High Corrosion Resistance Research Articles

New insight on the formation of uneven oxide scales on AFA steel in supercritical CO2: Roles of recrystallization degree on the high temperature corrosion resistance

Uneven oxide scale is a common phenomenon in high-temperature corrosion, but the formation mechanism has not been fully uncovered. A new alumina-forming austenitic (AFA) stainless steel with superior corrosion resistance in 650°C/15MPa SC-CO2, has been systematically investigated. It is demonstrated that the uneven oxide was formed by the significant impact of the recrystallization behavior of AFA steel on its microstructural evolution and subsequent corrosion behavior. Compared with the thin oxide scale, the thick oxide scale was caused by the relatively higher density of dislocations and grain boundaries of matrix resulting from delayed recrystallization, which facilitated the rapid outward diffusion of ions.

Lattice distortion effects in high-entropy oxides: Boosting PMS activation for effective and durable pollutant degradation

Advanced Oxidation Processes (AOPs) are highly effective for pollutant removal, but achieving an optimal combination of high reactivity, corrosion resistance, and long-term stability remains challenging. In this study, we present the synthesis of a distinctive hollow prismatic high-entropy oxide, (Co0.2Ni0.2Mn0.2Cu0.2Zn0.2)3O4, derived from complex coordination polymers. This high-entropy oxide exhibits significant lattice distortion effects compared to conventional (Co1/3Ni1/3Mn1/3)3O4 and Co3O4. These distortions reduce the metal-O bond length, which enhances cyclic stability during peroxymonosulfate (PMS) activation for pollutant degradation. Additionally, the improved interaction between the catalyst and PMS enhances the generation of reactive oxygen species (ROS), leading to superior catalytic degradation activity. Electron paramagnetic resonance (EPR) and other analytical techniques identify ·OH, 1O2, O2−· as the primary active species in the (Co0.2Ni0.2Mn0.2Cu0.2Zn0.2)3O4/PMS system. A degradation mechanism for tetracycline (TC) is also proposed. This study introduces an innovative approach to water treatment by employing high-entropy oxides to activate PMS, demonstrating substantial potential for practical applications.

Facilitative preparation of graphene/cellulose aerogels with tunable microwave absorption properties for ultra-lightweight applications

Graphene aerogels, as a novel type of carbon-based composite material, have shown great potential in the field of wave absorption due to its characteristics of high conductivity, adjustable structure and good corrosion resistance. It is of great significance to precisely control the dielectric properties of graphene aerogel composites by effectively adjusting their microstructures through the preparing process design, ultimately leading to improve their wave-absorbing performances. In this study, two kinds of graphene/cellulose aerogel composites with three-dimensional porous structures, were successfully prepared using graphene and short staple cellulose as raw materials via the freeze-drying method based on the dissolution-regeneration strategy. A comparative analysis was conducted to examine the differences of microstructures, dielectric properties and corresponding electromagnetic wave absorption performances, which reveals that the graphene/cellulose aerogel composites with graphene nanosheets incorporated into the cellulose matrix realize superior absorbing performances. The graphene/cellulose aerogel composite with a 32 wt% graphene addition realizes effective electromagnetic wave absorbing (reflection loss less than −10 dB) in the whole X-band (8–12.4 GHz) in a relatively large thickness range (3.9–4.7 mm). The densities of the proposed aerogel are no more than 0.02 g/cm3, demonstrating great potential for excellent lightweight microwave absorbing materials. The multiscale electromagnetic wave absorption mechanism is summarized, which would provide an important reference for designing ultra-lightweight absorbing materials with perfect absorption in wideband.

Enhanced thermal stability and corrosion resistance of novel high-entropy spinels in cryolite-alumina molten salt applications

The development of spinel oxide materials with high thermal stability and corrosion resistance is essential for thermochemical reactions, particularly in aluminum electrolysis. This study presents the structural design of a family of high-entropy spinels (HESs) with a stable cubic spinel structure (<i>Fd3‾m</i>), specifically formulated as (Cr5/12 Mn5/12 Fe5/12 Co3/8 Y3/8)3O4, (Y = Ni, Cu, or Zn). Our results demonstrate that these high-entropy spinels significantly outperform conventional NiFe₂O₄, exhibiting superior corrosion resistance and thermal properties. Specifically, we observe lower high-temperature weight loss (0.24 %–0.74 % at 1000 °C), reduced thermal conductivity (1.810–2.258 W m−1 K−1 at room temperature), and lower thermal expansion coefficients (8.2 - 10.7 × 10−6 K−1 from 400 °C to 800 °C), while maintaining comparable specific heat capacities (0.51–0.55 J g−1 K−1). Corrosion testing at 800 °C for 20 h in a KF3-AlF3-Al2O3 molten salt environment shows a corrosion layer thickness of less than 150 μm, with minimal corrosion product formation. These findings not only advance our understanding of material properties under extreme conditions but also pave the way for the development of next-generation materials for thermochemical applications, specifically aimed at improving the efficiency of aluminum electrolysis.

Bridging the gap between high-entropy alloys and metallic glasses: Control over disorder and mechanical properties of coatings

High-entropy alloys (HEAs) and high-entropy metallic glasses (HEMGs) represent two intensively researched classes of materials with high technological interest for applications as functional coatings with high strength, hardness, toughness, and corrosion resistance. The distinctive structural difference between single-phase crystalline solid solutions for HEAs and liquid-like disorder for HEMGs generates a seemingly insuperable contrast. In this work, we demonstrate that we can deliberately choose between crystalline or glassy properties by introducing structural disorder in HfMoNbTiZr thin films of identical composition. Using pulsed laser deposition (PLD) at different growth conditions, we reproducibly tune the structure of HfMoNbTiZr coatings from crystalline to fully amorphous. We show that the level of disorder has a profound impact on the mechanical properties of the coatings using the hardness derived from nanoindentation measurements as an example. While the hardness of polycrystalline HfMoNbTiZr layers already exceeds the single-phase bulk value, the amorphous HfMoNbTiZr is even clearly harder, demonstrating a distinctive improvement with introducing disorder. Our findings bridge the two seemingly different concepts of HEAs and HEMGs and demonstrate that structural disorder is not a given material property. Instead, disorder can serve as a useful design parameter for customizing the properties of functional coatings.

Facilitating Oriented Dense Deposition: Utilizing Crystal Plane End-Capping Reagent to Construct Dendrite-Free and Highly Corrosion-Resistant (100) Crystal Plane Zinc Anode.

Dendrite growth and corrosion issues have significantly hindered the usability of Zn anodes, which further restricts the development of aqueous zinc-ion batteries (AZIBs). In this study, a zinc-philic and hydrophobic Zn (100) crystal plane end-capping reagent (ECR) is introduced into the electrolyte to address these challenges in AZIBs. Specifically, under the mediation of 100-ECR, the electroplated Zn configures oriented dense deposition of (100) crystal plane texture, which slows down the formation of dendrites. Furthermore, owing to the high corrosion resistance of the (100) crystal plane and the hydrophobic protective interface formed by the adsorbed ECR on the electrode surface, the Zn anode demonstrates enhanced reversibility and higher Coulombic efficiency in the modified electrolyte. Consequently, superior electrochemical performance is achieved through this novel crystal plane control strategy and interface protection technology. The Zn//VO2 cells based on the modified electrolyte maintained a high-capacity retention of ≈80.6% after 1350 cycles, corresponding to a low-capacity loss rate of only 0.014% per cycle. This study underscores the importance of deposition uniformity and corrosion resistance of crystal planes over their type. And through crystal plane engineering, a high-quality (100) crystal plane is constructed, thereby expanding the range of options for viable Zn anodes.

Corrosion-mechanical destruction of bainite structures in oilfield environments

The main direction in solving the problem of increasing the reliability of field equipment, is the creation of new steels with higher resistance to corrosion-mechanical destruction. Currently, to produce oil and gas pipeline systems, low-carbon, low-alloy steels are used, in which lath carbide-free bainite is formed when quenched in water. Such a structure provides a combination of high strength and resistance to brittle fracture. However, issues of increasing corrosion resistance are still open. The purpose of this work is to identify the structural condition of low-carbon, low-alloy, pipe steels, providing a combination of high mechanical properties with increased corrosion resistance in oilfield environments. The studies were carried out on the latest generation 08KhFA, 08KhFMA and 05KhGB steels, most popular when manufacturing oil and gas pipelines. Samples for the study were cut from the pipes and quenched from the austenite region in water, which formed the structure of lath carbide-free bainite. The quenched samples were tempered at temperatures of 200, 300, 400, 500, 600, and 700°C. To identify the relationship between the morphology of bainite structures and their properties, the samples after quenching and tempering at each temperature, were subjected to metallographic analysis, X-ray diffraction analysis, mechanical tests, and corrosion resistance tests. The work shows the sequence of structure transformation, temperature ranges of phase and structural transformations, changes in mechanical properties, and corrosion resistance that occur during tempering of lath carbide-free low-carbon bainite. It is shown that tempering of lath carbide-free bainite (08KhFA, 08KhMFA and 05KhGB steels) does not affect the rate of carbon dioxide corrosion. It has been found that medium tempering forms the structural condition of carbide-free low-carbon lath bainite providing a combination of high mechanical properties and high corrosion resistance in oil field environments. For each of the steels under study, the authors give recommended heat treatment modes.

Photothermal/magnetothermal coupled polyphenylene sulfide composite membranes for ultra-efficient and continuous seawater desalination

As the population continues to expand and industrialization gathers pace, the rate at which freshwater resources are dwindling is alarming. Solar desalination technology has shown encouraging results in generating clean water. However, solar-driven interfacial evaporation technology still faces a series of major challenges, specifically manifested in its low efficiency, poor chemical stability, and the tendency for salt crystallization to accumulate on the evaporation surface during operation. In this work, we proposed a novel magneto/photo-thermal coupled evaporator based on polyphenylene sulfide (PPS) fibrous membrane, which showed excellent high temperature and corrosion resistance. This non-contact responsive interfacial evaporator exhibited outstanding photothermal and magnetothermal conversion performance properties. Under one solar illumination, the evaporation rate of this evaporator could reach 1.52 kg m−2 h−1, corresponding to an evaporation efficiency of 91.84 %. In addition, under a magnetic field power of 2 kW m−2, the evaporator could achieve a remarkable evaporation rate of 4.2 kg m−2 h−1 under one solar illumination, with an evaporation efficiency of up to 93.77 %. Moreover, it also exhibited superb salt resistance, great mechanical properties, long-term operational stability, and outstanding dye purification property. Furthermore, by integrating the thermoelectric generator with the evaporator and utilizing the waste heat from the evaporation process to generate electricity, the efficiency of energy utilization has been improved. The interfacial evaporator opens up vast prospects for efficient and rapid clean water production, demonstrating significant potential and advantages.

Hardness and Corrosion Behavior of CrMnFeCoNi Alloy Fabricated by Ball Milling and Spark Plasma Sintering.

The mechanical properties and electrochemical stability of high-entropy alloys are substantially affected by their composition distribution and crystal structure. However, the details concerning the conditions of milling and sintering for sintered alloys have rarely been reported. In this work, a series of CrMnFeCoNi alloys were fabricated by ball milling and spark plasm sintering for different periods. Their crystal structure, density, hardness, and corrosion resistance were investigated. As a result, a partial alloying of Cr, Mn, Fe, Co, and Ni was achieved by ball milling. However, Cr-rich particles, including Mn, were formed in the milled powders. The sintered alloys inherited the Cr-rich particles to form Cr-rich zones. The formation and change of chromium carbide were also confirmed in sintered alloys. Extended milling or sintering to 12 h achieved high hardness and corrosion resistance for the sintered alloys. The Cr-rich zones showed high hardness and Kelvin potential, which affect both the hardness and the corrosion resistance.

Use of Pulsed Potentials for Electropolishing TA6V Parts Elaborated By Additive Manufacturing in Deep Eutectic Solvent

The Ti-6Al-4V alloy's high mechanical properties, low density, excellent biocompatibility, and corrosion resistance make it an ideal material for sectors such as aeronautics, astronautics and medical technology. The demand for increasingly complex part designs is speeding up the development of Additive Manufacturing (AM) technology, enabling the creation of shapes unachievable with traditional machining. However, the parts manufactured present significant surface roughness, thus reducing resistance to corrosion and mechanical stress. To mitigate these risks, homogeneous polishing of the entire shape is required. Electrochemical polishing is an all-round part treatment technique ideal for addressing AM challenges. Deep Eutectic Solvent (DES) electrolytes are well-suited for this application. The aim of this study is to develop electropolishing of Ti-6Al-4V parts in a DES solvent of ethylene glycol and choline chloride. The challenges posed by viscous layer thickness problems, as well as two methods to overcome them, are described, including agitation control and pulsed potentials.

Physics-Informed Neural ODE with Heterogeneous Control Inputs (PINOHI) for Quality Prediction of Composite Adhesive Joints

Composite materials have long been used in various industries due to their superior properties such as high strength, lightweight and corrosive resistance. Bonded composite joints are finding increasing applications as they provide extensive structural benefits and design flexibility. On the other hand, the failure mechanism of composite adhesive joints is not fully understood. A model that bridges manufacturing parameters and final quality measures is highly desired for the design and optimization of the composite adhesive joints manufacturing process. In this study, a novel framework of physics-informed Neural Ordinary Differential Equation (ODE) with heterogeneous control input (PINOHI) is proposed, which links the heterogeneous manufacturing parameters to the final bonding quality of composite joints. The proposed model structure is heavily motivated by engineering knowledge, by incorporating a calibrated mathematical physics model into the Neural ODE framework, which can significantly reduce the number of data samples required from costly experiments while maintaining high prediction accuracy. The proposed PINOHI model is implemented in the quality prediction of composite adhesive joints bonding problem. A set of experiments and associated data analytics are conducted to demonstrate the superior property of the PINOHI model by using both the leave-one-batch-out cross-validation and sensitivity analysis.

Experimental Research on the Influence of Repeated Overheating on the Thermal Diffusivity of the Inconel 718 Alloy

The Inconel 718 superalloy, a precipitation-hardenable material, is of particular interest for applications involving components operating under extreme conditions due to its excellent mechanical properties, high corrosion resistance at temperatures up to 700 °C, and good workability. At high temperatures, thermal transfer processes are crucial for temperature distribution across the component’s section, structural transformations, and variations in the alloy’s properties. The history of accidental overheating events is critical for the microstructure and properties of the alloy. Studies on thermal transfer in the Inconel 718 alloy available in the literature typically focus on the alloy in its as-delivered state. The experimental research presented in this paper examines the influence of repeated overheating history on the thermal diffusivity of the alloy.

The effect of temperature during plasma nitriding on the properties of IN718 additively manufactured by laser beam powder bed fusion

The IN718 superalloy has become a strategic alloy for applications in critical components in aerospace, oil, and gas, or power generation. Commercially, IN718 is produced by conventional casting processes. However, manufacturing is evolving towards 3D printing, which allows the manufacturing of near-net-shape parts and complex designs, thus optimizing manufacturing steps, reducing production costs, and adding other advantages to the final product. However, high corrosion resistance and mechanical strength are required in applications such as oil and gas, whereas IN718 superalloys have limitations. Surface hardening by applying plasma nitriding can protect against corrosion by increasing mechanical strength and wear resistance. For this, plasma nitriding has been widely applied for surface hardening of IN718; however, little is found on the effects of surface treatments (coating or nitriding) of additively manufactured alloys. The effects of temperature during plasma nitriding on the surface properties of IN718 superalloy 3D printed by the Laser Beam Powder Bed Fusion (LB-PBF) method are reported here. Samples of IN718 fabricated by 3D printing were plasma nitrided at fixed temperatures between 500 and 650 °C in a semi-industrial reactor, their effects are analyzed and correlated with their microstructural characteristics, the mechanical properties at the micro- and nanoscale, and the tribological responses in a pin-on-disk configuration.

A Review of the Development of Titanium-Based and Magnesium-Based Metallic Glasses in the Field of Biomedical Materials.

This article reviews the research and development focus of metallic glasses in the field of biomedical applications. Metallic glasses exhibit a short-range ordered and long-range disordered glassy structure at the microscopic level, devoid of structural defects such as dislocations and grain boundaries. Therefore, they possess advantages such as high strength, toughness, and corrosion resistance, combining characteristics of both metals and glasses. This novel alloy system has found applications in the field of biomedical materials due to its excellent comprehensive performance. This review discusses the applications of Ti-based bulk metallic glasses in load-bearing implants such as bone plates and screws for long-term implantation. On the other hand, Mg-based metallic glasses, owing to their degradability, are primarily used in degradable bone nails, plates, and vascular stents. However, metallic glasses as biomaterials still face certain challenges. The Young's modulus value of Ti-based metallic glasses is higher than that of human bones, leading to stress-shielding effects. Meanwhile, Mg-based metallic glasses degrade too quickly, resulting in the premature loss of mechanical properties and the formation of numerous bubbles, which hinder tissue healing. To address these issues, we propose the following development directions: (1) Introducing porous structures into titanium-based metallic glasses is an important research direction for reducing Young's modulus; (2) To enhance the bioactivity of implant material surfaces, the surface modification of titanium-based metallic glasses is essential. (3) Developing antibacterial coatings and incorporating antibacterial metal elements into the alloys is essential to maintain the long-term effective antibacterial properties of metallic biomaterials. (4) Corrosion resistance must be further improved through the preparation of composite materials, while ensuring biocompatibility and safety, to achieve controllable degradation rates and degradation modes.

Microstructure and functional properties of light weight AlMgxTiSnZn high entropy alloy

Lightweight high-entropy alloys (LWHEAs) present new opportunities for exploring innovative, low-cost materials with a high strength-to-weight ratio, thanks to their expansive alloy-design space. This study introduces the newly designed AlMgxTiSnZn HEAs to examine the relationship between microstructure, phase stability, and functional properties (including mechanical, thermal, and electrochemical properties alongside oxidation resistance). These alloys were produced by mechanically mixing them in a high-energy ball mill (HEBM), followed by heating with spark plasma sintering (SPS). Thermodynamic calculations were utilized to ascertain the phase structure. XRD studies revealed a predominant ordered BCC phase with minor peaks indicating a tetragonal structure. The correlation between microhardness (Hv) and fracture strength (σf) with Mg content indicates that the HEA sample featuring the highest microhardness concurrently exhibits the highest fracture strength (AlMgTiSnZn). This AlMgTiSnZn HEA sample, noted for its high corrosion resistance and distinct properties (such as favorable over-potential, low corrosion current density (Icorr), and minimal corrosion rate), is particularly promising for high-temperature applications.

Feasibility study of carbon-fiber reinforced polymer linerless pressure vessel tank

Composite pressure vessels are used in aerospace engineering for storing fluids such as propellants, nitrogen, and oxygen. They are also used in life-support systems, High-performance pressure suits for astronauts, Helium Tanks for Balloons and Airships. Among many types of composites, Carbon fiber composites uses have been increasing due to its high strength to weight ratio, high thermal expansion, corrosion, fatigue and impact resistance and design flexibility. In order to improve the volume of the pressure vessel, the liner-less concept is tried. This increased volume efficiency is crucial in aerospace applications where space is at a premium and maximizing storage capacity within limited dimensions is important. Not only the volume efficiency, but also the Reduced Permeability Concerns, Enhanced Durability and Longevity, better thermal continuity and simplified manufacturing process make this research significant in the area of pressure vessel. This research paper deals with the fabrication and development of a cylinder without a lining. The test sample was subjected to several tests: tensile test, impact, shear test (3P Bending), leak test and Pressure test. The test sample was capable of withstanding 20 Bars without failure. The numerical results were also performed and compared with the experimental results. The difference was only 3%. Unsymmetrical dimethyl hydrazine (UDMH) AND red-fuming nitric acid can both be stored in this cylinder (RFNA). Unlike traditional composite overwrapped pressure vessels, the liner-less composite tanks rely completely on the composite shell to act as a permeation barrier as well as handling all pressure and environmental loads. The absence of a liner eliminates the potential for delamination or failure at the interface between the liner and the composite material.

The effect of various Sn and Ca equal proportional addition on the microstructure, mechanical behavior and corrosion performance of Mg alloys

In the present study, the effects of various Sn and Ca equal proportional addition (0.3:0.1, 0.6:0.2, 1.2:0.4, wt%) on the microstructure, mechanical properties and corrosion behavior of Mg-Sn-Ca alloys were systematically investigated. With the increase of Sn and Ca content, microstructure uniformity of the Mg-Sn-Ca alloy was improved, the average grain size was refined (from 34.4 μm to 21.62 μm, 13.47 μm), and more CaMgSn phases were generated (from 0.39 % to 1.64 %, 4.53 %). With increasing Sn and Ca content, the tensile yield strength (TYS) and ultimate tensile strength (UTS) of Mg-Sn-Ca alloys were gradually increased (TYS: from 91.8 MPa to 98.24 and 125.05 MPa; UTS: from 187.48 MPa to 190.73 and 214.58 MPa), mainly due to the contribution of grain refinement. The electrochemical tests revealed that the corrosion resistance of the Mg-Sn-Ca alloy initially decreases and then increases with the increase of Sn and Ca contents. The hydrogen evolution volume of Mg-0.3Sn-0.1Ca alloy was 41.91 mL cm−2, and the corrosion current density was −1.54 × 10−3 A/cm2. As for Mg-0.6Sn-0.2Ca alloy, deteriorated corrosion resistance compared to the Mg-0.3Sn-0.1Ca alloy was mainly ascribed to the micro-galvanic corrosion between the CaMgSn phase and Mg-matrix. The Mg-1.2Sn-0.4Ca alloy had the best corrosion resistance, with the lowest hydrogen evolution volume of 34.09 mL cm−2 and a minimum current density of −1.15×10−3 mA cm−2, its high corrosion resistance could be attributed to the grain refinement and homogenous distributed CaMgSn phase and more generated Ca(OH)2 product film with dense-structure.

Planification of amorphous carbon coatings via periodically transitional sp2/sp3 bonds to enhance cavitation erosion resistance

In the marine sector, hydraulic machinery suffers severe damage from cavitation erosion. Although amorphous carbon (a-C) coatings are an effective measure to enhance the cavitation erosion resistance (CER), their widespread application is hindered by their metastable nature characterized by internal stress. In this study, a planification strategy was employed via different sp2/sp3 distributions (including uniform ones with different sp2/sp3 levels and periodically transitional ones with different periods), aiming to construct a pure a-C coating that enhances CER on 316L stainless steel by modulating the bias during magnetron sputtering. The effects of the sp2/sp3 distributions on the microstructure, chemical bonding, adhesion strength, fracture toughness, corrosion resistance and CER was investigated and compared with the coatings featuring uniform sp2/sp3 distributions. The results show that the periodic-mode coatings exhibit much higher CER due to their lower internal stress, excellent adhesion strength, enhanced fracture toughness and high corrosion resistance. After the cavitation erosion test for 4 h, the periodic-mode coatings only show striped structures without any coating delamination, along with less graphitization tendency during cavitation erosion. Hence, the design approach of periodic sp2/sp3 carbon bonds provides a promising new direction for marine equipment with improved CER and potential applications in various other environments.

Rapid electrodeposition synthesis of partially phosphorylated cobalt iron phosphate for application in seawater overall electrolysis

To obtain hydrogen energy from seawater, it is of utmost importance to design an efficient bifunctional electrocatalyst that can be produced on a large scale and in a rapid manner. In this work, iron cobalt phosphate (CoFe-EP/NF) for long-term efficient and stable seawater electrolysis were rapidly synthesized by a simple electrodeposition. The study showed that metal phosphides/phosphates provided additional active sites for the catalysts for hydrogen evolution reaction (HER, 160 mV at 100 mA/cm2) and oxygen evolution reaction (OER, 266 mV at 100 mA/cm2), in alkaline seawater electrolyte (1 M KOH + seawater), respectively. Notably, the presence of phosphate groups facilitates the transformation of cobalt-iron metal phosphates into the truly reactive substance CoOOH, which improves the OER kinetics. In addition, the phosphate layer formed after catalyst activation avoids the occurrence of chlorine evolution reaction (CER) by shielding the adsorption of Cl−, thus enhancing the corrosion resistance and enabling long-term stable operation in seawater. The two-electrode overall seawater electrolysis easily reaches 100 mA/cm2 at 1.68 V and exhibit a long-term durability of more than 100 h. This study offers a viable approach for the synthesis of electrocatalysts with high activity and corrosion resistance, which is vital for the practical realization of large-scale seawater electrolysis.

Ordered 2D/3D CoNi-LDH/FeSe electrode for efficient and durable seawater oxidation

The superior electrocatalysts for seawater oxygen evolution reaction (OER) require fast kinetic to promote reactant (OH−) transport and adsorption, and to optimize oxygenated intermediates (O* and OOH*) adsorption, but also high corrosion resistance by impeding Cl− adsorption under harsh seawater conditions, while the incomprehensive design greatly hinder the system advancement at high current densities. Herein, we propose orderly incorporating amorphous FeSe nanosheets as the dynamic anti-corrosion layer to reinforce charge redistribution of CoNi layered double hydroxide (LDH) nanosheets array and create favorable microenvironments. The ordered two-dimensional/three-dimensional structure prepared by novel non-equilibrium electrodeposition strategy allows amorphous FeSe component not only to activate CoNi-LDH for promoting OH− adsorption, optimizing oxygenated intermediates adsorption and increasing Cl− adsorption energy, but also repel Cl− by dynamic polyanion layer without blocking active sites, thus affording effective seawater OER with low overpotential, excellent stability and high selectivity at high current densities. The integrated CoNi-LDH/FeSe electrode delivers a small overpotential (338 mV at 500 mA cm−2) and possesses outstanding stability and selectivity during a 500-hour durability test at 500 mA cm−2 in alkaline seawater.