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.

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.

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.

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.

Microstructures,corrosion behavior and mechanical properties of as-cast Mg-6Zn-2X(Fe/Cu/Ni)alloys for plugging tool applications

Mg-6Zn-2X(Fe/Cu/Ni)alloys were prepared through semi-continuous casting,with the aim of identifying a degradable magnesium(Mg)alloy suitable for use in fracturing balls.A comparative analysis was conducted to assess the impacts of adding Cu and Ni,which result in finer grains and the formation of galvanic corrosion sites.Scanner electronic microscopy examination revealed that precipitated phases concentrated at grain boundaries,forming a semi-continuous network structure that facilitated corrosion penetration in Mg-6Zn-2Cu and Mg-6Zn-2Ni alloys.Pitting corrosion was observed in Mg-6Zn-2Fe,while galvanic corrosion was identified as the primary mechanism in Mg-6Zn-2Cu and Mg-6Zn-2Ni alloys.Among the tests,the Mg-6Zn-2Ni alloy exhibited the highest corrosion rate(approximately 932.9 mm/a)due to its significant potential difference.Mechanical testing showed that Mg-6Zn-2Ni alloy possessed suitable ultimate compressive strength,making it a potential candidate material for degradable fracturing balls,effectively addressing the challenges of balancing strength and degradation rate in fracturing applications.

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.

Stress-assisted corrosion mechanism of 3Ni steel by using gradient boosting decision tree machining learning method

Traditional 3Ni weathering steel cannot completely meet the requirements for offshore engineering development,resulting in the design of novel 3Ni steel with the addition of microalloy elements such as Mn or Nb for strength enhancement becoming a trend.The stress-assisted corrosion behavior of a novel designed high-strength 3Ni steel was investigated in the current study using the corrosion big data method.The information on the corrosion process was recorded using the galvanic corrosion current monitoring method.The gradi-ent boosting decision tree(GBDT)machine learning method was used to mine the corrosion mechanism,and the importance of the struc-ture factor was investigated.Field exposure tests were conducted to verify the calculated results using the GBDT method.Results indic-ated that the GBDT method can be effectively used to study the influence of structural factors on the corrosion process of 3Ni steel.Dif-ferent mechanisms for the addition of Mn and Cu to the stress-assisted corrosion of 3Ni steel suggested that Mn and Cu have no obvious effect on the corrosion rate of non-stressed 3Ni steel during the early stage of corrosion.When the corrosion reached a stable state,the in-crease in Mn element content increased the corrosion rate of 3Ni steel,while Cu reduced this rate.In the presence of stress,the increase in Mn element content and Cu addition can inhibit the corrosion process.The corrosion law of outdoor-exposed 3Ni steel is consistent with the law based on corrosion big data technology,verifying the reliability of the big data evaluation method and data prediction model selection.

An ionic liquid-assisted strategy for enhanced anticorrosion of low-energy PEO coatings on magnesium–lithium alloy

A low-energy plasma electrolytic oxidation(LePEO)technique is developed to simultaneously improve energy efficiency and anti-corrosion.Ionic liquids(1-butyl-3-methylimidazole tetrafluoroborate(BmimBF_(4)))as sustainable corrosion inhibitors are chosen to investigate the corrosion inhibition behavior of ionic liquid(ILs)during the LePEO process for LA91 magnesium-lithium(Mg-Li)alloy.Results show that the ionic liquid BmimBF_(4)participates in the LePEO coating formation process,causing an increment in coating thickness and surface roughness.The low conductivity of the ionic liquid is responsible for the voltage and breakdown voltage increases during the LePEO with IL process(LePEO-IL).After adding BmimBF_(4),corrosion current density decreases from 1.159×10^(−4)A·cm^(−2)to 8.143×10^(−6)A·cm^(−2).The impedance modulus increases to 1.048×10^(4)Ω·cm^(−2)and neutral salt spray remains intact for 24 h.The superior corrosion resistance of the LePEO coating assisted by ionic liquid could be mainly attributed to its compact and thick barrier layer and physical absorption of ionic liquid.The ionic liquid-assisted LePEO technique provides a promising approach to reducing energy consumption and improving film performance.

Corrosion behavior of pure metals(Ni and Ti)and alloys(316H SS and GH3535)in liquid GaInSn

In this study,the interactions between a Ga-based liquid metal,GaInSn,and several metal materials,including pure metals(Ni and Ti)and alloys(316H stainless steel(SS)and GH3535),at 650℃were investigated.The aim was to evaluate the corrosion performance and select a suitable candidate material for use as a molten salt manometer diaphragm in thermal energy storage systems.The results indicated that the alloys(316H SS and GH3535)exhibited less corrosion than pure metals(Ni and Ti)in liquid GaInSn.Ga-rich binary intermetallic compounds were found to form on the surfaces of all the tested metal materials exposed to liquid GaInSn,as a result of the decomposition of liquid GaInSn and its reaction with the constituent elements of the metal materials.The corrosion mechanism for all the tested materials exposed to liquid GaInSn was also investigated and proposed,which may aid in selecting the optimal candidate material when liquid GaInSn is used as the pressure-sensing medium.

Review on synergistic damage effect of irradiation and corrosion on reactor structural alloys

The synergistic damage effect of irradiation and corrosion of reactor structural materials has been a prominent research focus.This paper provides a comprehensive review of the synergistic effects on the third-and fourth-generation fission nuclear energy structural materials used in pressurized water reactors and molten salt reactors.The competitive mechanisms of multiple influencing factors,such as the irradiation dose,corrosion type,and environmental temperature,are summarized in this paper.Conceptual approaches are proposed to alleviate the synergistic damage caused by irradiation and corrosion,thereby promoting in-depth research in the future and solving this key challenge for the structural materials used in reactors.

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.

Corrosion behavior of HVOF Inconel 625 coating in the simulated marine environment

High velocity oxygen fuel(HVOF)spraying process is commonly used to produce superalloy coatings.Inconel 625 coating was prepared on Q235B low carbon steel by HVOF.A series of experiments were conducted to examine the surface and corrosion resistance properties of Inconel 625 HVOF coating.In this paper,potentiodynamic polarization tests and electrochemical impedance spectroscopy(EIS)tests were carried out to evaluate the corrosion resistance of Inconel 625 coating under simulated marine environment.The experiment-al results showed that Inconel 625 coating revealed low porosity and desired coating thickness.Shift in the corrosion potential(E_(corr))to-wards the noble direction combined with much low corrosion current density(i_(corr))indicating a significant improvement of HVOF Inconel 625 coating compared with the substrate.

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.

Effect of interrupted aging on mechanical properties and corrosion resistance of 7A75 aluminum alloy

The effects of interrupted aging on mechanical properties and corrosion resistance of 7A75 aluminum alloy extruded bar were investigated through various analyses,including electrical conductivity,mechanical properties,local corrosion properties,and slow strain rate tensile stress corrosion tests.Microstructure characterization techniques such as metallographic microscopy,scanning electron microscopy(SEM),and transmission electron microscopy(TEM)were also employed.The results indicate that the tensile strength of the alloy produced by T6I6 aging is similar to that produced by T6I4 aging,and it even exceeds 700 MPa.Furthermore,the yield strength increases by 52.7 MPa,reaching 654.8 MPa after T6I6 aging treatment.The maximum depths of intergranular corrosion(IGC)and exfoliation corrosion(EXCO)decrease from 116.3 and 468.5μm to 89.5 and 324.3μm,respectively.The stress corrosion factor also decreases from 2.1%to 1.6%.These findings suggest that the alloy treated with T6I6 aging exhibits both high strength and excellent stress corrosion cracking resistance.Similarly,when the alloy is treated with T6I4,T6I6 and T6I7 aging,the sizes of grain boundary precipitates(GBPs)are found to be 5.2,18.4,and 32.8 nm,respectively.The sizes of matrix precipitates are 4.8,5.7 and 15.7 nm,respectively.The atomic fractions of Zn in GBPs are 9.92 at.%,8.23 at.%and 6.87 at.%,respectively,while the atomic fractions of Mg are 12.66 at.%,8.43 at.%and 7.00 at.%,respectively.Additionally,the atomic fractions of Cu are 1.83 at.%,2.47 at.%and 3.41 at.%,respectively.

Fatigue and Corrosion Fatigue Properties of Mg-Zn-Zr-Nd Alloys in Glucose-Containing Simulated Body Fluids

Medical bone implant magnesium(Mg)alloys are subjected to both corrosive environments and complex loads in the human body.The increasing number of hyperglycemic and diabetic patients in recent years has brought new challenges to the fatigue performance of Mg alloys.Therefore,it is significant to study the corrosion fatigue(CF)behavior of medical Mg alloys in glucose-containing simulated body fluids for their clinical applications.Herein,the corrosion and fatigue properties of extruded Mg-Zn-Zr-Nd alloy in Hank’s balanced salt solution(HBSS)containing different concentrations(1 g/L and 3 g/L)of glucose were investigated.The average grain size of the alloy is about 5μm,which provides excellent overall mechanical properties.The conditional fatigue strength of the alloy was 127 MPa in air and 88 MPa and 70 MPa in HBSS containing 1 g/L glucose and 3 g/L glucose,respectively.Fatigue crack initiation points for alloys in air are oxide inclusions and in solution are corrosion pits.The corrosion rate of the alloy is high at the beginning,and decreases as the surface corrosion product layer thickens with the increase of immersion time.The corrosion products of the alloy are mainly Mg(OH)_(2),MgO and a small amount of Ca-P compounds.The electrochemical results indicated that the corrosion rate of the alloys gradually decreased with increasing immersion time,but the corrosion tendency of the alloy was greater in HBSS containing 3 g/L glucose.On the one hand,glucose accelerates the corrosion process by adsorbing large amounts of aggressive Cl^(-)ions.On the other hand,glucose will be oxidized to form gluconic acid,and then reacts with Mg(OH)_(2) and MgO to form Mg gluconate,which destroys the corrosion product film and leads to the aggravation of corrosion and the accumulation of fatigue damage.

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.

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.

Corrosion behavior of co-gasification slag of furfural residue and coal on alumina-silica refractories

Gasification of furfural residue with coal can realize its efficient and clean utilization.But the high alkali metal content in furfural slag is easy to cause the corrosion of gasifier refractory.Two gasification coals with different silica alumina ratio and a furfural residue were selected in the study.The effects of furfural residue additions on corrosion of silica brick,corundum brick,high alumina brick and mullite brick were investigated by using XRD,SEM-EDS and Factsage Software,and the corrosion mechanism was analyzed.With increasing furfural residue addition,the permeability of the slags to high-aluminium-bearing refractories first decreases and then increases,while the permeability on silica brick shows a slight decrease trend.Leucite(KAlSi_(2)O_(6))with high-melting temperature is generated from the reaction of K_(2)O and SiO_(2)in slag with Al_(2)O_(3)in refractories after furfural residue is added,which hinders the infiltration of slag in refractories.Kaliophilite(KAlSiO_(4))of low-melting point is formed when K_(2)O content increases,and this contributes to the infiltration of slag in refractories.The acid-base reaction between slag and silica brick is distinctly occurred,more slag reacts with SiO_(2)in the silicon brick,resulting in a decrease in the amount of slag infiltrating into the silicon brick as furfural residue is added.The corrosion of silica brick is mainly caused by the acid-base reaction,while the corrosion of three alumina based refractory bricks of corundum,mullite and high alumina brick is determined by slag infiltration.A linear correlation between the percolation rate and slag viscosity is established,the slag permeability increases with decreasing viscosity,resulting in stronger permeability for the high Si/Al ratio slag with lower viscosity.

Effect of In doping on the evolution of microstructure,magnetic properties and corrosion resistance of NdFeB magnets

The grain boundary phase affects the magnetic properties and corrosion resistance of sintered NdFeB magnets.In this work,a small amount of In was added to NdFeB magnets by induction melting to systematically investigate its effect on the evolution of the microstructure,magnetic properties and corrosion resistance of NdFeB magnets.Microstructural analysis illustrated that minor In addition generated more grain boundary phases and an abundant amorphous phase at the triple-junction grain boundary.While the addition of In failed to enhance the magnetic isolation effect between adjacent matrix grains,its incorporation fortuitously elevated the electrochemical potential of the In-containing magnets.Besides,during corrosion,an In-rich precipitate phase formed,hindering the ingress of the corrosive medium into the magnet.Consequently,this significantly bolstered the corrosion resistance of the sintered NdFeB magnets.The phase formation,magnetic properties and corrosion resistance of In-doped NdFeB magnets are detailed in this work,which provides new prospects for the preparation of high-performance sintered NdFeB magnets.