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Acta Metall Sin  2026, Vol. 62 Issue (7): 1273-1287    DOI: 10.11900/0412.1961.2024.00323
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Microstructural Evolution and Dynamic Failure Mechanism of B10 Cu-Ni Alloy Under Multiple Stress Coupling in Flowing Seawater
LI Ruixue1, ZHOU Chenxi1, YANG Huimin1, YONG Xingyue2(), LIU Jingjun1()
1 School of Materials Science and Engineering, Beijing University of Chemical Technology, Beijing 100029, China
2 School of Chemical Engineering, Beijing University of Chemical Technology, Beijing 100029, China
Cite this article: 

LI Ruixue, ZHOU Chenxi, YANG Huimin, YONG Xingyue, LIU Jingjun. Microstructural Evolution and Dynamic Failure Mechanism of B10 Cu-Ni Alloy Under Multiple Stress Coupling in Flowing Seawater. Acta Metall Sin, 2026, 62(7): 1273-1287.

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Abstract  

To address the critical issue of microstructural degradation and dynamic failure of Cu-Ni alloys subjected to multiple stress couplings in flowing seawater, this study systematically investigates the microstructural evolution and failure characteristics of the alloy in a complex service environment. Focusing on the widely used B10 Cu-Ni alloy in pipeline systems, a combined experimental and computational simulation approach was employed. A molecular dynamics method was used to construct an alloy/seawater solvation model, with emphasis on the effects of seawater flow rate, pressure, and their coupled interactions on microstructural evolution and corrosion kinetics. In flowing seawater, the strain level of the alloy increases markedly, accompanied by a rise in microstructural defects. The results reveal that corrosion of Cu-Ni alloys proceeds through a multi-step coupled mechanism governed by the migration-dissolution energy barrier of Cu atoms. Density functional theory calculations show that as seawater pressure increases from 0.1 MPa to 12 MPa, the migration-dissolution energy barrier decreases from 1.76 eV to 1.54 eV, significantly accelerating the corrosion rate. Furthermore, increasing seawater flow rate induces atomic-level axial elastic tensile strain on the (111) crystal plane of the alloy, further reducing the migration-dissolution energy barrier. A critical flow rate of 4 m/s has been identified as exacerbating corrosion. Under the coupled influence of flow rate and pressure, the migration-dissolution energy barrier is further reduced, the work function decreases, and corrosion kinetics are significantly accelerated. The corrosion rate constants obtained from simulations exhibit highly consistent trends with experimentally measured corrosion rates, enabling reliable assessment and prediction of the corrosion tendency of the B10 Cu-Ni alloy during dynamic failure under real operational conditions.

Key words:  B10 Cu-Ni alloy      flowing seawater      microstructure      fluid dynamics      corrosion kinetics     
Received:  11 September 2024     
ZTFLH:  TG178  

URL: 

https://www.ams.org.cn/EN/10.11900/0412.1961.2024.00323     OR     https://www.ams.org.cn/EN/Y2026/V62/I7/1273

Fig.1  Structural characterizations and EDS analyses of B10 Cu-Ni alloy
(a) refined XRD patterns
(b) microstrains of different crystal facets
(c) dislocation densities of different crystal facets
(d) HRTEM image (e) EDS (f) SEM image
(g-j) EDS mappings of Cu (g), Ni (h), Fe (i), and Mn (j) elements
Fig.2  Fast Fourier transforms (FFT), inverse fast Fourier transforms (IFFT), interplanar spacings, and strain level analyses of different crystal planes of B10 Cu-Ni alloy (The color scale bars indicate strains: red-to-yellow for tensile strain, green-to-blue for compressive strain; white boxes mark tensile-compressive stress concentration zones) (a1-a3) FFT and IFFT on the (111) (a1), (200) (a2), and (220) (a3) crystal planes, along with their corresponding interplanar spacing line profiles (b1-b3) x-direction strain (εxx ) (b1), xy-direction strain (εxy ) (b2), and y-direction strain (εyy ) (b3) on the (111) crystal plane (c1-c3) εxx (c1), εxy (c2), and εyy (c3) on the (200) crystal plane (d1-d3) εxx (d1), εxy (d2), and εyy (d3) on the (220) crystal plane
Fig.3  Establishment of the stable structure model of B10 alloy and analyses of the migration-dissolution kinetics process
(a) pure Cu model
(b) B10 alloy model
(c) B10seg (featuring a Cu-segregated surface in the lowest-energy state) alloy model
(d) comparisons of formation energy, surface energy, and work function
(e1-e3) migration-dissolution process analyses of Cu atom in pure Cu model (e1), Cu atom in B10seg alloy model (e2), and Ni atom in B10seg alloy model (e3) (IS—initial state, TS—transition state, FS—final state, Vac 1—surface Cu atom vacancy, Vac 2—re-formation of surface vacancy)
(f) atomic dissolution energy diagram
Fig.4  SEM images of B10 alloy before (a) and after corrosion for 10 h under seawater pressures 0.1 MPa (b), 4.0 MPa (c), 6.0 MPa (d), 8.0 MPa (e), and 12.0 MPa (f); XRD patterns (g); microstrains of (111) crystal plane (h); and dislocation density of (111) crystal plane (i) at a seawater flow rate of 0
Fig.5  Establishment of the solvation model at the B10seg alloy/seawater interface under different seawater pressures (a), density distributions of H2O molecule on the alloy surface (b), schematic model for simulating the effect of H2O molecules on the dissolution of surface atoms in alloys under different pressures (c), surface energy (d), work function (e), schematic of the influence of seawater pressure on the Helmholtz layer (OHP—outer Helmholtz plane) (f), Cu (g) and Ni (h) atomic migration-dissolution processes under different pressures, and comparisons of corrosion rate constant and mass loss under different pressures (i)
Fig.6  Corrosion behaviors of alloys under atmospheric pressure (0.1 MPa) at various seawater flow rates (1-5 m/s) (a1-a5) SEM images of B10 alloy under atmospheric pressure with seawater flow rates of 1 m/s (a1), 2 m/s (a2), 3 m/s (a3), 4 m/s (a4), and 5 m/s (a5) (b) XRD patterns of B10 alloy (c) microstrains of (111) crystal plane in B10 alloy (d) dislocation densities of B10 alloy (e) B10seg-Cu migration-dissolution process (f) B10seg-Ni migration-dissolution process (g) comparisons of corrosion rate constant and mass loss at different flow rates (h) relationship between surface energy and flow rate of B10seg alloy model (i) vacancy energies of B10seg alloy model (j) work functions of B10seg alloy model
Fig.7  Migration-dissolution process of B10seg alloy at 4.0 MPa with seawater flow velocities of 1-5 m/s, and the corrosion behavior of B10 alloy under the individual effects of pressure (4.0 MPa, 0 m/s) and flow velocity (0.1 MPa, 4 m/s) versus coupled effect (4.0 MPa, 4 m/s)
(a, b) migration-dissolution processes of B10seg-Cu (a) and B10seg-Ni (b) under 4.0 MPa pressure and different flow rates
(c) comparisons of corrosion rate constant and mass loss at different flow rates under 4.0 MPa
(d-f) SEM images of the surface corrosion morphology of the B10 alloy under 4.0 MPa (d), at 4 m/s (e), and under 4.0 MPa and at 4 m/s (f)
(g) XRD patterns of B10 alloy
(h) microstrains of (111) crystal plane in B10 alloy
(i) dislocation densities of B10 alloy
Fig.8  Migration-dissolution processes, corrosion kinetics parameters, and charge density distributions of B10seg alloy under the effect of pressure (4.0 MPa, 0 m/s)/flow velocity (0.1 MPa, 4 m/s) as single factors and coupled factors (4.0 MPa, 4 m/s)
(a, b) migration dissolution of Cu (a) and Ni (b) atoms under single/coupled mechanical conditions in B10seg alloy model
(c) comparisons of corrosion rate constant of B10seg alloy model
(d) surface energies of B10seg alloy model
(e) vacancy energies of B10seg alloy model
(f) work functions of B10seg alloy model
(g-i) charge density distributions of B10seg alloy model under 4.0 MPa (g), at 4 m/s (h), and under 4.0 MPa and at 4 m/s (i)
Fig.9  Schematic showing the migration dissolution kinetics of B10 Cu-Ni alloy under deep-sea dynamic environment
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