High-Performance Corrosion-Resistant Materials: Iron-Based Amorphous-Metal Thermal-Spray Coatings: SAM HPCRM Program ? FY04 Annual Report ? Rev. 0 - DARPA DSO & DOE OCRWM Co-Sponsored Advanced Materials Program

Abstract

Table 3 -The melt-spinning process was used to perform a systematic study of various elemental compositions, each based on the Fe-based DAR40 composition, with 1, 3, 5, and 7 atomic percent additions of specific elements believed to be beneficial to glass formation or corrosion resistance. Elemental additions investigated included nickel, molybdenum, yttrium, titanium, zirconium, and chromium. ___________________________________ 56 Table 4 -Composition of observed phases in PEA451 as detected by quantitative EDS-analysis.All numbers are atomic percent, with an accuracy of +/-0.5 %. ____________________ 57 Table 5 -Summary of thermal analysis (DTA or DSC) on Fe-based glass forming alloys suitable for spray deposition. ______________________________________________________ 57 Table 6 -Temperature-dependent heat transfer coefficients used in modeling heat transfer during wedge-cast of DAR35. ____________________________________________________ 58 Table 7 -Temperature-dependent heat transfer coefficients used in modeling heat transfer during wedge-cast of LDAR2X7. _________________________________________________ 58 Table 8 -Temperature-dependent heat transfer coefficients used in modeling heat transfer during wedge-cast of LDAR7 (CBCTL1651).________________________________________ 58 Table 9 -A compilation of various amorphous-metal samples, and the measured values of the open circuit corrosion potential (E corr ), the potential coinciding with the anodic oxidation peak (E peak ), the repassivation potential (E rp ), and the penetration rate based upon the maximum passive current density (dx/dt), in concentrated calcium chloride solutions at elevated temperature. _____________________________________________________ 59 Table 10 -A compilation of various amorphous-metal samples, and the measured values of the open circuit corrosion potential (E corr ), the potential coinciding with the anodic oxidation peak (E peak ), and the repassivation potential (E rp ) in Half Moon Bay seawater at various temperatures, ranging from 30 to 90°C _______________________________________ 61 Table 11. A compilation of the results from early cyclic polarization of Type 316L stainless steel, Alloy C-22, HVOF DAR35, HVOF DAR40, and HVOF DAR40X3 in standard 4M NaCl, SCW and BSW test solutions. Note that both SCW and BSW are bicarbonate-type brines. These data were reported at the HPCRM Team Meeting in Key West, held in January 2004. These results were used as the basis of recommending the pursuit of theoretically dense, pore-free materials for testing, so that the effects of alloy composition could be separated from the effects of coating morphology. _______________________ 62 funded by DARPA DSO and DOE OCRWM, and utilizes both theoretical and experimental materials science to develop corrosion-resistant amorphous-metal coatings suiJCF- Table for the desired applications. ___________________________________________________ 65 Figure 4 -The HPCRM Team is multi-institutional and involved three of DOE laboratories (LLNL, SNL, and ORNL), th...

Maximizing the Glass Fraction in Iron-Based High Velocity Oxy-Fuel Coatings

“…The stability of the SAM2X5 alloy chemistry in various environments has been modeled using THERMOCALC to both calculate and produce multicomponent phase and Pourbaix diagrams to determine the oxides present and their stability at the surface in both oxidizing and reducing environments. [7] The SAM2X5 alloy was designed to have high glass forming ability and exceptional resistance to electrochemical attack in various acidic and basic solutions.…”