"Corrosion Assessment and Prediction Laboratory (CAPLab)" was established, focusing on the safety assessment and life prediction of materials, components, and facilities/structures in industries such as marine engineering, oil, petrochemical, and energy and power, etc. The CAPLab enables the reproduction and accelerated simulation of single-factor and multi-factor coupled environments, including temperature, humidity, sunlight, rainfall, salt spray, surge, atmospheric pollutants, deep-sea high hydrostatic pressure, high-altitude low pressure, vibration, and complex loading scenarios.
Unlike traditional test platforms that perform pass or fail (" YES or NO ") assessments based on existing standards, the assessment methods developed by CAPLab are closer to real service conditions, aiming to uncover the "why and how" behind the deterioration in service performance. On the basis of service performance evaluation, CAPLab can provide clients with value-added services such as material selection, manufacturing process improvements, structural design optimization, as well as service life prediction and feasibility assessments for life extension.
The CAPLab covers an area of over 1,500 square meters and is equipped with state-of-the-art test facilities, including large walk-in comprehensive corrosion test chambers, aging test chambers, and a series of small- and medium-sized test devices that simulate atmospheric, marine, polar, and various service environments. It also possesses high-throughput and/or in-situ/quasi-in-situ advanced characterization capabilities, as well as field monitoring capabilities. In addition, the research team at CAPLab has established comprehensive capabilities for cross-scale modeling and simulation, ranging from the atomic level to environmental factor distributions spanning tens of meters, including corrosion behavior and mechanical behavior predictions. This encompasses first-principles calculations, finite element modeling, and phase-field simulations, all closely aligned with corresponding experiments. In the international evaluation conducted in 2021, the research capabilities of AETFES and CAPLab were rated as "world-leading".
Research Areas
CAPLab focuses on evaluating and predicting the corrosion, stress corrosion, hydrogen embrittlement, and corrosion fatigue of engineering materials and components, as well as their residual mechanical strength, fracture toughness, and crack propagation characteristics, under various harsh natural and industrial environments worldwide. Its main research directions include:
1. Environmental adaptability and reliability assessment of materials/components/facilities/structures
2. Development of in-situ/quasi-in-situ advanced characterization methods, high throughput characterization methods, indoor accelerated testing methods, and their corresponding equipment
3. Multi-scale modeling and simulation
4. Development of coatings and corrosion inhibitors
5. Residual life prediction and feasibility assessment for life extension
6. Optimization of operation and maintenance strategies
7. Failure analysis and formulation of improvement measures
Research Highlights
1. DFT calculations deepens the understanding on corrosion and hydrogen induced material deterioration__Ying JIN
Focusing on first-principle calculations of surface/interface behaviors, corrosion and hydrogen damage mechanism, our research group leads in the deep integration of theoretical calculation and experimental techniques, in-depth analysis of complex grain boundary/phase interface processes, and analysis of mechano-chemical multi-field coupling effects. At the atomic/electronic scale, we have revealed the adsorption/desorption of aggressive substances, passivation/depassivation/ repassivation, stress corrosion, and hydrogen damage/embrittlement properties on surfaces of metals. The correlation between the interfacial work function difference calculated theoretically and the Volta potential measured by scanning Kelvin probe force microscopy (SKPFM) was established, enabling theoretical predictions of (micro-) galvanic corrosion driving forces and uncovering the theoretical essence behind a series of experimental phenomena. Through first-principles calculations combined with atomic force microscopy (AFM), transmission electron microscopy (TEM), and synchrotron radiation-based in-situ tensile diffraction (SR-XRD), the mechanisms of microstructural evolution and mechanical performance degradation induced by tensile loading and hydrogen permeation have been elucidated.
Related publications: Int J Hydrogen Energ, 72 (2024) 338-348; ACS Appl Mater Interfaces, 16(42) (2024) 57901-57914; Appl Surf Sci, 621 (2023) 156859; Mater Today Commun, 31 (2022) 103425; J Electrochem Soc, 168(8) (2021) 081508; Surf & Interfaces, 26 (2021) 101366; Vacuum, 192 (2021) 110459; Molecules, 24 (2019) 4284; J Electrochem Soc, 166 (11) (2019) C3124-3130; Top Catal, 61(9-11) (2018) 1169-1182; J Theor Comput Chem, 17(1) (2018) 1850002; Chem Phys, 504 (2018) 48-56; J Electrochem Soc, 164 (2017) (9) C465-C473; J Phys & Chem Solids, 110 (2017) 129-135; Appl Surf Sci, 357 (2015) 2028-2038.
2. Development and application of high-throughput characterization and high-throughput data processing technology__Ying JIN, Feifei HUANG
We have developed a series of innovative high-throughput characterization and data processing methods, and successfully transformed patented technologies into self-built testing equipment, providing efficient solutions for establishing material composition-microstructure-property correlations and enabling rapid material selection. Leveraging high-throughput sample features, we pioneered the capillary-photolithography mask joint testing technology, significantly improving the precision of electrochemical testing on micron-scale. This technology achieves precise control of the working electrode area, low ohmic resistance, leakage prevention, and crevice corrosion prevention, making it particularly suitable for high-throughput detection. Applied to the study of single-phase/multi-phase corrosion performance of duplex stainless steel and dissimilar metal cladding welded joints, this technology has revealed the microscopic mechanisms of metal corrosion resistance. Furthermore, we have established two high-throughput data processing systems. 1) For handling large volumes of XRD spectra, we developed automated background subtraction, noise reduction, and clustering analysis algorithms, ultimately enabling the automatic construction of composition-microstructure-property relationships. 2) We automated the entire process of anomaly identification, equivalent circuit matching, and data fitting for hundreds of electrochemical impedance spectra, significantly improving the analysis efficiency of massive experimental data.
Related publications: Anal Chem, 95(49) (2023) 18006–18019; Electrochim Acta, 461 (2023) 142661; Electrochim Acta, 418 (2022) 140350; J Electrochem Soc, 168(9) (2021) 091501; ACS Comb Sci, 21(12) (2019) 833-842; Corros Sci, 155 (2019) 75-85; Electrochem Commun, 87, (2017) 53-57.
3. Multiscale modelling and numerical simulation to understand the local environment and the electrochemcial corrosion dynamics__Ying JIN, Fuhai LIU, Wenchao LI
At the microscopic scale, a series of modeling and simulation works have been conducted to explore the dynamics of trenching triggered by intermetallic particles in aluminum alloys, the pitting dynamics induced by inclusions in 304 stainless steel, and the atmospheric corrosion dynamics of carbon steel under thin liquid films or droplets. The model comprehensively considers the dynamic deposition of porous corrosion products and their impact on interfacial reactions and mass transfer, achieving the multiphase, multi-process, and multi-physics simulations. At the macroscopic scale, multi-physics simulations incorporating temperature, relative humidity, flow velocity, fluid composition, and even phase transitions such as condensation/evaporation were employed to estimate the local environment and subsequent corrosion distribution on the surfaces of specific large-scale facility, ultimately predicting the service life of the facility.
Related publications: Electrochim Acta, 514 (2025) 145607; npj Mater Degrad, 7 (2023) 3; Inter J Hydrogen Energ, 48 (12) (2023) 4773-4788; J Electroanal Chem, 882 (2021) 114977; Electrochim Acta, 324 (2019) 134847; J Electrochem Soc, 165(13) (2018) D604-D611; J Electrochem Soc, 164 (14) (2017) C1035-C1043; J Electrochem Soc, 164 (2017) C768-C778; J Electrochem Soc, 164 (2017) C75-C84; Electrochim Acta, 192 (2016) 310–318.
4. Application of EC-XAFS/XRD/XAS, EC-AFM, EC-Raman/SERS and other advanced in-situ characterization techniques in mechanism studies of material damage__ Hai CHANG, Ying JIN, Feifei HUANG
By combining synchrotron radiation sources, atomic force microscopy (AFM), surface-enhanced Raman spectroscopy (Raman/SERS), and electrochemical techniques, the damage mechanisms of metallic materials such as stainless steel and pipeline steel, etc. in Cl⁻-containing and/or hydrogen-containing environments have been systematically studied. A mechano-chemical coupled in-situ synchrotron radiation characterization module was developed and applied at the 12SW beamline of the Shanghai Synchrotron Radiation Facility to reveal the damage dynamics of pipeline steel and titanium alloys under tensile stress and/or hydrogen permeation. To achieve dynamic monitoring of the compositional evolution of all-solid-state iridium oxide pH electrodes, an in-situ electrochemical cell compatible with the 4B9A-XAFS beamline of the Beijing Synchrotron Radiation Facility was constructed. XAS spectroscopy characterization of passive films on titanium alloys formed under different conditions was conducted at Japan's HiSOR and Sweden's MAX IV. Using in-situ characterization techniques such as EC-Raman/SERS and EC-AFM, the synergistic mechanism of two additives in damascene electroplating for microelectronic packaging was explored. Additionally, the evolution process of MnS-induced localized corrosion in stainless steel was dynamically analyzed.
Related publications: Related publications: J Mater Eng Perform, Article in press, 2025, DOI: 10.1007/s11665-024-10427-4; Int J Hydrogen Energ, 48(92) (2023) 36169-36184; Rare Metals 42(5) (2023) 1760-1772; Corros Sci, 211 (2023) 110860; J Electrochem Soc, 169 (2022) 101505; J Electrochem Soc, 169 (2022) 037530; Appl Surf Sci, 544 (2021) 148888; J Electrochem Soc, 167 (2020) 167501; ACS Comb Sci, 21(12) (2019) 833-842; J Electrochem Soc, 166(2) (2019) D10-D20; Corros Sci, 131 (2018) 190-203; Corros Sci, 131 (2018) 94-103; Electrochim Acta, 211 (2016) 245-254; J Electrochem Soc, 160(1) (2013) D20-D27; Electrochim Acta, 78 (2012) 459-465.
5. Deep-sea corrosion behavior of pipeline steel and titanium alloys__Lei WEN, Ying JIN, Feifei HUANG
X80 steel is recommended by the American Petroleum Institute (API) for deep-sea environments due to its high strength, high toughness, and excellent weldability. Titanium alloys are widely used in marine environments because of their high strength-to-weight ratio and superior corrosion resistance. However, the harsh environmental factors in deep-sea conditions, such as high hydrostatic pressure, low dissolved oxygen content, low ambient temperature, and strong medium corrosiveness, pose significant threats to the safe use of these metals. In simulated deep-sea environments, in-situ electrochemical measurements and cumulative probability distribution methods were employed to study the synergistic effects of deep-sea environmental factors on the pitting behavior of X80 steel, revealing the mechanisms of metastable and stable pitting. The influence of hydrostatic pressure on the nucleation mechanisms and microstructural evolution of passive films on titanium alloys in marine environments was investigated. Additionally, through electrochemical measurements and slow strain rate tensile tests, the synergistic effects of dissolved oxygen on the stress corrosion cracking (SCC) behavior of titanium alloys were studied, uncovering their fracture characteristics.
Related publications: Corros, 77(2021) 1301-1310; Corros Eng Sci Techn, 56(2021) 383-391; Metals, 13(2023) 449; J Mater Res Technol, 33(2024) 1201-1210.
6. Evaluation of fluid-Solid multiphase flow characteristics and Structural damage assessment__Fuhai LIU
In high-temperature and high-pressure environments, industries such as oil and gas, thermal energy, and metallurgy extensively utilize pipeline systems, combustion equipment, and furnace reactors. In these sectors, industrial systems and individual units are continuously subjected to "fluid-solid" multiphase flow, encountering various damage mechanisms, including particle erosion, mechanical spalling, and high-temperature melting. Through theoretical calculations, water and erosion experiments, numerical simulations, along with the particle image velocimetry and energy spectrum analysis, the flow characteristics of "gas-solid" multiphase systems and the damage mechanisms of typical materials and structures were studied. Finally, the coupling effects of system structural parameters, multiphase flow characteristics, process reaction rates, and erosion rates were analyzed. Simultaneously, the research team conducts customized structural design and optimization tailored to the specific characteristics of various operating conditions and technical requirements from the clients, aiming to enhance the durability, stability, and efficiency of gas-liquid transportation pipelines, high-temperature burner devices, and metallurgical reaction vessels.
Related publications: Biomass Bioenerg, 194 (2025) 107628; Coatings, 14 (2024) 1444; MMTB, 55B (2024) 935; ISIJ Int, 64 (2024) 1384; ISIJ Int, 64 (2024) 1251; MMTB, 55B (2024) 1217; MMTB, 55B (2024) 600; ISIJ Int, 64 (2024) 1775; MMTB, 52B (2021) 2626; Materials, 14 (2021) 5034; ISIJ Int, 64 (2020) 682; Materials, 13 (2020) 1043; Can Metall Quart, 58 (2019) 285; MMTB, 49B (2018) 2050; ISIJ Int, 58 (2018) 852; ISIJ Int, 58 (2018) 496; MMTB, 49B (2016) 228; ISIJ Int, 56 (2016) 1519; ISIJ Int, 56 (2015) 2365.
7. Series studies on the development and application of sensors__Feifei HUANG, Ying JIN, Yurong WANG
To achieve real-time monitoring of the operational behavior of engineering materials/structures/equipment, the development of high-precision, long-life, and highly reliable sensing systems is crucial. An iridium pH sensor fabricated using cyclic heat treatment and quenching processes was proposed, featuring a wide pH linear response range, near-Nernstian E-pH response sensitivity, fast response rate, and excellent long-term stability. To address potential errors caused by potential drift of metal oxide electrodes during long-term pH monitoring, a potential compensation method with a specially designed probe structure was introduced. The successful application of the iridium oxide pH electrode in reductive solutions and the surface pH detection of zinc/steel galvanic couples in corrosive solutions demonstrated its excellent adaptability. Besides, a series of high-performance composite materials for nitrite electrochemical detection were developed. The effects of two-dimensional material and oxide crystal surface regulation, as well as heterostructure modification on sensing kinetics, were systematically studied. A novel mechanism of heterostructure modification on specific crystal surface on the durability of oxide-based electrode materials was proposed. Up to now, the developed all-solid-state reference electrodes, deep-sea pH monitoring electrodes, chloride ion sensing electrodes, and hydrogen permeation sensors have achieved field applications.
Related publications: J Colloid Interf Sci, 660 (2024) 1058-1070; Mater Today Chem, 30 (2023) 101490; J Electrochem Soc, 169 (2022) 037530; Coatings, 11(10) (2021) 1202; J Electrochem Soc, 167 (2020) 167501; Sens Mater, 32(10) (2020) 3313-3334; J Electrochem Soc, 165(2) (2018) B12-B21; J Electrochem Soc, 164(13) (2017) B632-B640; J Electrochem Soc, 162(12) (2015) B337-B343; 162(12) (2015) B1-B7; J Electrochem Soc, 160(10) (2013) B184-B191.
Relevant authorized patents: 201210251445.8, 201210270507.X, 201610835511.4.
8. Service Safety Evaluation of Energy Equipment Materials and Development of Novel Materials __Jinyang ZHU
To address the risks of material damage in energy equipment used in oil, gas, and chemical industries, our research focus on studying corrosion and fatigue damage under complex and harsh working conditions. This includes supercritical CO2 corrosion in CCUS (Carbon Capture, Utilization, and Storage) applications, hydrogen-induced damage in high-pressure hydrogen environments, and CO2/H2S corrosion in oil and gas pipelines. Utilizing self-developed high-temperature and high-pressure CO2/H2S reactors, slow strain rate test devices for supercritical CO2 corrosion, in-situ electrochemical test devices for high-temperature and high-pressure conditions, and gas/electrochemical hydrogen permeation test devices, the corrosion and hydrogen damage mechanisms of carbon steel, stainless steel, and various corrosion-resistant alloys (CRAs) under the aforementioned conditions have been thoroughly investigated. Consequently, we have established material selection guidelines for typical working conditions and introduced a series of cost-effective corrosion-resistant materials, such as low-chromium steel and Fe-Cr-Al low-alloy steels. To meet the needs of on-site corrosion evaluation and the application of big data technology, we have independently developed a variety of field safety monitoring sensor systems, including high-resolution localized corrosion monitoring probes, in-situ hydrogen permeation monitoring probes, and array ultrasonic wall thickness monitoring probes, which have been successfully implemented in the field.
Related publications: J Alloy Compd, 1010 (2025) 177217; Surf & Interfaces, 56 (2025) 105709; Process Saf Environ, 192 (2024) 738-749; Electrochim Acta, 478 (2024) 143818; J Mater Res Technol, 15 (2021) 5078-5094; Oxid Met, 94 (2020) 265-281; J Mater Res Technol, 9 (2020) 8104-8116; Appl Surf Sci, 511 (2020) 145624; Rsc Adv, 9 (2019) 38597-38603; Corros Sci, 111 (2016) 711-719; Corros Sci, 111 (2016) 391-403; Appl Surf Sci, 379 (2016) 39-46; Corros, 71 (2015) 854-864; Corros Sci, 93 (2015) 336-340.
9. Advanced surface coating technologies and their applications__Yanpeng XUE
We have researched and developed a variety of surface technologies, including cathodic plasma electrolytic deposition, micro-arc oxidation, high-speed laser cladding, microwave plasma chemical vapor deposition, double glow plasma surface metallurgy, electrochemical deposition, low-temperature nano-catalytic nitriding, etc., aiming to prepare coatings with corrosion resistance, wear resistance, and functionality. Our key research areas include developing continuous cathodic plasma electrolytic deposition and electrodeposition coating technologies to prepare metallurgically bonded metal coatings (such as Ni, Cr), ceramic coatings, and superhydrophobic coatings on the surfaces of steel, aluminum, and nickel alloys. High-speed laser cladding has been utilized to develop wear-resistant and corrosion-resistant high-temperature alloy coating systems (such as nickel-based, iron-based, high-entropy alloys, etc.) and processes, resulting in highly wear-resistant and corrosion-resistant laser cladding layers with performance significantly superior to hard chromium plating. Electrochemical deposition and hydrothermal methods have been employed to produce high-performance electrocatalysts and bipolar plate coatings for electrochemical energy conversion, including ALK water electrolysis, AEM water electrolysis, seawater electrolysis for green hydrogen production, and hydrogen fuel cells. Microwave plasma chemical vapor deposition technology has been used to prepare high-performance boron-doped diamond electrodes for electrochemical wastewater treatment and electrochemical biosensors.
Related publications: Ceram Int, 50 (2024) 7006; Surf Coat Tech, 494 (2024) 131408; Appl Surf Sci, 677 (2024) 161032; Intermetallics, 171 (2024) 108345; J Mater Res Technol, 30 (2024) 7020; Mater Charact, 211 (2024) 113879; J Mater Res Technol, 30 (2024) 626; Appl Surf Sci, 659 (2024) 159838; J Mater Res Technol, 27 (2023) 1537; Mater Today Commun, 31 (2022) 103425; J Colloid Interf Sci , 660 (2024) 1058; Nanoscale, 13 (2021) 3911; Surf Coat Tech, 385 (2020) 125390; Sep Purif Technol, 355 (2025) 129550; Diam Relat Mater, 139 (2023) 110377; Diam Relat Mater, 139 (2023) 110377; Surf Coat Tech, 472 (2023) 129876; Ceram Int, 49 (2023) 9512.
10. Green functional corrosion inhibitors and their applications__Yujie QIANG
Based on a research philosophy that integrates experimental and simulation approaches, we focus on the theoretical design and application of novel green corrosion inhibitors and their intelligent protective coatings. A systematic research has revealed the structure-activity relationship between the chemical structure of organic molecules and their corrosion inhibition performance. Innovatively, concepts such as multi-anchor adsorption effects, multi-effect synergy, and multi-layer competitive adsorption theory have been proposed, providing new strategies to enhance corrosion inhibition efficiency. Through precise screening using multi-scale molecular simulations, a range of environmentally friendly corrosion inhibitors—including ionic liquids, plant extracts, and nanomaterials—have been successfully synthesized with high efficiency, achieving molecular-level control over corrosion inhibition performance. To address the limitations of long-term use in traditional anti-corrosion coatings, a series of intelligent and durable marine protective coatings have been developed based on nanocontainers such as layered double hydroxides (LDH), graphene, halloysite, and metal-organic frameworks (MOFs). These coatings significantly enhance the durability and self-healing capabilities of materials. Furthermore, the developed corrosion inhibitor technologies have been successfully applied in aqueous metal battery systems, including aluminum-air batteries, zinc-air batteries, and zinc-ion batteries. These inhibitors effectively suppress the corrosion of metal anodes, substantially extending battery lifespan and providing critical support for the stable operation of energy storage systems.
Related publications: Chem Eng J, 503 (2025) 158559; Corros Sci, 245 (2025) 112676; Corros Sci 246 (2025) 112712; J Power Sources, 629 (2025) 236064; J Colloid Interf Sci, 2025, 682:983-994; Corros Sci, 230 (2024) 111903; Corros Sci, 240 (2024) 112500; J Mater Res Technol, 30 (2024) 7830-7842; J Mater Res Technol, 29 (2024) 5402-5411; J Power Sources, 2024, 593:233957; Prog Org Coat, 2023, 174 (2023) 107293; J Colloid Interf Sci, 642 (2023) 595-603.
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Email：ncms@ustb.edu.cn
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