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High-Performance, Corrosion-Resistant Materials


Program Manager: Leo Christodoulou, Ph.D.

logoDSO's Structural Amorphous Metals program demonstrated the ability to produce iron-based amorphous alloys with low critical cooling rates enabling large-scale production in commercially available facilities. The High-Performance, Corrosion-Resistant Materials program has leveraged these revolutionary alloy compositions to develop a class of high-performance amorphous metal coatings for long-term corrosion resistance at elevated temperatures and in saline environments.

These coatings provided extraordinary corrosion resistance along with high damage tolerance. Furthermore, the materials provided neutron absorption capabilities twice that of typical borated stainless steels. Microstructure modeling has shown that coatings will remain amorphous for thousands of years at service temperatures. The coatings can be applied and repaired in the field with minimal training and equipment.

Program accomplishments include―

  • Successfully sprayed atomized iron-based amorphous powder (>5 tons produced).
  • Developed thermal spray processes to deposit on steel substrates while retaining amorphous microstructure.
  • Demonstrated superior corrosion performance of thermal spray coatings compared to (much more expensive and state of the art) nickel-based Alloy C-22.








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