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Advancements in Metalworking Techniques Lead to New Approaches in Monitoring Corrosion

By Oliver Peckham

Researchers are pushing the boundaries of metalworking with innovative methods like Shear Assisted Processing and Extrusion (ShAPEÔäó) and friction stir welding, resulting in metal components that are not only lighter and stronger but also more precise than ever before. As we delve deeper into these new frontiers of metalworking, it becomes increasingly important to have a comprehensive understanding of the performance and properties of the produced metals, as well as the bonds between them. Corrosion, the gradual deterioration of metals, presents a significant challenge over time. However, visualizing and explaining the progression of corrosion through a metal or the bond between two metals has been a complex task.

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The Challenge of Monitoring Corrosion Using Traditional Methods

Traditional methods of measuring corrosion often involve a “cook-and-look” approach, where researchers immerse a sample in a chosen medium and observe the corrosion after a certain period. This method has limitations as it only provides snapshots of the corrosion process and requires researchers to hypothesize about its initiation and progression. Additionally, repeated removal and reinsertion of the sample can skew the results, leading to inaccuracies in the analysis.

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Introducing Multimodal Corrosion Analysis

Researchers at Pacific Northwest National Laboratory (PNNL) have introduced a novel technique called multimodal corrosion analysis to overcome the limitations of traditional corrosion monitoring methods. This approach allows for real-time observation of specific initiation sites of corrosion and provides a detailed insight into how corrosion progresses through materials. By combining sensors, cameras, electrodes, and a hydrogen collection tube, researchers can monitor corrosion in simple atmospheres, analyze the electrochemical properties of surfaces, and detect hydrogen gases produced during corrosion.

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Enhancing Corrosion Analysis with Scanning Electrochemical Cell Impedance Microscopy

To achieve even greater precision in corrosion analysis, scientists at PNNL have developed a cutting-edge technique called scanning electrochemical cell impedance microscopy. This technique allows researchers to measure localized and time-dependent electrochemical properties on surfaces with high resolution, providing insights into corrosion mechanisms at a microscopic level.

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Implications for Advanced Metalworking Techniques

This new approach to corrosion analysis has significant implications for advanced metalworking techniques like friction stir welding and ShAPE. By gaining a deeper understanding of corrosion patterns at the microscopic level, researchers can design high corrosion-resistant materials for various applications, including lightweight vehicle components.

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This research, highlighted in scientific publications, showcases the innovative work being done at PNNL to advance scientific knowledge and address challenges in sustainable energy and national security.

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