Varvara Shubina Helbert

Localized detection of hydrogen permeation in steel membranes is crucial for practical applications but remains challenging. We present a reflective microscopy (RM) approach combined with machine learning (ML)-driven image analysis to address this issue. Hydrogen permeation in press-hardened steel alters the Fe(II)/Fe(III) ratio in the surface layer, affecting reflected light intensity due to changes in the refractive index. Although initially near the optical detection limit, this subtle contrast was enhanced using time-series analysis with UMAP and K-means clustering. The detected regions corresponded to hydrogen-affected zones confirmed by Scanning Kelvin Probe measurements. This work establishes a novel RM-ML framework for detecting and quantifying hydrogen permeation, offering a promising and accessible alternative to conventional methods for localized analysis of metallic membranes.

The atmospheric corrosion of high-strength steels can lead to hydrogen absorption directly linked to hydrogen embrittlement or delayed fracture phenomena. A scanning Kelvin probe (SKP) and electrochemical permeation technique (EPT) were applied to correlate the potential of an oxidized surface with the flux of hydrogen across a thin steel membrane. The side of the membrane opposite the corroding or electrochemically charged area was analyzed. The potential drop in the oxide was calibrated in terms of surface hydrogen activity, and SKP can be applied in situ for the mapping of hydrogen distribution in the corroding metal. A very low flux of hydrogen can be characterized and quantified by SKP, which is typically observed under atmospheric corrosion conditions. Therefore, hydrogen localization that drives steel durability under atmospheric corrosion conditions can be evaluated.

Hydrogen, due to corrosion processes, can degrade high strength steels (HSS) through embrittlement and stress corrosion cracking mechanisms. Scanning Kelvin probe (SKP) mapping of surface potential was applied, to visualize the locations with an increased subsurface concentration of hydrogen in mild steel and martensitic HSS. This work can help to determine the reasons behind hydrogen localization in a steel microstructure, leading to embrittlement and hydrogen-assisted cracking. Cathodic charging was used to insert hydrogen, which decreased the steel potential. Hydrogen effusion in air passivates steel, increasing the potential of HSS and mild steel. The passivation of steels was monitored depending on different conditions of cathodic pre-charging and the amount of absorbed hydrogen. The SKP could determine the area of diffusible hydrogen and the area of cracks. In addition, low potential locations linked to the hydrogen trapped in the deformed HSS microstructure were also determined, which delayed the steel passivation. Mild steel showed a uniform potential distribution related to interstitial hydrogen, without potential extremes attributed to locally accumulated hydrogen. Thus, SKP sensing can detect locations containing increased concentrations of hydrogen and sensitive to steel cracking.

This study investigated the corrosion behavior of AISI 316L produced by direct energy deposition (DED). Microstructural and chemical analysis showed a homogeneous distribution of Si and Si–Mn inclusions of 0.5–1 µm and the Cr and Mo enrichment within interdendritic areas. Scanning Kelvin probe analysis of additively manufactured stainless steel highlighted a regular “striped‐like” surface potential feature with a potential gradient of 30 mV for a mean value of 0.320 ± 0.017 V versus standard hydrogen electrode. It can be related to the presence of the residual stress in the oxide film and the complex thermal history due to the fabrication process. A cyclic corrosion test simulating atmospheric conditions revealed the same corrosion properties for stainless steel fabricated by DED compared to cold rolled one. Various surface preparations of 316L were also exposed for corrosion tests. It was found that the “as‐received” and “brushed” surfaces exhibited poorer corrosion resistance due to the presence of an as‐build defective layer. However, prior passivation of brushed surface, machining, or mechanical grinding down to P1200 improve significantly the corrosion resistance.

The effects of cathodic polarisation switch-off on the passivation of AISI 304L stainless steel in air and its crevice corrosion susceptibility in 3.5 wt.% NaCl aqueous electrolyte were investigated. Scanning Kelvin probe (SKP) data showed that the oxide film is significantly destabilised and the rate of steel passivation in air is slowed down. Thermal desorption analysis (TDA) highlighted that hydrogen absorption is proportional to the applied cathodic current density. A special crevice corrosion set-up was designed to realise simultaneous reproducible monitoring of potential and galvanic current to study the impact of prior cathodic polarisation on crevice corrosion onset.

Providing high hardness, low friction coeffcient, as well as, relatively good corrosion resistance, chromium-plated coatings ( ≈ 20 μm) are widely used for steel cylinder rods in marine environment. However, the standardized corrosion test method (ISO 9227, NSS) used to evaluate effciency of this type of coatings does not take into account in-service mechanical loadings on cylinder rods. Nevertheless, the uniform initial network of microcracks in chromium coating is changing under mechanical loadings. Propagation of these microcracks explains premature corrosion of the steel substrate. The aim of the study was to evaluate relationship between mechanical loadings, propagation of microcracks network and corrosion resistance of chromium coatings. After monotonic pre-loading tests, it was demonstrated by microscopic observations that the microcracks propagation started at stress levels higher than the substrate yield stress (520 MPa). The microcracks become effective, ie. they have instantly undergone through the whole coating thickness to reach the steel substrate. The density of microcracks increases with the total macroscopic level, i.e. the intercrack distance goes from 60 ± 5 μm at 1% of total strain to approximately 27 ± 2 μm at 10%. Electrochemical measurements have shown that the higher the plastic strain level applied during mechanical loading, the more the corrosion potential of the sample decreased until reaching the steel substrate value of approximately -0.65 V/ECS after 2 hours of immersion. The polarization curves have also highligthed an increase in the corrosion current density with the strain level. Therefore, electrochemical measurements could be used to realize quick and comprehensive assesment of the effect of monotonic pre-loadings on corrosion properties of the chromium coating.