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One dimensional wormhole corrosion in metals.

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  • 1National Center for Electron Microscopy, Molecular Foundry, Lawrence Berkeley National Laboratory, Berkeley, CA, USA. yang@psu.edu.

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|February 22, 2023
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Summary
This summary is machine-generated.

Researchers discovered a new form of corrosion called 1D wormhole corrosion, previously miscategorized. This finding, observed in Ni-Cr alloys, is crucial for developing materials with better corrosion resistance.

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Area of Science:

  • Materials Science
  • Corrosion Science
  • Physical Chemistry

Background:

  • Corrosion is a common material failure mechanism.
  • Localized corrosion often leads to porosity.
  • Previous classifications may have misidentified certain corrosion morphologies.

Purpose of the Study:

  • To identify and characterize a previously miscategorized form of corrosion, termed 1D wormhole corrosion.
  • To elucidate the underlying mechanism of 1D wormhole corrosion in a Ni-Cr alloy exposed to molten salt.
  • To establish a foundation for designing materials with improved corrosion resistance.

Main Methods:

  • Electron tomography was employed to visualize and confirm the 1D and percolating morphology of the corrosion.
  • Energy-filtered four-dimensional scanning transmission electron microscopy (4D-STEM) was combined with ab initio density functional theory (DFT) calculations.
  • A novel vacancy mapping method with nanometer resolution was developed to quantify vacancy concentrations.

Main Results:

  • Multiple instances of 1D wormhole corrosion morphology were identified and documented.
  • A significantly high vacancy concentration, up to 100 times the equilibrium value, was detected in the diffusion-induced grain boundary migration zone.
  • The study revealed a direct link between high vacancy concentrations and the initiation of 1D wormhole corrosion.

Conclusions:

  • 1D wormhole corrosion represents a distinct and previously underappreciated corrosion morphology.
  • High vacancy concentrations, particularly in grain boundary migration zones, are a key factor driving this corrosion mechanism.
  • Understanding and mitigating 1D wormhole corrosion is essential for enhancing the durability of structural materials in corrosive environments.