Corrosion morphology is a key factor that influences the reliability and service life of a structure. As most structures service under stress corrosion, there is a great need to understand the effect of stress on the formation conditions of different morphologies. This paper introduces a numerical method to simulate the evolution of surface morphologies. The results indicate that a corroded surface will become rougher and sharper with an increase in stress, and as a consequence, the corrosion morphology will transfer from a flatter surface to a pit and then a crevice. The critical stress values for different morphologies (crevice, pit, and a flatter surface) were captured. Among the three morphologies, the flatter surface and pit maintain a fixed shape, also known as stable morphology. As stress exceeds a critical value, crevices are generated, and the morphology evolution becomes unstable. On the basis of the simulation results, the influence of morphology on the service life of the structure was evaluated. The corrosion velocity of a rough surface exceeds that of a flat surface, and this reduces the service life of the structure more significantly. With a rise in applied stress, the acceleration of corrosion presents a quadratically increasing relationship with applied stress.

The surface morphology of specimens significantly affects the measurement accuracy of indentation hardness. Surface undulation leads to dispersion in measured hardness and makes it very difficult to obtain an accurate hardness. In the past, mechanical polishing and increasing the indentation depth were widely performed to decrease the influence of surface morphology. However, both methods have limitations for the hardness measurement of small-scale structures such as thin films or coatings. Thus, obtaining an accurate hardness measurement from one or two simple indentation tests is of great application value. In this study, we introduced a new regression method to eliminate the influence of surface undulation on hardness measurements. We simulated the indentation tests of thin films with undulating surfaces by finite element simulation and then analyzed the regularity of the measured hardness. The numerical simulations validated that the regression method can effectively eliminate the influence of surface undulation and obtain the accurate hardness of materials. This method breaks through the limitations of conventional methods, simplifies the testing workload, and improves measurement accuracy.

It is important to improve the liquid lead corrosion resistance of fuel cladding alloy for promoting the development of lead-based reactors. The corrosion behaviors of traditional T91 steel and similar oxide dispersion strengthen ODS-type steels with or without the addition of Al, and were examined and compared at 600 °C in static oxygen-controlled liquid Pb in this research. High-temperature liquid lead corrosion tests were carried out for 120 h, 240 h, 500 h, 1000 h, and 2000 h, respectively, for three prepared samples. After the experiment, the corrosion behavior was evaluated and compared mainly based on the aspects of appearance, corrosion depth, microstructure, and composition difference. It was found that just the ODS design did not show a positive effect on corrosion resistance, while the addition of Al is beneficial to improving the corrosion resistance of ODS steel. The maximum corrosion depth of 9CrAl ODS is only 51.8 μm after corrosion for 2000 h, which is much lower than that of 9Cr-ODS steel. A thin film containing Al/Cr formed in the corrosion area after adding Al in 9Cr ODS steel, which played a positive role in corrosion resistance.

The hydrogen emission of zirconium hydride at high temperature is a challenging issue for many researchers. The hydrogen emission content of zirconium hydride pins should be evaluated to confirm the application feasibility. The comparison of theory analysis and experiment data indicated that Richardson's law could offer a conservative result for calculating the hydrogen emission content of zirconium hydride pins at high temperature. Furthermore, the methods of preventing hydrogen loss should be developed for the purpose of extending the work temperature or time. The results showed that a ZrO2 layer prepared for zirconium hydride could not prevent hydrogen loss after exposure at 650 °C in an inert environment and ZrO2 transformed into Zr3O gradually due to the opposite movement of hydrogen and oxygen. Finally, a further improvement to prevent hydrogen loss was developed. The zirconium hydride with a ZrO2 layer in the cladding of He+CO2 exhibited no significant reduction of hydrogen content. It is helpful to prevent the hydrogen loss by increasing the oxygen potential on the outside of ZrO2 layer.