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Corrosion Mechanism and Protection Technology of Metallic Materials

A special issue of Materials (ISSN 1996-1944). This special issue belongs to the section "Corrosion".

Deadline for manuscript submissions: 20 May 2025 | Viewed by 13355

Special Issue Editors


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Guest Editor
Department of Mechanical and Aerospace Engineering, Benjamin M. Statler College of Engineering and Mineral Resources, West Virginia University, Morgantown, WV 26506, USA
Interests: high-temperature oxidation, hot corrosion, high-entropy alloys; electrochemistry

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Guest Editor
Department of Mechanical & Materials Engineering, University of Nebraska–Lincoln, Lincoln, NE, USA
Interests: field-assisted sintering; laser processing; high-entropy ceramics and alloys; lunar soil simulants; UHTCs

Special Issue Information

Dear Colleagues,

According to several studies in the last 30 years, the annual direct cost of corrosion to an industrial company is up to 3.1% of the country’s gross national product. Moreover, the corrosion of metallic materials also significantly impairs human safety and the environment. To mitigate the negative effects associated with corrosion, it is of significant importance to conduct research on corrosion to discover its underlying mechanism and to develop effective and efficient methods to mitigate the corrosion process. The intent of this Special Issue is to provide an overview of the new advances in the relevant study of corrosion, ranging from fundamental studies to applications.

This Special Issue covers a whole spectrum of investigations and studies on metallic corrosion, including stress corrosion cracking, soil corrosion, atmospheric corrosion, and high-temperature corrosion, which is meaningful and helpful to understand the corrosion mechanism in different media. In addition, research on novel methods to mitigate the degradation of base metals, including the development of new coatings, new corrosion inhibitors, and cathodic protection, is also welcome.

Dr. Shanshan Hu
Dr. Xiang Zhang
Guest Editors

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Keywords

  • metal corrosion
  • coating development
  • oxidation
  • cathodic protection
  • corrosion inhibitor

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Published Papers (11 papers)

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Research

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11 pages, 3397 KiB  
Article
The Influence of Alloying Elements on the Hot Corrosion Behavior of Nickel-Based Superalloys
by Teodor-Adrian Badea and Mădălin Dombrovschi
Materials 2025, 18(9), 1996; https://doi.org/10.3390/ma18091996 - 28 Apr 2025
Viewed by 73
Abstract
Nickel-based superalloys are extensively used in high-temperature applications because of their exceptional oxidation and corrosion resistance. However, their performance in aggressive environments containing molten salts, such as Na2SO4 and V2O5, remains a critical challenge. This study [...] Read more.
Nickel-based superalloys are extensively used in high-temperature applications because of their exceptional oxidation and corrosion resistance. However, their performance in aggressive environments containing molten salts, such as Na2SO4 and V2O5, remains a critical challenge. This study investigated the hot corrosion behavior of Inconel 718, Udimet 710, Nimonic 75, and Inconel 625, focusing on the role of the alloying elements in the corrosion layers and degradation mechanisms. The superalloys were exposed to 50/50 wt.% Na2SO4–V2O5 at 900 °C for 8, 48, and 96 h, and their corrosion resistance was evaluated through weight gain measurements, scanning electron microscopy (SEM), and energy-dispersive X-ray spectroscopy (EDS). These results indicate that Mo is a key factor in accelerating degradation, with Inconel 625 exhibiting the highest weight gain owing to the formation of thermally unstable Mo-rich phases. Fe also negatively impacted the stability of the protective scale of Inconel 718, contributing to an increased corrosion rate. In contrast, Nimonic 75 exhibited the best resistance, forming more of the NiCr2O4 spinel phase through the reaction of Cr2O3 with NiO from the high Ni and Cr contents in the corrosive layers. These findings highlight the importance of alloy composition in optimizing corrosion resistance and suggest that using superalloys with lower Mo and Fe contents and higher Cr and Ni concentrations can significantly enhance the durability of superalloys in molten salt environments. Full article
(This article belongs to the Special Issue Corrosion Mechanism and Protection Technology of Metallic Materials)
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19 pages, 14510 KiB  
Article
The Influence of Roughness on the Protective Layer Formation Induced by Marine Microorganisms on 5083 Aluminum Alloy
by Julien Jaume, Marie-Line Délia and Régine Basséguy
Materials 2025, 18(3), 708; https://doi.org/10.3390/ma18030708 - 6 Feb 2025
Viewed by 576
Abstract
This study investigates the formation of a protective layer on a 5083 aluminum alloy surface induced by microorganisms from salt marsh. The influence of the initial surface roughness was examined to identify optimal conditions for maximum coverage and thickness of the protective layer. [...] Read more.
This study investigates the formation of a protective layer on a 5083 aluminum alloy surface induced by microorganisms from salt marsh. The influence of the initial surface roughness was examined to identify optimal conditions for maximum coverage and thickness of the protective layer. As two opposing effects are suspected, where high surface roughness enhances bacterial adhesion but reduces the resistance to abiotic corrosion, various degrees of roughness were tested. Using electrochemical experiments (OCP measurement, 1/Rp determination, and pitting sensitivity), SEM/TEM observation and EDX characterization, a compromise was found on the initial roughness to obtain a thick protective layer through good bacterial adhesion while minimizing abiotic corrosion. The optimal roughness, achieved through 240-grit grinding, facilitates a uniform distribution of microorganisms and the development of a dense, evenly thick protective layer that significantly enhances the alloy’s resistance to pitting corrosion. The passivity domain doubled when comparing the electrochemical behavior of electrodes immersed in the presence of microbial activity to those immersed without it. Full article
(This article belongs to the Special Issue Corrosion Mechanism and Protection Technology of Metallic Materials)
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17 pages, 6602 KiB  
Article
Studies of Corrosion Inhibition Performance of Inorganic Inhibitors for Aluminum Alloy
by Redouane Farid, Dilip K. Sarkar and Santanu Das
Materials 2025, 18(3), 595; https://doi.org/10.3390/ma18030595 - 28 Jan 2025
Cited by 1 | Viewed by 746
Abstract
In this study, the behavior of sodium silicate (Na2SiO3), manganese sulfate monohydrate (MnSO4·H2O), and ammonium metavanadate (NH4VO3) as corrosion inhibitors for AA6061 aluminum alloy (Al) was investigated. The polarization resistance (R [...] Read more.
In this study, the behavior of sodium silicate (Na2SiO3), manganese sulfate monohydrate (MnSO4·H2O), and ammonium metavanadate (NH4VO3) as corrosion inhibitors for AA6061 aluminum alloy (Al) was investigated. The polarization resistance (Rp) of the Al substrate immersed in 0.1 M NaCl solution was found to be 13 kΩ·cm2. In comparison, the Rp of the Al substrate immersed in 0.1 M NaCl in the presence of Na2SiO3, Na2SiO3/MnSO4·H2O, and Na2SiO3/NH4VO3 inhibitors was found to be 100, 133, and 679 kΩ·cm2, respectively. The best inhibition result was obtained when the mixture of the inhibitors was used with Rp of 722 kΩ·cm2. The maximum percentage of the corroded area calculated from the scanning electron microscopy (SEM) images was found to be 5.7% for Al substrate immersed in 0.1 M NaCl, which decreased to 0.06% when the mixture of the inhibitors was used. The synergetic effects between the three inhibitors were studied, and the results illustrated that the combination of Na2SiO3, MnSO4·H2O, and NH4VO3 provided the best corrosion inhibition properties for Al in aqueous NaCl environments. Full article
(This article belongs to the Special Issue Corrosion Mechanism and Protection Technology of Metallic Materials)
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20 pages, 10591 KiB  
Article
Study and Characterisation of Bimetallic Structure (316LSI and S275JR) Made by Hybrid CMT WAAM Process
by Alejandro Pereira, Antonio Alonso, Primo Hernández, Javier Martínez, David Alvarez and Michal Wieczorowski
Materials 2024, 17(22), 5422; https://doi.org/10.3390/ma17225422 - 6 Nov 2024
Viewed by 1247
Abstract
The main objective of this research is to conduct an experimental investigation of the bimetallic material formed by 316LSI stainless steel and S275JR structural steel, produced via hybrid wire arc additive manufacturing technology with cool metal transfer welding and machining, and with the [...] Read more.
The main objective of this research is to conduct an experimental investigation of the bimetallic material formed by 316LSI stainless steel and S275JR structural steel, produced via hybrid wire arc additive manufacturing technology with cool metal transfer welding and machining, and with the objective of being able to reduce the industrial cost of certain requirements for one of the materials. A methodological investigation has been carried out starting with welding beads of 316LSI on S275JR plates, followed by overlapping five beads and conducting final experiments with several vertical layers, with or without intermediate face milling. The results achieved optimal bead conditions for wire speeds of 4 m/min and 5 m/min at a travel speed of 400 mm/min. Overlap experiments show that the best deposition results are obtained with an overlap equal to or greater than 28%. Cooling time does not significantly influence the final geometry of the coatings. Regarding metallographic analysis, the filler material presents an austenitic columnar structure. In the base material, a bainitic structure with inferred grain refinement was detected in the heat-affected zone. An increase in hardness is observed in the heat-affected zone. In the results obtained from the tensile tests of the bimetallic material, an increase in mechanical strength and yield strength is observed in the tested specimens. Full article
(This article belongs to the Special Issue Corrosion Mechanism and Protection Technology of Metallic Materials)
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17 pages, 7054 KiB  
Article
Corrosion Behavior of Nacre-Inspired (TiBw-TiB2)/Al Composites Fabricated by Freeze Casting
by Jidong Zhang, Mingfang Qian, Ruiqing Yang, Feng Yu, Xuexi Zhang, Zhenggang Jia, Aibin Li, Guisong Wang and Lin Geng
Materials 2024, 17(11), 2534; https://doi.org/10.3390/ma17112534 - 24 May 2024
Cited by 1 | Viewed by 960
Abstract
Nacre-inspired metal matrix composites have received much attention due to their excellent deformation coordination ability, which can achieve the synergy of strength and ductility. The preparation of nacre-like Al matrix composites by freeze casting has been a promising application, but the continuous ceramic-rich [...] Read more.
Nacre-inspired metal matrix composites have received much attention due to their excellent deformation coordination ability, which can achieve the synergy of strength and ductility. The preparation of nacre-like Al matrix composites by freeze casting has been a promising application, but the continuous ceramic-rich layer affects the corrosion resistance of the composites, facing complex corrosion problems during service. In this work, the microstructure and corrosion behavior of the nacre-inspired (TiBw-TiB2)/Al composites fabricated by freeze casting and squeeze casting were systematically studied. The results indicated that the Al layers and ceramic-rich layers had little change, about 35 μm and 31 μm, respectively, with an increasing ratio of the Ti/TiB2. Meanwhile, a high Ti/TiB2 ratio resulted in an increase in the Fe-Ti intermetallic phases, which was detrimental to the corrosion performance of the composites and was prone to pitting. The electrochemical test results showed that the 3Ti7TiB2 composite had the lowest corrosion current density (15.9 μA) and intergranular corrosion depth (231 μm), indicating that it had the best corrosion resistance, which can be attributable to its stable and dense passivation film. Two different corrosion phenomena during the intergranular corrosion test existed in the present nacre-inspired (TiBw-TiB2)/Al composites: intergranular corrosion in the Al matrix layer and pitting corrosion in the ceramic-rich layer. Among all the composites, the corrosion depth of the 3Ti7TiB2 composite was the smallest and significantly less than that of the 2024Al alloy. In addition, the continuous ceramic-rich layer acted as a corrosion channel during corrosion, significantly degrading the corrosion resistance of the nacre-like Al composites. Full article
(This article belongs to the Special Issue Corrosion Mechanism and Protection Technology of Metallic Materials)
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22 pages, 14618 KiB  
Article
Corrosion Behavior of Ni-Cr Alloys with Different Cr Contents in NaCl-KCl-MgCl2
by Peng Lei, Lizhen Zhou, Yu Zhang, Fuli Wang, Qinzhe Li, Jiangyan Liu, Xueyun Xiang, Hang Wu, Wen Wang and Fuhui Wang
Materials 2024, 17(10), 2335; https://doi.org/10.3390/ma17102335 - 14 May 2024
Cited by 2 | Viewed by 1386
Abstract
This study investigates the corrosion behavior of Ni-Cr binary alloys, including Ni-10Cr, Ni-15Cr, Ni-20Cr, Ni-25Cr, and Ni-30Cr, in a NaCl-KCl-MgCl2 molten salt mixture through gravimetric analysis. Corrosion tests were conducted at 700 °C, with the maximum immersion time reaching up to 100 [...] Read more.
This study investigates the corrosion behavior of Ni-Cr binary alloys, including Ni-10Cr, Ni-15Cr, Ni-20Cr, Ni-25Cr, and Ni-30Cr, in a NaCl-KCl-MgCl2 molten salt mixture through gravimetric analysis. Corrosion tests were conducted at 700 °C, with the maximum immersion time reaching up to 100 h. The corrosion rate was determined by measuring the mass loss of the specimens at various time intervals. Verifying corrosion rates by combining mass loss results with the determination of element dissolution in molten salts using Inductively Coupled Plasma Optical Emission Spectroscopy (ICP-OES). Detailed examinations of the corrosion products and morphology were conducted using X-ray diffraction (XRD) and scanning electron microscopy (SEM). Micro-area elemental analysis on the corroded surfaces was performed using an energy dispersive spectrometer (EDS), and the elemental distribution across the corrosion cross-sections was mapped. The results indicate that alloys with lower Cr content exhibit superior corrosion resistance in the NaCl-KCl-MgCl2 molten salt under an argon atmosphere compared to those with higher Cr content; no corrosion products were retained on the surfaces of the lower Cr alloys (Ni-10Cr, Ni-15Cr). For the higher Cr alloys (Ni-20Cr, Ni-25Cr, Ni-30Cr), after 20 h of corrosion, a protective layer was observed in certain areas. The formation of a stable Cr2O3 layer in the initial stages of corrosion for high-Cr content alloys, which reacts with MgO in the molten salt to form a stable MgCr2O4 spinel structure, provides additional protection for the alloys. However, over time, even under argon protection, the MgCr2O4 protective layer gradually degrades due to chloride ion infiltration and chemical reactions at high temperatures. Further analysis revealed that chloride ions play a pivotal role in the corrosion process, not only facilitating the destruction of the Cr2O3 layer on the alloy surfaces but also possibly accelerating the corrosion of the metallic matrix through electrochemical reactions. In conclusion, the corrosion behavior of Ni-Cr alloys in the NaCl-KCl-MgCl2 molten salt environment is influenced by a combination of factors, including Cr content, chloride ion activity, and the formation and degradation of protective layers. This study not only provides new insights into the corrosion resistance of Ni-Cr alloys in high-temperature molten salt environments but also offers significant theoretical support for the design and optimization of corrosion-resistant alloy materials. Full article
(This article belongs to the Special Issue Corrosion Mechanism and Protection Technology of Metallic Materials)
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16 pages, 5880 KiB  
Article
Rust Prevention Property of a New Organic Inhibitor under Different Conditions
by Xingxing Guo, Chengsheng Wang, Hua Fu, Li Tian and Hua Song
Materials 2024, 17(9), 2168; https://doi.org/10.3390/ma17092168 - 6 May 2024
Cited by 2 | Viewed by 1238
Abstract
The corrosion resistance properties of a new type of environmentally-friendly organic inhibitor containing amino ketone molecules are presented in this paper. To evaluate the prevention effect of the inhibitor on corrosion of reinforcement, the electrochemical characteristics of steels in the simulated concrete pore [...] Read more.
The corrosion resistance properties of a new type of environmentally-friendly organic inhibitor containing amino ketone molecules are presented in this paper. To evaluate the prevention effect of the inhibitor on corrosion of reinforcement, the electrochemical characteristics of steels in the simulated concrete pore solution (SPS) were investigated under varied conditions of the relevant parameters, including concentrations of the inhibitor and NaCl, pH value, and temperature. The inhibition efficiency of the material was characterized through electrochemical impedance spectroscopy (EIS), potentiodynamic polarization, and the weight loss of steels. The results reveal a significant improvement in the corrosion resistance of steels with the inhibitor. A maximum resistance value of 89.07% was achieved at an inhibitor concentration of 4%. Moreover, the new organic inhibitor exhibited good corrosion protection capability for steels under different NaCl concentrations. Its inhibition efficiency was determined to be 65.62, 80.06, and 66.30% at NaCl concentrations of 2, 3.5 and 5%, respectively. On the other hand, it was found that an alkaline environment was favorable for an enhanced corrosion prevention effect, and an optimal pH value of 11.3 was observed in this work. Besides, the inhibition efficiencies at different temperatures showed a trend of 25 > 35 > 40 > 20 > 30 °C, with a maximum value of 81.32% at 25 °C. The above results suggest that the new organic material has high potential to be used as an eco-friendly and long-term durable inhibitor for steel corrosion prevention under complex conditions. Full article
(This article belongs to the Special Issue Corrosion Mechanism and Protection Technology of Metallic Materials)
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10 pages, 3972 KiB  
Communication
Pioneering Enhanced Corrosion Resistance along the Normal Plane of an Ultra-Light Mg-Li Extruded Sheet
by Jiexi Liang, Binbin Deng, Chuanqiang Li, Yong Dong, Naiguang Wang, Zhengrong Zhang and Shidong Wang
Materials 2023, 16(19), 6435; https://doi.org/10.3390/ma16196435 - 27 Sep 2023
Cited by 1 | Viewed by 1165
Abstract
The microstructure and corrosion anisotropy of the Mg-5Li extruded sheet were investigated in this work. Three distinct samples cut from the normal plane (A), longitudinal plane (B), and cross-sectional plane (C) of the as-extruded sheet were prepared. The microstructure was analyzed using optical [...] Read more.
The microstructure and corrosion anisotropy of the Mg-5Li extruded sheet were investigated in this work. Three distinct samples cut from the normal plane (A), longitudinal plane (B), and cross-sectional plane (C) of the as-extruded sheet were prepared. The microstructure was analyzed using optical microscopy (OM), scanning electron microscopy (SEM), and X-ray diffraction (XRD). The corrosion resistance and behaviors of the three samples in a 0.1 mol/L NaCl solution were evaluated by employing hydrogen evolution, mass loss testing, electrochemical assessments, and corrosion morphology analyses. The results revealed that sample A displayed a distinctive bimodal (0002) basal texture, along with clearly distinguishably larger grain sizes than the other samples. The effect of grain size and crystallographic orientation on the corrosion resistance was highlighted, indicating the pioneering corrosion resistance of sample A and the lowest corrosion resistance of sample C. Furthermore, all three samples exhibited the characteristic filiform corrosion during the initial stages of corrosion, progressing into the formation of corrosion pits, with sample C displaying pronounced susceptibility. Full article
(This article belongs to the Special Issue Corrosion Mechanism and Protection Technology of Metallic Materials)
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20 pages, 17038 KiB  
Article
Microstructural Understanding of Flow Accelerated Corrosion of SA106B Carbon Steel in High-Temperature Water with Different Flow Velocities
by Ying Hu, Long Xin, Chang Hong, Yongming Han and Yonghao Lu
Materials 2023, 16(11), 3981; https://doi.org/10.3390/ma16113981 - 26 May 2023
Cited by 12 | Viewed by 2296
Abstract
All light or heavy water reactors fabricated with carbon steels suffer from flow-accelerated corrosion (FAC). The FAC degradation of SA106B with different flow velocities was investigated in terms of microstructure. As flow velocity increased, the major corrosion type changed from general corrosion to [...] Read more.
All light or heavy water reactors fabricated with carbon steels suffer from flow-accelerated corrosion (FAC). The FAC degradation of SA106B with different flow velocities was investigated in terms of microstructure. As flow velocity increased, the major corrosion type changed from general corrosion to localized corrosion. Severe localized corrosion occurred in the pearlite zone, which can be the prior location for generating pits. After normalizing, the improvement in microstructure homogeneity reduced the oxidation kinetics and lowered cracking sensitivity, causing a decrease in FAC rates of 33.28%, 22.47%, 22.15%, and 17.53% at flow velocity of 0 m/s, 1.63 m/s, 2.99 m/s, and 4.34 m/s, respectively. Additionally, localized corrosion tendency was decreased by reducing the micro-galvanic effect and tensile stresses in oxide film. The maximum localized corrosion rate decreased by 21.7%, 13.5%, 13.8%, and 25.4% at flow velocity of 0 m/s, 1.63 m/s, 2.99 m/s, and 4.34 m/s, respectively. Full article
(This article belongs to the Special Issue Corrosion Mechanism and Protection Technology of Metallic Materials)
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15 pages, 6003 KiB  
Article
Effect of I-Phase on Microstructure and Corrosion Resistance of Mg-8.5Li-6.5Zn-1.2Y Alloy
by Ziming Fang, Liangxu He, Jiaxiu Wang, Xiaochun Ma, Guixiang Wang, Ruizhi Wu, Siyuan Jin, Jiahao Wang, Zihui Lu, Zhenzhao Yang, Boris Krit, Sergey Betsofen and Iya I. Tashlykova-Bushkevich
Materials 2023, 16(8), 3007; https://doi.org/10.3390/ma16083007 - 10 Apr 2023
Cited by 3 | Viewed by 1742
Abstract
The effects of solid solution treatment duration on the corrosion behavior and microstructure behavior of the cast Mg-8.5Li-6.5Zn-1.2Y (wt.%) alloy were investigated. This study revealed that with the treatment time for solid solutions increasing from 2 h to 6 h, the amount of [...] Read more.
The effects of solid solution treatment duration on the corrosion behavior and microstructure behavior of the cast Mg-8.5Li-6.5Zn-1.2Y (wt.%) alloy were investigated. This study revealed that with the treatment time for solid solutions increasing from 2 h to 6 h, the amount of α-Mg phase gradually decreases, and the alloy presents a needle-like shape after solid solution treatment for 6 h. Meanwhile, when the solid solution treatment time increases, the I-phase content drops. Exceptionally, under 4 h of solid solution treatment, the I-phase content has increased, and it is dispersed uniformly over the matrix. What we found in our hydrogen evolution experiments is that the hydrogen evolution rate of the as-cast Mg-8.5Li-6.5Zn-1.2Y alloy following solid solution processing for 4 h is 14.31 mL·cm−2·h−1, which is the highest rate. In the electrochemical measurement, the corrosion current density (icorr) value of as-cast Mg-8.5Li-6.5Zn-1.2Y alloy following solid solution processing for 4 h is 1.98 × 10−5, which is the lowest density. These results indicate that solid solution treatment can significantly improve the corrosion resistance of the Mg-8.5Li-6.5Zn-1.2Y alloy. The I-phase and the α-Mg phase are the primary elements influencing the corrosion resistance of the Mg-8.5Li-6.5Zn-1.2Y alloy. The existence of the I-phase and the border dividing the α-Mg phase and β-Li phase easily form galvanic corrosion. Although the I-phase and the boundary between the α-Mg phase and β-Li phase will be corrosion breeding sites, they are more effective in inhibiting corrosion. Full article
(This article belongs to the Special Issue Corrosion Mechanism and Protection Technology of Metallic Materials)
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Review

Jump to: Research

29 pages, 28581 KiB  
Review
Peening Techniques for Mitigating Chlorine-Induced Stress Corrosion Cracking of Dry Storage Canisters for Nuclear Applications
by Subin Antony Jose, Merbin John, Manoranjan Misra and Pradeep L. Menezes
Materials 2025, 18(2), 438; https://doi.org/10.3390/ma18020438 - 18 Jan 2025
Viewed by 715
Abstract
Fusion-welded austenitic stainless steel (ASS) was predominantly employed to manufacture dry storage canisters (DSCs) for the storage applications of spent nuclear fuel (SNF). However, the ASS weld joints are prone to chloride-induced stress corrosion cracking (CISCC), a critical safety issue in the nuclear [...] Read more.
Fusion-welded austenitic stainless steel (ASS) was predominantly employed to manufacture dry storage canisters (DSCs) for the storage applications of spent nuclear fuel (SNF). However, the ASS weld joints are prone to chloride-induced stress corrosion cracking (CISCC), a critical safety issue in the nuclear industry. DSCs were exposed to a chloride-rich environment during storage, creating CISCC precursors. The CISCC failure leads to nuclear radiation leakage. Therefore, there is a critical need to enhance the CISCC resistance of DSC weld joints using promising repair techniques. This review article encapsulates the current state-of-the-art of peening techniques for mitigating the CISCC in DSCs. More specifically, conventional shot peening (CSP), ultrasonic impact peening (UIP), and laser shock peening (LSP) were elucidated with a focus on CISCC mitigation. The underlying mechanism of CISCC mitigation in each process was summarized. Finally, this review provides recent advances in surface modification techniques, repair techniques, and developments in welding techniques for CISCC mitigation in DSCs. Full article
(This article belongs to the Special Issue Corrosion Mechanism and Protection Technology of Metallic Materials)
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