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At least 73 records · Page 4
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Critical role of slags in pitting corrosion of additively manufactured stainless steel in simulated seawater

Abstract Pitting corrosion in seawater is one of the most difficult forms of corrosion to identify and control. A workhorse material for marine applications, 316L stainless steel (316L SS) is known to balance resistance to pitting with good mechanical properties. The advent of additive manufacturing (AM), particularly laser powder bed fusion (LPBF), has prompted numerous microstructural and mechanical investigations of LPBF 316L SS; however, the origins of pitting corrosion on as-built surfaces is unknown, despite their utmost importance for certification of LPBF 316L SS prior to fielding. Here, we show that Mn-rich silicate slags are responsible for pitting of the as-built LPBF material in sodium chloride due to their introduction of deleterious defects such as cracks or surface oxide heterogeneities. In addition, we explain how slags are formed in the liquid metal and deposited at the as-built surfaces using high-fidelity melt pool simulations. Our work uncovers how LPBF changes surface oxides due to rapid solidification and high-temperature oxidation, leading to fundamentally different pitting corrosion mechanisms.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Pit growth kinetics in aluminum: effects of salt loading and relative humidity

Abstract The growth kinetics of localized corrosion, e.g. pits, in corrosive environments often controls the service life of metallic components. Yet, our understanding of these kinetics is largely based on coupon-level, e.g. mass-loss, studies which provide limited insights into the evolution of individual damage events. It is critical to relate observed cumulative loss trends, such as links between changing humidity and mass loss rates, to the growth kinetics of individual pits. Towards this goal, we leverage in-situ X-ray computed tomography to measure the growth rates of over sixty pits in aluminum in four different humid, chloride environments over ≈3 days of exposure. Pit growth rates and final volumes increased with increasing droplet volume, which was observed to increase with increasing humidity and salt loading. Two factors, droplet spreading and oxide jacking, dramatically increased pit growth rates and final volumes.

Noell, Philip J. (ORCID:0000000346998999)↗
DOE OSTI2025

Mitigation of Pitting on Nitrogen-Doped Niobium Surfaces through Two-Step Electropolishing

Surface processing of niobium superconducting RF cavities used in particle accelerators is crucial for determining their performance. The nitrogen (N)-doping method, developed at Fermilab, enhances the cavities’ quality factor by doping the cavity’s interior surface with N atoms at 800 °C. After N-doping, electropolishing (EP) is employed to remove the niobium nitride phases and attain the desired concentration of interstitial N atoms. This study explores the effects of EP conditions on N-doped niobium samples. The samples were electropolished at 5 to 40 °C and voltages between 3 and 22 V. Different EP voltage ranges produced two types of pits, classified based on their sizes. Larger pits, linked to higher voltages, are also affected by the reaction rate. Pitting could be reduced at a lower temperature and adequate EP voltage. However, to effectively minimize gas evolution forming large-sized pitting, peeling off the top nitride layer before EP might be beneficial. This was achieved through precise low-voltage etching, forming a two-step EP process. The process involves removing the top 100–200 nm layer at a low voltage, followed by standard EP to remove the required material. This two-step EP process effectively mitigated the pitting risk associated with gas evolution on N-doped surfaces.

43 PARTICLE ACCELERATORS↗
DOE OSTI2022

Pit depth analysis using automated software for three containers with complete imaging

The 3013 surveillance program is tasked with ensuring the long term safety of plutonium storage in 3013-compliant containers. One component of this task is to understand corrosion features found on the interior sidewall of the inner container closure weld region (ICCWR). To this end, three containers were selected to have laser confocal microscope (LCM) 20X imaging of the entire ICCWR. This report describes the analysis of the LCM pit depth data using the automated corrosion analysis software. The analysis included determining maximum pit depths and distributions of pit depths, volumes, and diameters for all pit features identified on the three containers. Results provided insight into possible corrosion mechanisms and were consistent with previous pit growth model predictions.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Natural Attenuation Progress, Plume Movement, and Source Reduction for the SRS CMP Pits VOC Plume - 18384

Monitoring the effectiveness of natural attenuation for remediating the Savannah River Site (SRS) Chemical, Metals, and Pesticides (CMP) Pits plume fringe has focused intensive sampling of shallow groundwater for different reaches of Pen Branch from 2005 to 2017. Volatile organic compounds (VOCs) were analyzed for the critical hyporheic zone beneath Pen Branch and adjacent floodplain. These sampling efforts assisted larger-scale compliance monitoring in accordance with US Environmental Protection Agency (EPA) guidelines. When applicable, EPA has found natural attenuation to be an acceptable mode of achieving regulatory compliance. While natural attenuation can include any ecosystem function that reduces contaminant loads, it is focused on microbial biochemical pathways. The study plume originated from CMP Pits, a waste disposal area in operation from 1971 to 1979, when the pits were closed and backfilled. In 1984, excavations of source material and contaminated soils were removed up to a depth of 7.6 m below the trenches. However, monitoring well data indicated that perchloroethylene (PCE) and trichloroethylene (TCE) had seeped beneath the vadose zone and formed groundwater plumes reaching the Pen Branch valley below. Although 'hot spots' of TCE were found within the Pen Branch floodplain, it was unknown just how the flow pattern was entering Pen Branch and to what degree natural attenuation was reducing the contaminant load. For this reason, our stations were located along the Pen Branch reach bordering the modelled plume fringe. In general, VOCs were highest at station piezometer holes in the middle study zone. Moderate VOC levels were detected at upstream stations and lowest VOC levels were found at downstream stations. Electrical resistance heating (ERH) with soil vapor extraction (SVE) conducted by Savannah River Nuclear Solutions (SRNS) from 2008 to 2009 at the filled CMP Pits helped to remove contaminants trapped in clay horizons beneath the CMP Pits and to reduce overall new plume concentrations. Collectively PCE, TCE, and their degradation products displayed a favorable yearly trend of contaminant natural attenuation. Additionally, phytoremediation actions by native bamboo, Arundinaria gigantea, added to VOC removal from wetlands soils. Total VOC concentrations at some stations declined by >25% and concentrations of vinyl chloride (VC), a nearly-final stage degradation product increased from 0.0 ppb to >20 ppb. Temporal patterns displayed a continued reduction of VOCs, while spatial patterns indicated a possible slow progression of the plume downstream along Pen Branch. Conclusions about plume export into surface waters must address the seasonal and geological complexities of this system. Hydrological patterns are complex and plumes do not directly outcrop into Pen Branch surface waters, but emerge into the stream through pathways in the porous hyporheic zone. For this reason, continued sampling must identify critical depths and downstream locations where plume flows may be more intense. During drought periods with no surface flow in Pen Branch, subsurface plume flows may be flowing downslope in the hyporheic zone. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2025

Automated Image Segmentation and Processing Pipeline Applied to X–Ray Computed Tomography Studies of Pitting Corrosion in Aluminum Wires

Understanding pitting corrosion is critical, yet its kinetics and morphology remain challenging to study from X-ray computed tomography (XCT) due to manual segmentation barriers. To address this, an automated pipeline leveraging deep learning for efficient large-scale XCT analysis is developed, revealing new corrosion insights. The pipeline enables pit segmentation, 3D reconstruction, statistical characterization, and a topological transformation for visualization. Here, the pipeline is applied to 87 648 XCT images capturing commercial purity aluminum (1100 Al) wire exposed to sodium chloride (NaCl) salt particles over a period of 122 h. The pipeline achieves complete feature extraction and statistical quantification across the entire XCT dataset, leveraging distributed computing environment for high efficiency. Global growth kinetics such as high-level stepwise sigmoidal volume loss patterns and granular individual pit developments are both captured for 36 detected pits. By combining automation, computer vision, and extensive XCT datasets, this research accelerates precise corrosion assessment to enable materials science discoveries at scale.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Pitting Corrosion of Supermartensitic Stainless Steel in Chloride Solutions Containing Thiosulfate or H{sub 2}S

Deepwater oil and gas extraction environment have high salinity, low oxygen content, and the presence of carbon dioxide and hydrogen sulfide (H{sub 2}S). Handling of H{sub 2}S-containing gaseous mixtures should be carried out in laboratories with special installations, owing to the high toxicity of this gas. An alternative is the use of non-toxic substances that can generate H{sub 2}S in the medium, such as sodium thiosulfate. The objective of this work is to study the viability of substituting H{sub 2}S by thiosulfate for the evaluation of the susceptibility to pitting corrosion in sour environments of the supermartensitic stainless steel (SMSS). The electrochemical behavior of SMSS in NACE TM0177-2016 solution C solution containing different concentrations of H{sub 2}S or thiosulfate ions at 10{sup −3} mol/L was performed by using cyclic potentiodynamic polarization (CPP). The condition of shorter OCP time (300 s) prevents the formation of a passive layer and allows the generation of H{sub 2}S due to the reaction of the solution with the metal surface. The CPP curves of SMSS in the media containing 3% H{sub 2}S/Ar (2.96 kPa) and 10{sup −3} M of thiosulfate ions (OCP 300 s) were similar, the pitting potential was about − 322.5 ± 8.7 and − 338.8 ± 11.4 mV{sub Ag/AgCl}, respectively, and the pit morphology showed several small pits on the steel surface in both conditions, suggesting the viability of the use of thiosulfate-containing brines to simulate H{sub 2}S solutions.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Understanding the efficacy of concentrated interstitial carbon in enhancing the pitting corrosion resistance of stainless steel

By introducing a high fraction of interstitial carbon through low temperature carburization, the pitting corrosion resistance of austenitic stainless steel can be significantly improved. Previous work attributed this to strengthening of the passive film by carbon. Here, however, we present a paradigm shift by showing that carbon actually weakens the passive film but strengthens the bonding within the alloy by forming localized (covalent) bonds with the metal atoms (Fe, Cr, Ni). Accordingly, the enhancement in pitting resistance is a result of carbon reducing the metal dissolution rate in a local pit environment by many orders of magnitude, which extremely decreases the growth stability of a pit and prevents it from transitioning into stable growth. Electronic structure calculations confirm that carbon bonds to the metal atoms and that the metal–carbon bonds are 1.4 to 2.0 times stronger than the metal–metal bonds. These results suggest a new strategy for the design of corrosion resistant alloys, namely surface engineering by infusion of concentrated interstitials that form strong bonds with the matrix atoms.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2022

Iraq/Afghanistan war lung injury reflects burn pits exposure

This descriptive case series retrospectively reviewed medical records from thirty-one previously healthy, war-fighting veterans who self-reported exposure to airborne hazards while serving in Iraq and Afghanistan between 2003 and the present. They all noted new-onset dyspnea, which began during deployment or as a military contractor. Twenty-one subjects underwent non-invasive pulmonary diagnostic testing, including maximum expiratory pressure (MEP) and impulse oscillometry (IOS). In addition, five soldiers received a lung biopsy; tissue results were compared to a previously published sample from a soldier in our Iraq Afghanistan War Lung Injury database and others in our database with similar exposures, including burn pits. We also reviewed civilian control samples (5) from the Stony Brook University database. Military personnel were referred to our International Center of Excellence in Deployment Health and Medical Geosciences, Donald and Barbara Zucker School of Medicine at Hofstra/Northwell under the auspices of Northwell IRB: 17-0140-FIMR Feinstein Institution for Medical Research “Clinicopathologic characteristics of Iraq Afghanistan War Lung Injury.” We retrospectively examined medical records, including exposure data, radiologic imaging, and non-invasive pulmonary function testing (MGC Diagnostic Platinum Elite Plethysmograph) using the American Thoracic Society (ATS) standard interpretation based on Morgan et al., and for a limited cohort, biopsy data. Lung tissue, when available, was examined for carbonaceous particles, polycyclic aromatic hydrocarbons (Raman spectroscopy), metals, titanium connected to iron (Brookhaven National Laboratory, National Synchrotron Light Source II, Beamline 5-ID), oxidized metals, combustion temperature, inflammatory cell accumulation and fibrosis, neutrophil extracellular traps, Sirius red, Prussian Blue, as well as polarizable crystals/particulate matter/dust. Among twenty-one previously healthy, deployable soldiers with non-invasive pulmonary diagnostic tests, post-deployment, all had severely decreased MEP values, averaging 42% predicted. These same patients concurrently demonstrated abnormal airways reactance (X5Hz) and peripheral/distal airways resistance (D5–D20%) via IOS, averaging – 1369% and 23% predicted, respectively. These tests support the concept of airways hyperresponsiveness and distal airways narrowing, respectively. Among the five soldiers biopsied, all had constrictive bronchiolitis. We detected the presence of polycyclic aromatic hydrocarbons (PAH)—which are products of incomplete combustion—in the lung tissue of all five warfighters. All also had detectable titanium and iron in the lungs. Metals were all oxidized, supporting the concept of inhaling burned metals. Combustion temperature was consistent with that of burned petrol rather than higher temperatures noted with cigarettes. All were nonsmokers. Neutrophil extracellular traps were reported in two biopsies. Compared to our prior biopsies in our Middle East deployment database, these histopathologic results are similar, since all database biopsies have constrictive bronchiolitis, one has lung fibrosis with titanium bound to iron in fixed mathematical ratios of 1:7 and demonstrated polarizable crystals. These results, particularly constrictive bronchiolitis and polarizable crystals, support the prior data of King et al. (N. Engl. J. Med. 365:222–230, 2011) Soldiers in this cohort deployed to Iraq and Afghanistan since 2003, with exposure to airborne hazards, including sandstorms, burn pits, and improvised explosive devices, are at high risk for developing chronic clinical respiratory problems, including: (1) reduction in respiratory muscle strength; (2) airways hyperresponsiveness; and (3) distal airway narrowing, which may be associated with histopathologic evidence of lung damage, reflecting inhalation of burned particles from burn pits along with particulate matter/dust. Non-invasive pulmonary diagnostic tests are a predictor of burn pit-induced lung injury

36 MATERIALS SCIENCE↗
DOE OSTI2025

An initial effort to study the influence of pitting in SAVY containers

As part of a broader effort to investigate a critical pit depth, below which SAVY containers fail a leak test after a drop test, surrogate testing using pristine SAVY container material was investigated. The original study involved producing pits in a SAVY wall to depths 35% to 55% of the wall thickness and subjecting the pitted container to a drop test under prototypic conditions. Subsequent leak testing after drop testing showed the container passed and that the pit size distribution and drop conditions were not sufficient to cause a leak test failure in this specific container.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Potential Biodegradation of Butyric Acid by Lysinibacillus fusiformis Isolated from a Pit Latrine in South Africa - 18150

Butyric acid is one of the volatile organic compounds (VOCs) which significantly contribute to pit latrine noxious odours. It has low odour detection thresholds. Current methods in reducing odour emitted from pit latrines in low incomes communities are ineffective due to economic, technological and social constraints. To seek the butyric acid-degrading bacteria, faecal sludge samples from pit latrine were collected to isolate them. Nine butyric acid-utilising isolates were obtained but the bacterial isolate designated as C4c was further investigated. The bacterial isolate was investigated under different environmental conditions. Under aerobic condition it was found that the isolate has best capability to utilise butyric optimally when the temperature was 30 deg. C and at pH of 7.0. The isolate was able to utilise butyric acid up to the concentration of 5000 mgL{sup -1}. In accordance with the 16S rRNA sequence analysis the isolate was identified as Lysinibacillus fusiformis. This, therefore, indicates that the isolate can be effectively used for bioremediation of butyric acid in the pit latrines. (authors)

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2017

The Microstructure and Pitting Resistance of Weld Joints of 2205 Duplex Stainless Steel

2205 duplex stainless steel (DSS) was welded by submerged arc welding. The effects of both heat input and groove type on the ferrite/austenite ratio and elemental diffusion of weld joints were investigated. The relationships among welding joint preparation, ferrite/austenite ratio, elemental diffusion, and pitting corrosion resistance of weld joints were analyzed. When the Ni content of the weld wire deposit was at minimum 2–4% higher than that of 2205 DSS base metal, the desired ratio of ferrite/austenite and elemental partitioning between the austenite and ferrite phases were obtained. While the pitting sensitivity of weld metal was higher than that of base metal, the self-healing capability of the passive film of weld metal was better than that of the base metal when a single V-type groove was used. Furthermore, the heat input should be carefully controlled since pitting corrosion occurred readily in the coarse-grained heat-affected zone near the fusion line of welded joints.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Pitting behavior of friction stir repair-welded 304L stainless steel in 3.5% NaCl solution at room temperature: role of grain and defect structures

Stainless steel (SS) canisters used for storing spent nuclear waste are prone to chloride-induced stress corrosion cracking. Friction stir welding (FSW), being a low heat input process, can be used for repair welding of these canisters. In this study, an artificial crack was introduced on the 304L SS coupons by an electric discharge machining process. The artificial crack was repair-welded by FSW by maintaining the tool temperature a constant at two levels (725 and 825 °C). Friction stirring significantly reduced the grain size of the stirred zone (SZ) from about 47 to 2–4 μm. The fraction of low-angle grain boundaries increased in the SZ from 2 to 37–43%. Here, on the other hand, the fraction of special grain boundaries (Σ3 and Σ9) that was ~ 50% in the base metal reduced to < 10% in the SZ. During friction stirring, the oxide layer of artificial crack was broken and aligned to form a spiral defect called lazy-S structure. All these microstructural changes affected the corrosion behavior of the FSW specimens when tested in 3.5% NaCl at room temperature using cyclic polarization, chronoamperometry, and electrochemical impedance spectroscopy. The FSW specimens showed lower polarization resistance and lower transpassive potential than those of the base metal specimens. However, the pitting protection potentials of the FSW specimens were higher than that of the base metal. The pitting behavior of the FSW specimens was influenced more by the preferential attack on the lazy-S region than by passive film breakdown. The flat band potentials of the passive film formed on the FSW specimens were more positive than that of base metal. The charge carrier density of passive film formed on the FSW specimens was higher than that of the base metal. The higher fraction of low-angle grain boundaries present in the FSW specimens could supply more number of misorientation dislocations at the metal/film interface which could form anion vacancies by a climb process leading to formation of oxide at these locations without stressing the substrate. Therefore, low-angle boundaries are considered helpful for formation of stress-free passive films that will be highly stable and enhance both pitting and stress corrosion cracking resistance.

Dry storage canister↗
DOE OSTI2021

Critical pitting temperature of selective laser melted 316L stainless steel: A mechanistic approach

In this work, the critical pitting temperature (CPT) of selective laser melted (SLM) 316 L stainless steel in 1.0 M NaCl was measured and compared with a commercial wrought alloy. Potentiostatic measurements determined a mean CPT value of 16 ± 0.7 °C, 27.5 ± 0.8 °C and 31 ± 1 °C for the wrought alloy, the SLM alloy normal to the build direction and parallel to the build direction, respectively. The lead-in pencil electrode technique was used to study the pit chemistry of the two alloys and to explain the higher CPT values observed for the SLM alloy. A lower critical current density required for passivation in a simulated pit solution was measured for the SLM alloy. Moreover, the ratio of the critical concentration to saturated concentration of dissolving metal cations was found to be higher for the SLM alloy, which was related to its different salt film properties, possibly as a result of the SLM’s distinct microstructure.

36 MATERIALS SCIENCE↗
DOE OSTI2025

CMP Pits and D-Area Watershed Infiltrometer Testing

Savannah River National Laboratory (SRNL) conducted saturated hydraulic conductivity field testing at the Chemical, Metals, and Pesticide Pits (CMP Pits) and the D-Area watershed to develop infiltration rates for use in future updates to the CMP Pits groundwater flow model. Approximately 18 testing locations were selected at each site based on the soil series that were identified in the Soil Survey of Savannah River Plant Area, Parts of Aiken, Barnwell, and Allendale Counties, South Carolina.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2025

CMP Pits and D-Area Watershed Infiltrometer Testing

Savannah River National Laboratory (SRNL) conducted saturated hydraulic conductivity field testing at the Chemical, Metals, and Pesticide Pits (CMP Pits) and the D-Area watershed to develop infiltration rates for use in future updates to the CMP Pits groundwater flow model. Approximately 18 testing locations were selected at each site based on the soil series that were identified in the Soil Survey of Savannah River Plant Area, Parts of Aiken, Barnwell, and Allendale Counties, South Carolina.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2026

Effect of Oil Viscosity and Impact of Ionic Liquid Additive on Electrically Induced Pitting in Rolling Contact

Electrically induced bearing damage (EIBD) is a growing concern in electric drivetrains, where electrical discharge currents generate localized pitting that accelerates wear and premature failure. While ionic liquids (ILs) have shown promise as lubricant additives due to their natural physical adsorption, strong capabilities of tribofilm formation, and high molecular tunability, their role in mitigating EIBD is little known. This gap is especially evident because lubricant viscosity and film thickness affect discharge behavior, and additive performance in these regimes has not been well explored. In this study, tribological tests were performed using a ball-on-disk pure rolling-contact system under an applied voltage on polyalphaolefin oils of three viscosities (4, 10, and 150 cSt measured at 100 °C), with and without the addition of a phosphonium-phosphate IL. Surface damage was analyzed using scanning electron microscopy (SEM) and stylus profilometry. Damage quantification was based on pit morphology analysis of SEM images. The results provide new insights into how oil viscosity governs the discharge behavior and how an IL additive could influence the pit formation. While viscosity seems to play a significant role, an IL additive shows potential to reduce EIBD and deserves further study.

electrically induced bearing damage (EIBD)↗
DOE OSTI2019

Pit Realization Process Manufacturing Readiness Assessments

This document defines a manufacturing readiness assessment process within a Product Realization Process (PRP) for pit manufacturing at Los Alamos National Laboratory (LANL) having the following objectives. Meet National Nuclear Security Administration (NNSA) Defense Programs Business Process System (DPBPS) PRP requirements. Use language established within LANL’s pit manufacturing program. Enable a disciplined approach to evaluate pit manufacturing readiness. Provide effective tools and metrics to assess manufacturing system maturity.

42 ENGINEERING↗