Prediction model for corrosion rate of low-alloy steels under atmospheric conditions using machine learning algorithms

This work constructed a machine learning(ML)model to predict the atmospheric corrosion rate of low-alloy steels(LAS).The material properties of LAS,environmental factors,and exposure time were used as the input,while the corrosion rate as the output.6 dif-ferent ML algorithms were used to construct the proposed model.Through optimization and filtering,the eXtreme gradient boosting(XG-Boost)model exhibited good corrosion rate prediction accuracy.The features of material properties were then transformed into atomic and physical features using the proposed property transformation approach,and the dominant descriptors that affected the corrosion rate were filtered using the recursive feature elimination(RFE)as well as XGBoost methods.The established ML models exhibited better predic-tion performance and generalization ability via property transformation descriptors.In addition,the SHapley additive exPlanations(SHAP)method was applied to analyze the relationship between the descriptors and corrosion rate.The results showed that the property transformation model could effectively help with analyzing the corrosion behavior,thereby significantly improving the generalization ability of corrosion rate prediction models.

New insights on the high-corrosion resistance of UHP Mg-Ge alloys tested in a simulated physiological environment

UHP Mg-Ge alloys was recently found to provide excellent corrosion resistance.This paper provides new insights on the mechanism of improved corrosion resistance of UHP Mg-Ge alloys in Hanks’solution.The studied UHP Mg-0.5Ge and UHP Mg-1Ge alloys showed superior corrosion resistance compared to UHP Mg and WE43,with the Mg-1Ge exhibiting the best corrosion performance.The exceptional corrosion resistance of the UHP alloy is attributed to(i)Mg_(2)Ge’s ability to suppress cathodic kinetics,(ii)Ge’s capability to accelerate the formation of a highly passive layer,and the(iii)low amounts of corrosion-accelerating impurities.

Prediction models of burst strength degradation for casing with considerations of both wear and corrosion

Casing wear and casing corrosion are serious problems affecting casing integrity failure in deep and ultra-deep wells.This paper aims to predict the casing burst strength with considerations of both wear and corrosion.Firstly,the crescent wear shape is simplified into three categories according to common mathematical models.Then,based on the mechano-electrochemical(M-E)interaction,the prediction model of corrosion depth is built with worn depth as the initial condition,and the prediction models of burst strength of the worn casing and corroded casing are obtained.Secondly,the accuracy of different prediction models is validated by numerical simulation,and the main influence factors on casing strength are obtained.At last,the theoretical models are applied to an ultra-deep well in Northwest China,and the dangerous well sections caused by wear and corrosion are predicted,and the corrosion rate threshold to ensure the safety of casing is obtained.The results show that the existence of wear defects results in a stress concentration and enhanced M-E interaction on corrosion depth growth.The accuracy of different mathematical models is different:the slot ring model is most accurate for predicting corrosion depth,and the eccentric model is most accurate for predicting the burst strength of corroded casing.The burst strength of the casing will be overestimated by more than one-third if the M-E interaction is neglected,so the coupling effect of wear and corrosion should be sufficiently considered in casing integrity evaluation.

High corrosion and wear resistant electroless Ni–P gradient coatings on aviation aluminum alloy parts

A Ni–P alloy gradient coating consisting of multiple electroless Ni–P layers with various phosphorus contents was prepared on the aviation aluminum alloy. Several characterization and electrochemical techniques were used to characterize the different Ni–P coatings’ morphologies, phase structures, elemental compositions, and corrosion protection. The gradient coating showed good adhesion and high corrosion and wear resistance, enabling the application of aluminum alloy in harsh environments. The results showed that the double zinc immersion was vital in obtaining excellent adhesion (81.2 N). The optimal coating was not peeled and shredded even after bending tests with angles higher than 90°and was not corroded visually after 500 h of neutral salt spray test at 35℃. The high corrosion resistance was attributed to the misaligning of these micro defects in the three different nickel alloy layers and the amorphous structure of the high P content in the outer layer. These findings guide the exploration of functional gradient coatings that meet the high application requirement of aluminum alloy parts in complicated and harsh aviation environments.

High-throughput calculations combining machine learning to investigate the corrosion properties of binary Mg alloys

Magnesium(Mg)alloys have shown great prospects as both structural and biomedical materials,while poor corrosion resistance limits their further application.In this work,to avoid the time-consuming and laborious experiment trial,a high-throughput computational strategy based on first-principles calculations is designed for screening corrosion-resistant binary Mg alloy with intermetallics,from both the thermodynamic and kinetic perspectives.The stable binary Mg intermetallics with low equilibrium potential difference with respect to the Mg matrix are firstly identified.Then,the hydrogen adsorption energies on the surfaces of these Mg intermetallics are calculated,and the corrosion exchange current density is further calculated by a hydrogen evolution reaction(HER)kinetic model.Several intermetallics,e.g.Y_(3)Mg,Y_(2)Mg and La_(5)Mg,are identified to be promising intermetallics which might effectively hinder the cathodic HER.Furthermore,machine learning(ML)models are developed to predict Mg intermetallics with proper hydrogen adsorption energy employing work function(W_(f))and weighted first ionization energy(WFIE).The generalization of the ML models is tested on five new binary Mg intermetallics with the average root mean square error(RMSE)of 0.11 eV.This study not only predicts some promising binary Mg intermetallics which may suppress the galvanic corrosion,but also provides a high-throughput screening strategy and ML models for the design of corrosion-resistant alloy,which can be extended to ternary Mg alloys or other alloy systems.

Greatly enhanced corrosion/wear resistances of epoxy coating for Mg alloy through a synergistic effect between functionalized graphene and insulated blocking layer

The poor corrosion and wear resistances of Mg alloys seriously limit their potential applications in various industries.The conventional epoxy coating easily forms many intrinsic defects during the solidification process,which cannot provide sufficient protection.In the current study,we design a double-layer epoxy composite coating on Mg alloy with enhanced anti-corrosion/wear properties,via the spin-assisted assembly technique.The outer layer is functionalized graphene(FG)in waterborne epoxy resin(WEP)and the inner layer is Ce-based conversion(Ce)film.The FG sheets can be homogeneously dispersed within the epoxy matrix to fill the intrinsic defects and improve the barrier capability.The Ce film connects the outer layer with the substrate,showing the transition effect.The corrosion rate of Ce/WEP/FG composite coating is 2131 times lower than that of bare Mg alloy,and the wear rate is decreased by~90%.The improved corrosion resistance is attributed to the labyrinth effect(hindering the penetration of corrosive medium)and the obstruction of galvanic coupling behavior.The synergistic effect derived from the FG sheet and blocking layer exhibits great potential in realizing the improvement of multi-functional integration,which will open up a new avenue for the development of novel composite protection coatings of Mg alloys.

The corrosion characteristic and mechanism of Mg-5Y-1.5Nd-xZn-0.5Zr(x=0,2,4,6 wt.%)alloys in marine atmospheric environment

The microstructure and precipitated phases of as-cast Mg-5Y-1.5Nd-x Zn-0.5Zr(x=0,2,4,6 wt.%)alloys were investigated by optical microscopy,scanning electron microscopy,energy-dispersive spectrometry and X-ray Diffraction.The exposure corrosion experiment of these magnesium alloys was tested in South China Sea and KEXUE vessel atmospheric environment.The corrosion characteristic and mechanism of magnesium alloys of Mg-5Y-1.5Nd-x Zn-0.5Zr(x=0,2,4,6 wt.%)alloys were analyzed by weight loss rate,corrosion depth,corrosion products and corrosion morphologies.The electrochemical corrosion tests were also measured in the natural seawater.The comprehensive results showed that Mg-5Y-1.5Nd-4Zn-0.5Zr magnesium alloy existed the best corrosion resistance whether in the marine atmospheric environment and natural seawater environment.That depended on the microstructure,type and distribution of precipitated phases in Mg-5Y-1.5Nd-4Zn-0.5Zr magnesium alloy.Sufficient quantity anodic precipitated phases in the microstructure of Mg-5Y-1.5Nd-4Zn-0.5Zr alloy played the key role in the corrosion resistance.

In-situ AFM and quasi-in-situ studies for localized corrosion in Mg-9Al-1Fe-(Gd) alloys under 3.5 wt.% NaCl environment

Revealing the localized corrosion process of Mg alloy is considered as one of the most significant ways for improving its corrosion resistance.The reliable monitor should be high distinguishability and real-time in liquid environment.Herein,Mg-9Al-1Fe and Mg-9Al-1Fe-1Gd alloys were designed to highlight the impact of intermetallic on the corrosion behaviour.In-situ AFM with a special electrolyte circulation system and quasi-in-situ SEM observation were used to monitor the corrosion process of the designed alloys.SEM-EDS and TEM-SAED were applied to identify the intermetallic in the designed alloys,and their volta potentials were measured by SKPFM.According to the real-time and real-space in-situ AFM monitor,the corrosion process consisted of dissolution of anodicα-Mg phase,accumulation of corrosion products around cathodic phase and shedding of some fine cathodic phase.Then,the localized corrosion process of Mg alloy was revealed combined with the results of the monitor of corrosion process and Volta potential difference.

Understanding the corrosion and bio-corrosion behaviour of Magnesium composites – a critical review

Realising the potential of Magnesium(Mg),several globally leading ventures have invested in the Mg industry,but their relatively poor corrosion resistance is a never ending saga till date.The corrosion and bio-corrosion behaviour of Mg has gained research attention and still remains a hot topic in the application of automobile,aerospace and biomedical industries.The intrinsic high electrochemical nature of Mg limits their utilization in diverse application.This scenario has prompted the development of Mg composites with an aim to achieve superior corrosion and bio-corrosion resistance.The present review enlightens the influence of grain size(GS),secondary phase,texture,type of matrix and reinforcement on the corrosion and bio-corrosion behaviour of Mg composites.Firstly,the corrosion and bio-corrosion behaviour of Mg composites manufactured by primary and secondary processing routes are elucidated.Secondly,the comprehensive corrosion and bio-corrosion mechanisms of these Mg composites are proposed.Thirdly,the individual role of GS,texture and corrosive medium on corrosion and bio-corrosion behaviour of Mg composites are clarified and revealed.The challenges encountered,unanswered issues in this field are explained in detail and accordingly the scope for future research is framed.The review is presented from basic concrete background to advanced corrosion mechanisms with an aim of creating interest among the readers like students,researchers and industry experts from various research backgrounds.Indeed,the corrosion and bio-corrosion behaviour of Mg composites are critically reviewed for the first time to:(i)contribute to the body of knowledge,(ii)foster research and development,(iii)make breakthrough,and(iv)create life changing innovations in the field of Mg composite corrosion.

Microstructural characterization,tribological and corrosion behavior of AA7075-TiC composites

Aluminum alloys are the potential materials in the automobile and aerospace sectors due to their lower density,easy forming and excellent corrosion resistance.The demand of high strength-to-weight ratio materials in structural applications needs the engineering industries to seek aluminum alloy with new versions of hard and brittle ceramic particles.The microstructure,hardness,wear and corrosion behaviors of AA7075 composites with 2.5wt.%and 5wt.%TiC particles were studied.Microscopic analysis is evident that the transformation of the strong dendritic morphology to non-dendritic morphology on the incorporation of TiC into AA7075.Furthermore,the precipitation of the second-phase compounds such as Al_(2)CuMg,Al_(2)Cu andFe-rich Al_6(Cu,Fe)/Al_(7)Cu_(2)Fe)is promoted by TiC particles at inter-and intra-dendritic regions.Accordingly,the hardness of composites is improved by grain boundary strengthening and particulate strengthening mechanisms.Both coefficient of friction and wear rate have an inverse relation with TiC concentration.The base alloy without TiC shows adhesive-type wear-induced deformation due to the formation of an oxide film,while composite samples exhibit a mechanically mixed layer and abrasive-type wear behavior.Composite samples shows a higher corrosion rate due to the presence of numerous precipitates which promote pitting corrosion.

Enhanced corrosion resistance of epoxy resin coating via addition of CeO_(2) and benzotriazole

The use of fillers to enhance the corrosion protection of epoxy resins has been widely applied.In this work,cerium dioxide(CeO_(2))and benzotriazole(BTA)were introduced into an epoxy resin to enhance the corrosion resistance of Q235 carbon steel.Scanning electron microscopy results indicated that the CeO_(2) grains were rod-like and ellipsoidal in shape,and the distribution pattern of BTA was analyzed by energy dispersive spectroscope.The dynamic potential polarization curve proved the excellent corrosion resistance of the composite epoxy resin with CeO_(2) and BTA co-addition,and electrochemical impedance spectroscopy test analysis indicated the significantly enhanced long-term corrosion protection performance of the composite coating.And the optimal protective performance was provided by the coating containing 0.3%(mass)CeO_(2) and 20%(mass)BTA,which was attributed to the barrier performance of CeO_(2) particles and the chemical barrier effect of BTA.The formation of corrosion products was analyzed using X-ray diffraction.In addition,the corrosion resistance mechanism of the coating was also discussed in detail.

Microstructure,Corrosion and Mechanical Properties of Medium-Thick 6061-T6 Alloy/T2 Pure Cu Dissimilar Joints Produced by Double Side Friction Stir Z Shape Lap-Butt Welding

A novel double side friction stir Z shape lap-butt welding(DS-FSZW)process was proposed to achieve excellent mechanical properties of Al/Cu medium-thick dissimilar joints.The influence of welding parameters on weld microstructure and properties of DS-FSZW joint were systematically investigated.It indicated that defect-free medium-thick Al/Cu DS-FSZW joint could be achieved under an optimal welding parameter.DS-FSZW joint was prone to form void defects in the bottom of the second-pass weld.The recrystallization mechanisms at the top and middle of the weld nugget zone(WNZ)were continuous dynamic recrystallization(CDRX)and geometric dynamic recrystallization(GDRX).While the major recrystallization mechanism at the bottom of the WNZ was GDRX.DS-FSZW joint of the optimal welding condition with 850 r/min-400 mm/min was produced with a continuous thin and crack-free IMCs layer at the Al/Cu interface,and the maximum tensile strength of this joint is 160.57 MPa,which is equivalent to 65.54%of pure Cu base material.Moreover,the corrosion resistance of Al/Cu DS-FSZW joints also achieved its maximum value at the optimal welding parameter of 850 r/min-400 mm/min.It demonstrates that the DS-FSZW process can simultaneously produce medium-thick Al/Cu joints with excellent mechanical performance and corrosion resistance.

Revisiting aluminum current collector in lithium-ion batteries:Corrosion and countermeasures

With the large-scale service of lithium-ion batteries(LIBs),their failures have attracted significant attentions.While the decay of active materials is the primary cause for LIB failures,the degradation of auxiliary materials,such as current collector corrosion,should not be disregarded.Therefore,it is necessary to conduct a comprehensive review in this field.In this review,from the perspectives of electrochemistry and materials,we systematically summarize the corrosion behavior of aluminum cathode current collector and propose corresponding countermeasures.Firstly,the corrosion type is clarified based on the properties of passivation layers in different organic electrolyte components.Furthermore,a thoroughgoing analysis is presented to examine the impact of various factors on aluminum corrosion,including lithium salts,organic solvents,water impurities,and operating conditions.Subsequently,strategies for electrolyte and protection layer employed to suppress corrosion are discussed in detail.Lastly and most importantly,we provide insights and recommendations to prevent corrosion of current collectors,facilitate the development of advanced current collectors and the implementation of next-generation high-voltage stable LIBs.

Effect of bipolar-plates design on corrosion,mass and heat transfer in proton-exchange membrane fuel cells and water electrolyzers:A review

Attaining a decarbonized and sustainable energy system,which is the core solution to global energy issues,is accessible through the development of hydrogen energy.Proton-exchange membrane water electrolyzers(PEMWEs)are promising devices for hydrogen production,given their high efficiency,rapid responsiveness,and compactness.Bipolar plates account for a relatively high percentage of the total cost and weight compared with other components of PEMWEs.Thus,optimization of their design may accelerate the promotion of PEMWEs.This paper reviews the advances in materials and flow-field design for bipolar plates.First,the working conditions of proton-exchange membrane fuel cells(PEMFCs)and PEMWEs are compared,including reaction direction,operating temperature,pressure,input/output,and potential.Then,the current research status of bipolar-plate substrates and surface coatings is summarized,and some typical channel-rib flow fields and porous flow fields are presented.Furthermore,the effects of materials on mass and heat transfer and the possibility of reducing corrosion by improving the flow field structure are explored.Finally,this review discusses the potential directions of the development of bipolar-plate design,including material fabrication,flow-field geometry optimization using threedimensional printing,and surface-coating composition optimization based on computational materials science.

Comparative analysis of microstructure,mechanical,and corrosion properties of biodegradable Mg-3Y alloy prepared by selective laser melting and spark plasma sintering

This work explored possibilities of biodegradable magnesium alloy Mg-3Y preparation by two modern powder metallurgy techniques–spark plasma sintering(SPS)and selective laser melting(SLM).The powder material was consolidated by both methods utilising optimised parameters,which led to very low porosity(∼0.3%)in the SLM material and unmeasurably low porosity in the SPS material.The main aim of the study was the thorough microstructure characterisation and interrelation between the microstructure and the functional properties,such as mechanical strength,deformability,and corrosion resistance.Both materials showed comparable strength of∼110 MPa in tension and compression and relatively good deformability of∼9%and∼21%for the SLM and SPS materials,respectively.The corrosion resistance of the SPS material in 0.1 M NaCl solution was superior to the SLM one and comparable to the conventional extruded material.The digital image correlation during loading and the cross-section analysis of the corrosion layers revealed that the residual porosity and large strained grains have the dominant negative effect on the functional properties of the SLM material.On the other hand,one of the primary outcomes of this study is that the SPS consolidation method is very effective in the preparation of the W3 biodegradable alloy,resulting in material with convenient mechanical and degradation properties that might find practical applications.

Synergistic enhancement on mechanical properties and corrosion resistance of biodegradable Mg-Zn-Y alloy via V-microalloying

For the sake of improving the mechanical properties and corrosion resistance of biodegradable Mg alloy synergistically,various content of element V(0,0.05,0.10,0.15,0.20 wt.%)are introduced into an Mg-Zn-Y alloy with long-period stacking ordered(LPSO)structure,and the effects of V on its microstructure,mechanical properties and corrosion resistance are investigated systematically.The results indicate that the grains are effectively refined by V addition,and the primaryα-Mg in Mg-Zn-Y-V0.1 alloy is most significantly refined,with grain size being decreased by 62%.The amount of 18R LPSO structure is increased owing to the V addition.The growth mode of the second phase(W-phase and 18R LPSO structure)is transformed to divorced growth pattern,which ascribes to the thermodynamic drive force of V to promote the nucleation of LPSO phase.Thus,18R LPSO structure presents a continuous distribution.Due to grains refinement and modification of second phase,the tensile strength and strain of alloys are both enhanced effectively.Especially,the ultimate tensile strength and the elongation of V0.1 alloy are 254 MPa and 15.26%,which are 41%and 61%higher than those of V-free alloy,respectively.Owing to the continuously distributed 18R LPSO structure with refined grains and stable product film,the weight loss and hydrogen evolution corrosion rates of V0.1 alloy are 7.1 and 6.2 mmy^(-1),respectively,which are 42.6%and 45.4%lower than those of V-free alloy.

Spark Plasma Sintering of Mg-based Alloys:Microstructure,Mechanical Properties,Corrosion Behavior,and Tribological Performance

Within the past ten years,spark plasma sintering(SPS)has become an increasingly popular process for Mg manufacturing.In the SPS process,interparticle diffusion of compressed particles is rapidly achieved due to the concept of Joule heating.Compared to traditional and additive manufacturing(AM)techniques,SPS gives unique control of the structural and microstructural features of Mg components.By doing so,their mechanical,tribological,and corrosion properties can be tailored.Although great advancements in this field have been made,these pieces of knowledge are scattered and have not been contextualized into a single work.The motivation of this work is to address this scientific gap and to provide a groundwork for understanding the basics of SPS manufacturing for Mg.To do so,the existing body of SPS Mg literature was first surveyed,with a focus on their structural formation and degradation mechanisms.It was found that successful Mg SPS fabrication highly depended on the processing temperature,particle size,and particle crystallinity.The addition of metal and ceramic composites also affected their microstructural features due to the Zener pinning effect.In degradative environments,their performance depends on their structural features and whether they have secondary phased composites.In industrial applications,SPS'd Mg was found to have great potential in biomedical,hydrogen storage,battery,automotive,and recycling sectors.The prospects to advance the field include using Mg as a doping agent for crystallite size refinement and using bulk metallic Mg-based glass powders for amorphous SPS components.Despite these findings,the interactions of multi-composites on the processing-structure-property relationships of SPS Mg is not well understood.In total,this work will provide a useful direction in the SPS field and serve as a milestone for future Mg-based SPS manufacturing.

The effect of Laves phases and nano-precipitates on the electrochemical corrosion resistance of Mg-Al-Ca alloys under alkaline conditions

The electrochemical corrosion mechanisms of Mg alloys were extensively studied in previous investigations of different chemical com-positions,modified surface states and various electrolyte conditions.However,recent research focused on the active state of Mg dissolution,leading to unresolved effects of secondary phases adjacent to a stableα-solid solution passive layer.The present study investigates the fundamental electrochemical corrosion mechanisms of three different Laves phases with varying phase morphologies and phase fractions in the passive state of Mg-Al-Ca alloys.The microstructure was characterized by(transmission-)electron microscopy and synchrotron-based transmission X-ray microscopy.The electrochemical corrosion resistance was determined with a standard three-electrode setup and advanced in-situ flow cell measurements.A new electrochemical activity sequence(C15>C36>α-Mg>C14)was obtained,as a result of a stable passive layer formation on theα-solid solution.Furthermore,nm-scale Mg-rich precipitates were identified within the Laves phases,which tend to inhibit the corrosion kinetics.

Evolution of mechanical properties,localized corrosion resistance and microstructure of a high purity Al-Zn-Mg-Cu alloy during non-isothermal aging

The evolution of mechanical properties,localized corrosion resistance of a high purity Al-Zn-Mg-Cu alloy during non-isothermal aging(NIA)was investigated by hardness test,electrical conductivity test,tensile test,intergranular corrosion test,exfoliation corrosion test,slow strain rate tensile test and electrochemical test,and the mechanism has been discussed based on microstructure examination by optical microscopy,electron back scattered diffraction,scanning electron microscopy and scanning transmission electron microscopy.The NIA treatment includes a heating stage from 40℃to 180℃with a rate of 20℃/h and a cooling stage from 180℃to 40℃with a rate of 10℃/h.The results show that the hardness and strength increase rapidly during the heating stage of NIA since the increasing temperature favors the nucleation and the growth of strengthening precipitates and promotes the transformation of Guinier-Preston(GPI)zones toη'phase.During the cooling stage,the sizes ofη'phase increase with a little change in the number density,leading to a further slight increase of the hardness and strength.As NIA proceeds,the corroded morphology in the alloy changes from a layering feature to a wavy feature,the maximum corrosion depth decreases,and the reason has been analyzed based on the microstructural and microchemical feature of precipitates at grain boundaries and subgrain boundaries.