Corrosion Behavior of Nanostructured Metallic Alloys

Nanostructured metallic alloys, characterised by grain sizes below 100 nm, exhibit markedly altered corrosion behaviour compared with their coarse-grained counterparts. Grain refinement increases the density of grain boundaries, which can accelerate passive‐film formation and enhance repassivation kinetics, yet may also introduce a higher density of active sites for localised attack. Alloy composition and microstructural features such as phase distribution, intermetallic particles and residual stresses further influence electrochemical responses. Processing techniques—including severe plastic deformation, high‐energy ball milling, hydrostatic extrusion and advanced sintering—enable tailored nanostructures that balance strength and corrosion resistance. In aluminium‐based systems, supersaturated solid solutions of transition metals promote enriched passive films, while in iron‐based alloys, ultrafine grains can lower the critical alloying threshold for self‐passivation. The complex interplay between enhanced barrier properties, microgalvanic coupling at heterogeneous interfaces and defect structures determines both general and pitting corrosion tendencies. Insights into mechanisms of passive‐film growth, breakdown and repair underpin the design of next‐generation lightweight and high‐strength alloys for transport, energy and infrastructure applications.

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Corrosion Behavior of Nanostructured Metallic Alloys publication trend

The graph below shows the total number of articles in corrosion behavior of nanostructured metallic alloys across all publications each year (not limited to Nature Index journals).

Technical terms

Nanostructured alloy: A metallic material whose average grain size is below 100 nm, enhancing mechanical and electrochemical properties.

Passivation: The formation of a thin, protective oxide film on a metal surface that reduces corrosion rate.

Pitting corrosion: Localised breakdown of the passive film, leading to the formation of small cavities or “pits”.

Grain boundary: The interface between two crystallites in a polycrystalline material, often acting as a fast diffusion path and active corrosion site.

Repassivation kinetics: The rate at which a protective film reforms after damage or breakdown.

Microgalvanic coupling: Local electrochemical interactions between regions of different composition or microstructure, promoting anodic dissolution.

References

1. Corrosion behavior of an in situ consolidated nanocrystalline Al-V alloy. npj Materials Degradation (2022).
2. Microstructural and Corrosion Characteristics of Al-Fe Alloys Produced by High-Frequency Induction-Sintering Process. Coatings (2019).
3. Effect of Grain Size on the Corrosion Behavior of Fe-3wt.%Si-1wt.%Al Electrical Steels in Pure Water Saturated with CO2. Materials (2021).
4. Enhanced Corrosion Resistance of Ultrafine-Grained Fe-Cr Alloys with Subcritical Cr Contents for Passivity. Metals (2018).
5. The Influence of Transition Metals Addition on the Corrosion Resistance of Nanocrystalline Al Alloys Produced by Mechanical Alloying. Metals (2016).