability. Most importantly, it can be shaped into a practical continuous oil-water separation device. In the oil-water separation test, it was found that the superhydrophobic-superoleophilic PZNM achieves highly efficient oil-water separation, with a water/n-hexadecane separation efficiency of up to 93.2 % and a water-chloroform separation flux of 6450±30 L·m−2·h−1. The preparation process is straightforward and green, providing an economical solution. This design holds considerable prospects for applications in the domain of oil-water separation.

Achieving Dendrite-Free Zinc Deposition by Large-Size Anion-Reinforced Solvated Structures for Highly Reversible Zinc Anode

The electrochemical instability of zinc anode caused by surface side reactions and irregular zinc deposition severely hinders the practical application of aqueous zinc ion batteries (AZIBs). In this work, diethylenetriaminepentaacetic acid, pentasodium salt (DTPA) was used as a novel electrolyte additive to modulate the electrochemical stability of Zn anode. The DTPA anion can strongly coordinate with Zn2+, thus enabling the formation of a unique large-size anion-enhanced solvation structure of electrolyte. In this, not only the generation of by-products on Zn anode can be effectively inhibited, but more importantly, the deposition kinetics of Zn2+ can be well regulated to induce even and stable zinc deposition. In addition, DTPA is more prone to chemically adsorbed on the surface of Zn anode than H2O, contributing to the resistance of electrochemical corrosion. Synergistically, the Zn anode demonstrates excellent cycling stability (3850 h at 1 mA cm−2, 1 mAh cm−2, and 500 h at 10 mA cm−2, 10 mAh cm−2), enhanced coulombic efficiency (99.83% upon 3500 cycles at 5 mA cm−2, 1 mAh cm−2), and high reversibility of 1050 h even at a stringent discharge depth of 80%. Particularly, the full cell assembled with NaV3O8·1.5H2O (NaVO) cathode can also operate stably for 1800 cycles at 2 A g−1 with a high capacity retain of 90.8%. This work may pave a new route to achieve high-performance AZIBs by regulating the deposition process of Zn2+ based on large-size anion-enhanced solvation structure of electrolyte.

Molecular dynamics mechanism of incorporating ZnO with varying particle sizes into ECTFE coatings and its impact on corrosion resistance

A composite coating of zinc oxide/chlorotrifluoroethylene copolymer (ZnO/ECTFE) was prepared on the surface of carbon steel via electrostatic spraying and heat treatment at 260 ℃. The influence of ZnO particle size variations on the anticorrosive properties of ECTFE coating was investigated by characterizing the microstructure, adhesion, hydrophilic/hydrophobic properties, electrochemical corrosion performance, as well as the dynamics simulation analysis on water molecule and chloride ions diffusion in the coating. The results show that the ECTFE coating incorporated with 100nm ZnO has the highest surface roughness (Roughness coefficient Ra = 30.6nm), the most robust adhesion (Bonding pull-out strength = 5.22MPa), and the lowest corrosion current density after a 90-day immersion (Icorr,90d = 4.05 × 10⁻⁸ A∙cm⁻²). These improvements represent an increase of 81.67% and 59.9% compared to the pure copolymer coating (Icorr,90d = 2.21 × 10⁻⁷ A∙cm⁻²) and the coating incorporated with 200nm ZnO (Icorr,90d = 1.01 × 10⁻⁷ A∙cm⁻²), respectively. This phenomenon can be attributed to the addition of small-sized ZnO, which enhances the density of the coating, induces a hydrophobic transition on its surface, strengthens the double electric layer effect, thereby improving its resistance against water molecule and chloride ions diffusion and ultimately enhances the corrosion resistance.

Electrochemical corrosion behavior and passive film properties of Fe2Ni2CrV0.5Nbx (x=0.2, 0.4, 0.6, 0.8) eutectic high-entropy alloy coating prepared by laser cladding

The phase composition, microstructure morphology, and corrosion behavior of Fe2Ni2CrV0.5Nbx (x=0.2, 0.4, 0.6, 0.8) eutectic high-entropy alloy (EHEA) coatings produced via laser cladding were investigated. The research delved into discerning the phase structures and microstructural variations of the EHEA coatings concerning differing Nb compositions. The findings highlighted a direct correlation between Nb content and the volume fraction of the eutectic structure, specifically the FCC/Laves phases. Electrochemical evaluations, including diverse tests such as potentiodynamic polarization, electrochemical impedance spectroscopy, cyclic polarization, Mott-Schottky measurements, and X-ray photoelectron spectroscopy, revealed distinct corrosion behaviors among the EHEA variants. Notably, the Fe2Ni2CrV0.5Nb0.2 coating exhibited relatively superior corrosion resistance compared with Fe2Ni2CrV0.5Nbx (x=0.4,0.6,0.8) coatings, attributed to its lower corrosion current density (Icorr) and the formation of a thicker passive film with prolonged passivation duration. Conversely, the Fe2Ni2CrV0.5Nb0.8 coating, characterized by increased eutectic structures and grain boundary density, yielded a thicker yet non-uniform passive film with higher vacancy defects. This comprehensive exploration into the corrosion behavior and passive film properties of these EHEA coatings provides a reference for designing materials that hold promising implications for future corrosion-resistant material development in industrial parts repair applications.

Step-by-Step Tuning of Tribological and Anticorrosion Performance of Zinc Phosphate Conversion Coatings through Effective Integration of Spherical P-Doped MoS2 Nanoparticles.

Surface coatings with enhanced mechanical stability, improved tribological performance, and superior anticorrosion performance find immense application in various industrial sectors. Herein, we report the development of multifunctional composite zinc phosphate coatings by the effective integration of a structurally and morphologically tuned P-doped MoS2 nanoparticle additive (3P-MoS2) into the zinc phosphate matrix to offer attractive characteristics suitable for industrial applications. The integration of spherical nanoparticles as additive leads to the formation of homogeneous and compact coatings with a densely packed crystalline microstructure having enhanced microhardness, distinctive leaf-like morphology, and comparatively smooth topographical features. The attractive lubricity of the additive (3P-MoS2), coupled with its spherical morphology, facilitates a transition from sliding to rolling friction and contributes significantly toward the performance enhancement of the tuned composition of the composite zinc phosphate coating (0.3-PMS). Thus, the tuned 0.3-PMS coating delivers the lowest specific wear rate (1.334 × 10-5 mm3/Nm) and coefficient of friction (0.114) that significantly outperform bare-zinc phosphate coating. Further, the electrochemical corrosion study results indicate the improvement in corrosion resistance behavior of the composite zinc phosphate coatings with reduced corrosion current density (icorr) and charge transfer resistance (Rct) values, as compared to the bare-zinc phosphate coating. The effect of passivation in conjunction with the barrier protection characteristics of the composite coatings induced by the optimal composition of the integrated additive nanoparticles (3P-MoS2) can efficiently prevent the infiltration of corrosive ions and thereby significantly reduce the rate of corrosion.

Investigation of the microstructural characteristics of laser-cladded Ti6Al4V titanium alloy and its corrosion behavior in simulated body fluid

Laser cladding technology has a wide range of potential industrial applications in the surface strengthening, repair and reuse of orthopedic implants. By employing this technique to conduct same-material surface restoration and enhancement on titanium alloys, it demonstrates significant developmental potential. However, the microstructure of laser additively manufactured titanium alloy differs significantly from that of traditional titanium alloys, which affects its corrosion resistance in human body fluids. To compare the corrosion resistance differences between the cladding layer and the substrate, this study investigates the microstructure of multi-pass laser cladding Ti6Al4V (TC4) titanium alloy and analyzes the corrosion morphology and corrosion products of the cladding layer in simulated body fluids (SBF). By comparing the electrochemical corrosion behavior of laser cladding with that of traditionally manufactured TC4, this research reveals the differences in corrosion resistance between the two titanium alloys. The research demonstrates that the microstructure of cladding primarily consists of prior-β grains and continuous grain boundary α phase, along with a complex basketweave structure composed of fine acicular α phase and lamellar α phase. Additionally, due to the complex thermal cycling process, the acicular α' colonies within the prior-β grains. These features enhance the cladding layer’s resistance to plastic deformation and increase microhardness, though with some uneven distribution. Interestingly, the TC4 cladding layer forms a porous passivation layer after corrosion, primarily composed of a TiO2 passivation film and deposits of hydroxyapatite and other phosphates. Due to the lower β-phase content, finer grains with higher energy states, and a greater proportion of high-angle grain boundaries (HAGBs) in the cladding layer, it exhibits higher electrochemical activity. As a result of these microstructural differences, the corrosion resistance of the TC4 cladding layer in SBF is inferior to that of TC4 manufactured using traditional techniques.