Steel is the global backbone material of industrialized societies, with more than 1.8 billion tons produced per year. However, steel-containing structures decay due to corrosion, destroying annually 3.4% (2.5 trillion US$) of the global gross domestic product. Besides this huge loss in value, a solution to the corrosion problem at minimum environmental impact would also leverage enhanced product longevity, providing an immense contribution to sustainability. Here, we report a leap forward toward this aim through the development of a new family of low-density stainless steels with ultra-high strength (> 1 GPa) and high ductility (> 35%). The alloys are based on the Fe–(20–30)Mn–(11.5–12.0)Al–1.5C–5Cr (wt%) system and are strengthened by dispersions of nano-sized Fe₃AlC-type κ-carbide. The alloying with Cr enhances the ductility without sacrificing strength, by suppressing the precipitation of κ-carbide and thus stabilizing the austenite matrix. The formation of a protective Al-rich oxide film on the surface lends the alloys outstanding resistance to pitting corrosion similar to ferritic stainless steels. The new alloy class has thus the potential to replace commercial stainless steels as it has much higher strength at similar formability, 17% lower mass density and lower environmental impact, qualifying it for demanding lightweight, corrosion resistant, high-strength structural parts.

The pitting corrosion resistance and passive behavior of type 304 borated stainless steels (Fe_balance–18Cr–12Ni–1.5Mn–(0.19, 0.78, and 1.76 wt %)B) manufactured through conventional ingot metallurgy were investigated. The alloys were composed of an austenitic matrix and Cr₂B phase, and the volume fraction of Cr₂B increased from 1.68 to 22.66 vol % as the B content increased from 0.19 to 1.76 wt %. Potentiodynamic polarization tests measured in aqueous NaCl solutions revealed that the pitting corrosion resistance was reduced as the B content increased and the pits were initiated at the matrix adjacent to the Cr₂B phase. It was found that the reduced resistance to pitting corrosion by B addition was due to the formation of more defective and thinner passive film and increased pit initiation sites in the matrix.

Stress corrosion cracking (SCC) behavior of Ni-free duplex stainless steels containing N and C (Fe_balance-19Cr-8Mn-0.25C-(0.03, 0.21)N, in wt %) was investigated by using a slow strain rate test (SSRT) in air and aqueous NaCl solution with different tensile directions, including parallel (longitudinal) and perpendicular (transverse) to the rolling direction. It was found that alloying N was effective in increasing the resistance to SCC, while it was higher along the longitudinal direction than the transverse direction. The SCC susceptibility of the two alloys was assessed based on the electrochemical resistance to pitting corrosion, the corrosion morphology, and the fractographic analysis.