6 Materialchemie
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The presentation summarizes our recent results on the coupled electrochemical methods for high resolution corrosion studies. The combination of Scanning Electrochemical Microscopy (SECM) and multielectrode (MMA) based real-time corrosion monitoring was presented as a new method for achieving high time resolution in local electrochemical analysis. Correlative imaging by means of Atomic Force Microscopy (AFM) and Scanning Electron Microscopy (SEM) was demonstrated as a tool for the investigation of local corrosion processes initiated by the intermetallic particles (IMPs) on AA2024-T3 aluminium alloy.
The performance of functional coatings and adhesively joined hybrid components relies strongly on the stability of the polymer-metal interface. With the increasing utilization of multi-material structures in the automotive and aerospace industry, it is of great scientific and technical interest to understand the processes leading to interface degradation and to develop novel strategies to increase corrosion and delamination resistance.
The aim of this project is to develop thin epoxy-based films and their carbon nanofiller loaded composites on aluminium alloy AA2024-T3 as a model system and to investigate their interfacial stability under corrosive and coupled corrosive-mechanical load. Spin coating was used for the layer-by-layer deposition of poly[(o-cresyl glycidyl ether)-co-formaldehyde] and poly-(ethylenimine) bi-layers. Atomic force microscopy (AFM) results indicate a very homogeneous and dense film with low surface roughness. Carbon nanofillers were introduced either by mixing into the coating components or in between individual layers to control the separation between the carbon nanofillers and alloy surface. The film chemistry and barrier properties were characterized by means of spectroscopic and electrochemical methods, respectively. The degradation and delamination behavior of the epoxy-based films was characterized by means of in situ AFM corrosion experiments. The quantitative imaging (QI) mode allowed the observation of hydrogen-generation induced blister formation during exposure to corrosive electrolyte and how the local corrosion processes evolved with exposure time. Complementary energy dispersive X-ray spectroscopy (EDX) analysis was performed to correlate the corrosion behavior with the different intermetallic particle chemistries and distributions. The presentation will summarize our results on the effect of interface chemistry and carbon nanofiller – alloy separation on the initiation of local corrosion processes on thin film covered AA2024-T3 aluminium alloys.
In service, most materials are operated under simultaneous corrosive and mechanical load and there are very few methods capable for testing material degradation under these conditions, especially when it comes to high resolution analysis. For this purpose, in this work, a tensile module capable of uniaxial stretching and compression with up to 5 kN force was integrated into an AFM stage. The elimination of the need for sample unmounting and remounting and the resulting possibility of keeping the sample under constant mechanical load during AFM measurements not only enables a precise positioning of the area of interest but also allows for the analysis of processes in the elastic deformation regime.
This methodology was demonstrated for two case studies. Scanning Kelvin Probe Force Microscopy (SKPFM) was used as the main tool to characterize the deformation behavior. Moreover, a flexible electrochemical measurement cell was used to enable electrochemical analysis by means of electrochemical impedance spectroscopy (EIS) and Linear Sweep Voltammetry (LSV) during AFM measurements at different levels of strain. The in situ AFM results are complemented by microstructure analysis by means of electron backscatter diffraction (EBSD).
In the first case study, the deformation induced delamination of a thin organic coating on AA2024 T3 aluminium alloy was investigated as a function of alloy surface treatment. The formation of cracks in the insulating passive film enabled an early detection of deformation processes by means of SKPFM. The second case study focused on the comparison of corrosion and deformation behavior of conventional and additively manufactured 316 stainless steels. In comparison to the conventional 316 stainless steel, the effect of processing was clearly detectable on the additively manufactured material as zones of inhomogeneous potential, which also affected the initiation of local corrosion processes. The contribution will provide detailed information on the new AFM setup and summarize our results from both case studies.
Antibiotic resistance is a growing global problem which poses a massive threat to human health. Although human activity contributes to the acceleration of the process, bacteria have a self-driven stabilisation mechanism to protect themselves from such and other external threats: biofilm formation. Nonetheless, it is the adhesion of a single bacterial cell to a surface that triggers the formation of such network of biomolecules and microorganisms, as well as its hazardous consequences. The main objective of this work was to quantify the adhesion force of a single E. coli cell on a Ti substrate via the AFM-related single-cell force spectroscopy, with both the cell and the substrate material being of high clinical relevance. A set of 25 x 25 force displacement curves was acquired with a maximum force of 3.2 nN without dwell time, yielding a topography map and an adhesion force map that showed to be correlated. A mean adhesion force of 0.85 ± 0.175 nN was measured and the presence of cell appendages on the bacterial cell wall was verified through individual force-displacement curves. Bacterial viability was assessed after the measurements via live/dead staining.
Trace elements play an important role in the fine-tuning of complex material properties. This study focuses on the correlation of microstructure, lattice misfit and creep properties. The compositionally complex alloy Al10Co25Cr8Fe15Ni36Ti6 (in at. %) was tuned with high melting trace elements Hf and W. The microstructure consists of a γ matrix, γ' precipitates and the Heusler phase and it is accompanied by good mechanical properties for high temperature applications. The addition of 0.5 at.% Hf to the Al10Co25Cr8Fe15Ni36Ti6 alloy resulted in more sharp-edged cubic γ′ precipitates and an increase in the Heusler phase amount. The addition of 1 at.% W led to more rounded γ′ precipitates and the dissolution of the Heusler phase. The shapes of the γ' precipitates of the alloys Al9.25Co25Cr8Fe15Ni36Ti6Hf0.25W0.5 and Al9.25Co25Cr8Fe15Ni36Ti6Hf0.5W0.25, that are the alloys of interest in this paper, create a transition from the well-rounded precipitates in the alloy with 1% W containing alloy to the sharp angular particles in the alloy with 0.5% Hf. While the lattice misfit has a direct correlation to the γ' precipitates shape, the creep rate is also related to the amount of the Heusler phase. The lattice misfit increases with decreasing corner radius of the γ' precipitates. So does the creep rate, but it also increases with the amount of Heusler phase. The microstructures were investigated by SEM and TEM, the lattice misfit was calculated from the lattice parameters obtained by synchrotron radiation measurements.
The high-throughput synthesis and characterization of potential material combinations plays an important role in accelerating the development of new materials. Diffusion controlled synthesis of gradient alloys is widely used to create phase diagrams, and it is also one of the most effective combinatorial approaches for rapid realization of potential material combinations.
This study focuses on the synthesis and investigation of the quaternary multi-principle-element alloy (MPEA) FeNiCrMn by means of diffusion multiples, the correlation of their microstructural and chemical characterization data with their application relevant properties like local mechanical and corrosion properties. A diffusion system was set up by combining an equimolar ternary alloy (FeNiCr) with a single diffusing metallic component (Mn) with the highest interdiffusion coefficient. Scanning electron microscopy (SEM) and energy dispersive X-ray spectroscopy (EDX) were used to collect microstructural and compositional information which were correlated to local mechanical properties studied with nanoindentation. Local corrosion properties were investigated by means of Atomic Force Microscopy (AFM) and Scanning Electrochemical Microscopy (SECM). We have observed that a >50 μm deep homogeneous diffusion zone was formed the thickness of which scales with the duration of the thermal treatment. Beyond the Mn-concentration gradient in the FeNiCr matrix, a distinct Cr-rich secondary phase, characterized by high hardness and elastic modulus values appeared. We synthesized MPEAs with selected compositions from the diffusion zone as well as the Cr-rich phase as bulk alloys for electrochemical corrosion studies under different environmental conditions. The presentation will summarize the results of our correlative study on the mechanical properties and corrosion resistance of the quaternary multi-principle-element alloy (MPEA) FeNiCrMn family.
The efficient exploration of novel alloy chemistries is crucial for advancing the development of new materials. Diffusion-controlled synthesis of gradient alloys is an intelligent approach for creating phase diagrams and to effectively identify potential material combinations with tailored properties.
This project focusses on the design of quaternary multi-principle-element alloys (MPEAs) using diffusion couples. Our diffusion system contains an equimolar ternary alloy (FeNiCr) and additional single diffusing elements e.g. Mn and Mo. We determined the optimal temperature ranges for the diffusion thermal treatment by means of ThermoCalc simulations with the aim to form single-phase MPEAs. Microstructure and chemical characterization of the diffusion couples were performed by means of scanning electron microscopy (SEM) and energy dispersive X-ray spectroscopy (EDX). For most alloy couples, the diffusion zone contained a single-phase alloy matrix with diffusion-induced compositional gradient as well as precipitation phases. This heterogeneity makes the diffusion couples interesting materials to investigate local mechanical and corrosion properties. Thus, local corrosion properties were examined using Atomic Force Microscopy (AFM) and Scanning Electrochemical Microscopy (SECM). Nanoindentation was used for the analysis of local mechanical properties.
Based on the results of the local corrosion analysis, we have selected single-phase alloy chemistries along the diffusion zone and reproducibly synthesized these alloys in bulk for detailed corrosion studies by means of potentiodynamic polarization and SECM.
The presentation will briefly summarize our methodology and motivation for using diffusion couples as an efficient tool for exploring phase diagrams of MPEAs in the search for new alloy chemistries and the results of our correlative study on the mechanical and corrosion properties of these materials.
The efficient exploration of novel alloy compositions is crucial for advancing the development of new materials. One widely utilized approach for creating phase diagrams is the use of diffusion-controlled synthesis for gradient alloys. This method is also an effective means for rapidly identifying potential material combinations.
The present study focusses on the exploration of quaternary multi-principle-element alloys (MPEAs) using diffusion multiples. We established a diffusion system by combining an equimolar ternary alloy (FeNiCr) with single diffusing elements Mn and Mo. Using ThermoCalc simulations, we determined suitable temperature ranges where we can expect the formation of single-phase alloys. Depending on the diffusion constants of the selected metals, diffusion times were adjusted to obtain diffusion zones with a depth of greater than 50 μm. Microstructural and compositional information was gathered via scanning electron microscopy (SEM) and energy dispersive X-ray spectroscopy (EDX) and correlated to local mechanical properties evaluated by means of nanoindentation. Local corrosion properties were examined using Atomic Force Microscopy (AFM) and Scanning Electrochemical Microscopy (SECM).
Our results indicate that the ThermoCalc simulations have a good predictive power for crystallographic phases. However, especially with the Mn-FeNiCr system, formation of Cr-rich secondary phases were observed, which led to Cr-depletion and thus to localized corrosion processes in the matrix at the vicinity of the secondary phases. Based on the results of the local electrochemical tests, we have selected single-phase compositions along the diffusion zone and synthesized these alloys in bulk for corrosion studies by means of potentiodynamic polarization and SECM.
The presentation will summarize our methodology using diffusion couples as an
efficient tool for exploring compositional spaces of MPEAs in the search for novel single-phase alloys and the results of our correlative study on the mechanical and corrosion properties of these materials.
Stainless steel AISI 304 surfaces were studied after a mild anodic polarization for oxide growth in the presence and absence of two derivatives of vitamin B2 (riboflavin and flavin mononucleotide) that can be secreted by metal‐reducing bacteria and act as a chelating agent for iron species. The alterations in oxide chemistry were studied by means of surface‐sensitive techniques such as X‐ray photoelectron spectroscopy and time‐of‐flight secondary ion mass spectrometry analysis. The complementary electrochemical characterization revealed a preferential growth of an oxide/hydroxide iron‐rich film that is responsible for an altered pit initiation and nucleation behavior. These findings suggest that as the corrosion behavior is determined by the interplay of the chemical and electronic properties, only a mild anodic polarization in the presence of redox‐active molecules is able to alter the chemical and electronic structure of the passive film formed on stainless steel AISI 304. This helps to achieve a profound understanding of the mechanisms of microbially influenced corrosion (MIC) and especially the possible effects of the redox‐active biomolecules, as they may play an important role in the corrosion susceptibility of stainless steel surfaces.
Biofilm formation and microbially influenced corrosion of the iron-reducing microorganism Shewanella putrefaciens were investigated on stainless steel surfaces preconditioned in the absence and presence of flavin molecules by means of XANES (X-ray absorption near-edge structure) analysis and electrochemical methods. The results indicate that biofilm formation was promoted on samples preconditioned in electrolytes containing minute amounts of flavins. On the basis of the XANES results, the corrosion processes are controlled by the iron-rich outer layer of the passive film. Biofilm formation resulted in a cathodic shift of the open circuit potential and a protective effect in terms of pitting corrosion. The samples preconditioned in the absence of flavins have shown delayed pitting and the samples preconditioned in the presence of flavins did not show any pitting in a window of −0.3- to +0.0-V overpotential in the bacterial medium. The results indicate that changes in the passive film chemistry induced by the presence of minute amounts of flavins during a mild anodic polarization can change the susceptibility of stainless steel surfaces to microbially influenced corrosion.
This paper reports results from in situ electrochemical X-ray absorption near-edge spectroscopy (XANES) studies of the corrosion processes on model thin iron films in the presence of iron reducing bacteria Shewanella putrefaciens. Here we investigate the electrochemical activity of two cultures grown in the presence and absence of Fe(III) citrate in the culture medium. The XANES spectra and the OCP data of the Fe sample incubated with the culture grown in absence of Fe(III) did not show any significant changes during twenty hours of monitoring. In the case of the culture grown in Fe(III) containing medium, an accelerated dissolution of the iron film was observed together with the formation of a mixed Fe(II)-Fe(III) hydroxide surface layer. The open circuit potential (OCP) steadily approached the free corrosion potential of iron in neutral chloride containing electrolytes, indicating a continuous dissolution process without passivation.
The effect of the presence of Fe(III) during the cultivation on the electrochemical activity and corrosion behaviour of dissimilatory iron reducing bacteria Shewanella putrefaciens was studied by means of ex situ and in situ X-ray absorption near-edge spectroscopy (XANES). Stainless steel AISI 304 and thin iron films were studied as substrates. XANES analysis indicated an accelerated iron dissolution and growth of an oxide/hydroxide film for the culture grown with Fe(III) in comparison to the culture grown in absence of Fe(III). Electrochemical Analysis indicated that the biofilm resulted in acceleration of the general corrosion but provides protection against local corrosion.
The initial attachment and subsequent biofilm formation of electroactive bac-teriaShewanella putrefaciensCN32 was investigated to clarify the influence oforganic conditioning layers. A selection of macromolecules and self-assembledmonolayers (SAMs) of different chain lengths and functional groups were pre-pared and characterized by means of infrared spectroscopy in terms of theirchemistry. Surface energy and Zeta (ζ-) potential of the conditioning layers wasdetermined with contact angle and streaming current measurements. Amongthe studied surface parameters, a high polar component and a high ratio ofpolar-to-disperse components of the surface energy has emerged as a successfulindicator for the inhibition of the initial settlement ofS. putrefacienson stainlesssteel AISI 304 surfaces. Considering the negative surface charge of planktonicS. putrefacienscells, and the strong inhibition of cell attachment by positivelycharged polyethylenimine (PEI) conditioning layers, our results indicate thatelectrostatic interactions do play a subordinate role in controlling the attach-ment of this microorganism on stainless steel AISI 304 surfaces. For the biofilmformation, the organization of the SAMs affected the local distribution of thebiofilms. The formation of three-dimensional and patchy biofilm networks waspromoted with increasing disorder of the SAMs.
The characteristics of different molecules chosen as representatives for specific functionalities in conditioning layers play an important role on attachment behavior and later biofilm formation of bacteria. The chemical composition is a major component influencing the attachment but there is a conglomerate of influences.
Bulk metallic glasses (BMG) are amorphous metal alloys known for their unique physical and mechanical properties. In the present study, the formation of femtosecond (fs) laser-induced periodic surface structures (LIPSS) on the Zr-based BMGs Zr46Cu46Al8, Zr61Cu25Al12Ti2, Zr52.5Cu17.9Al10Ni14.6Ti5 (Vit105) and Zr57Cu15.4Al10Ni12.6Nb5 (Vit106) was investigated as a function of their different chemical composition. For this purpose, LIPSS were generated on the sample surfaces in an air environment by fs-laser irradiation (λ = 1025 nm, τ = 300 fs, frep = 100 kHz). The surface topography was characterized by scanning electron microscopy and atomic force microscopy. Moreover, the impact of LIPSS formation on the structure and chemical surface composition was analyzed before and after fs-laser irradiation by X-ray diffraction and X-ray photoelectron spectroscopy as well as by transmission electron microscopy in combination with energy dispersive X-ray spectroscopy. Despite the different chemical composition of the investigated BMGs, the fs-laser irradiation resulted in almost similar properties of the generated LIPSS patterns. In the case of Zr61Cu25Al12Ti2, Vit105 and Vit106, the surface analysis revealed the preservation of the amorphous state of the materials during fs-laser irradiation. The study demonstrated the presence of a native oxide layer on all pristine BMGs. In addition, fs-laser irradiation results in the formation of laser-induced oxide layers of larger thickness consisting of an amorphous ZrAlCu-oxide. The precise laser-structuring of BMG surfaces on the nanoscale provides a versatile alternative to thermoplastic forming of BMG surfaces and is of particular interest for the engineering of functional material surfaces.
The performance of functional coatings relies strongly on the stability of the polymer-metal interface. The increasing utilization of multi-material structures in the automotive and aerospace industry necessitates a fundamental understanding of the processes leading to interface degradation for the development of novel strategies to increase corrosion and delamination resistance.
The aim of this project is to investigate the corrosion processes at the buried interface of thin film coated aluminium alloy AA2024-T3 under corrosive and coupled corrosive-mechanical load. A spin coating procedure was developed to synthesize epoxy-like coatings and their nanofiller loaded composites with controlled thickness by layer-by-layer deposition of poly[(o-cresyl glycidyl ether)-co-formaldehyde] and poly-(ethylenimine) bi-layers. Our results indicate that the incorporation of graphene into the epoxy-based coatings leads to the improvement of mechanical and barrier properties. Furthermore, the functional groups play important roles in the interfacial bonding between polymer matrix and the nanofillers. Atomic force microscopy (AFM) results indicate very homogeneous and dense films with a thickness of ~25 nm per bi-layer and the successful integration of the nanofillers into the composite coatings. Ellipsometry measurements of film thickness verified a proportional film growth with the number of deposited layers.
The degradation and delamination behavior of the coating systems was characterized by means of in situ AFM corrosion experiments. Complementary energy dispersive X-ray spectroscopy (EDX) analysis was used to correlate the corrosion and delamination behavior with the different intermetallic particle chemistries and distributions. The presentation will summarize our results on the effect of coating composition and build-up on the local corrosion processes on thin film covered AA2024-T3 aluminium alloys.