High Throughput Discovery of Lightweight Corrosion-Resistant Compositionally Complex Alloys

Compositionally complex alloys hold the promise of simultaneously attaining superior combinations of properties such as corrosion resistance, light-weighting, and strength. Achieving this goal is a challenge due in part to a large number of possible compositions and structures in the vast alloy design space. High throughput methods offer a path forward, but a strong connection between the synthesis of a given composition and structure with its properties has not been fully realized to date. Here we present the rapid identification of light weight highly corrosion-resistant alloys based on combinations of Al and Cr in a Cantor-like base alloy (Al-Co-Cr-Fe-Ni). Previously unstudied alloy stoichiometries were identified using a combination of high throughput experimental screening coupled with key metallurgical and electrochemical corrosion tests, identifying alloys with excellent passivation behavior. Importantly, the electrochemical impedance modulus of the exposure-modified, air-formed film at the corrosion potential was found as an accurate non-destructive predictor of corrosion and passivation characteristics. Multi-element EXAFS analyses connected more ordered type chemical short range order in the Ni-Al 1st nn shell to poorer corrosion. This report underscores the utility of high throughput exploration of compositionally complex alloys for the identification and rapid screening of vast stoichiometric space.

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