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Corrosion resistance of thermally sprayed high-boron iron-based amorphous-metal coatings: Fe49.7Cr17.7Mn1.9Mo7.4W1.6B15.2C3.8Si2.4

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Abstract

An iron-based amorphous metal, Fe49.7Cr17.7Mn1.9Mo7.4W1.6B15.2C3.8Si2.4 (SAM2X5), with very good corrosion resistance has been developed. This material was prepared as a melt-spun ribbon, as well as gas atomized powder and a thermal-spray coating. During electrochemical testing in several environments, including seawater at 90 °C, the passive film stability was found to be comparable to that of high-performance nickel-based alloys and superior to that of stainless steels, based on electrochemical measurements of the passive film breakdown potential and general corrosion rates. This material also performed very well in standard salt fog tests. Chromium (Cr), molybdenum (Mo), and tungsten (W) provided corrosion resistance, and boron (B) enabled glass formation. The high boron content of this particular amorphous metal made it an effective neutron absorber and suitable for criticality control applications. This material and its parent alloy maintained corrosion resistance up to the glass transition temperature and remained in the amorphous state during exposure to relatively high neutron doses.

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ACKNOWLEDGMENTS

This work was performed by Lawrence Livermore National Laboratory (LLNL) under Contract No. W-7405-Eng-48 and under the auspices of the United States Department of Energy (US DOE). Work was cosponsored by the Office of Civilian and Radioactive Waste Management (OCRWM) of the US DOE, and the Defense Science Office (DSO) of the Defense Advanced Research Projects Agency (DARPA). The guidance of Jeffrey Walker at DOE OCRWM and Leo Christodoulou at DARPA DSO is gratefully acknowledged. Recent salt fog testing has been conducted by E-Labs in Fredericksburg, VA by Ken Maloy and co-workers. Several substantive scientific comments were provided by Thomas Wolery at LLNL and served to improve this work.

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Authors and Affiliations

  1. Lawrence Livermore National Laboratory, Livermore, California, 94551-0808, USA

    J.C. Farmer, J.J. Haslam, S.D. Day, T. Lian, C.K. Saw, P.D. Hailey, J-S. Choi & R.B. Rebak

  2. Sandia National Laboratory, Livermore, California, 94551, USA

    N. Yang

  3. Case Western Reserve University, Cleveland, Ohio, 44106-7204, USA

    J.H. Payer

  4. University of Wisconsin, Madison, Wisconsin, 53706, USA

    J.H. Perepezko & K. Hildal

  5. University of California, Davis, California, 95616, USA

    E.J. Lavernia & L. Ajdelsztajn

  6. The NanoSteel Company, Idaho Falls, Idaho, 83402, USA

    D.J. Branagan & E.J. Buffa

  7. Strategic Analysis, Arlington, Virginia, 21811, USA

    L.F. Aprigliano

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  1. J.C. Farmer
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Correspondence to J.C. Farmer.

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Farmer, J., Haslam, J., Day, S. et al. Corrosion resistance of thermally sprayed high-boron iron-based amorphous-metal coatings: Fe49.7Cr17.7Mn1.9Mo7.4W1.6B15.2C3.8Si2.4. Journal of Materials Research 22, 2297–2311 (2007). https://doi.org/10.1557/jmr.2007.0291

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