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Carbon monoxide is commonly encountered in energy systems, yet its reactivity with structural alloys—critical heat-resistant components in these systems—has been largely overlooked compared to the well-documented effects of oxidizing gases. In contrast, we demonstrate the high-temperature reaction of CO with NiAl using in-situ low-energy electron microscopy and X-ray photoemission electron microscopy. Our results show that CO dissociates into atomic oxygen and carbon, resulting in two concurrent reactions: selective oxidation of aluminum to form Al₂O₃ and the initiation of dusting corrosion through carbon dissolution into the alloy and subsequent carbon deposition on the surface. These reactions produce spatially distinct surface products,more » preventing the formation of a continuous protective Al oxide layer. These results reveal a preference for the dissociative pathway of CO over the classic Boudouard disproportionation reaction that forms CO₂. These insights not only advance our understanding of CO-induced alloy degradation but also highlight the practical implications for managing alloy stability and optimizing catalysis in carbon-rich environments, such as those in petrochemical processing and hydrocarbon combustion.« less

In contrast to the traditional perspective that thermal fluctuations are insignificant in surface dynamics, here we report their influence on surface reaction dynamics. Using real-time low-energy electron microscopy imaging of NiAl(100) under both vacuum and O₂ atmospheres, we demonstrate that transient temperature variations substantially alter the direction of atom diffusion between the surface and bulk, leading to markedly different oxidation outcomes. During heating, substantial outward diffusion of atoms from the bulk to the surface results in step growth. Conversely, cooling induces considerable inward diffusion of adatoms, producing a distinct oxide morphology. In both scenarios, initially formed oxide islands impede localmore » atomic step mobility, thereby increasing step length due to mass transfer between the surface and bulk, with atomic steps acting as adatom sinks during heating and sources during cooling. Furthermore, we show that this pinning effect on atomic step mobility can be mitigated by applying persistent temperature fluctuations. As a result, understanding these nuances is vital for accurately predicting and dynamically manipulating the performance of active materials in various chemical processes under transient thermal conditions.« less

The oxidation resistance of Ni-based alloys is typically improved by additions of elements segregating to grain boundaries, contributing to reducing scale growth, and improving scale adherence. To develop a mechanistic understanding of doping, outward Al and inward O fluxes through the scale formed on β-NiAl with Ti, Y, and Ti+Y additions were characterized for oxidation at 1200°C and times up to 100h. Doped alloys exhibited varying reductions in oxidation rates and Al and O fluxes affecting scale grain morphologies. In conclusion, Ti+Y co-doping further reduced the outward Al and inward O transport compared to doping with Ti or Y alone.

Crystal structure and composition are inter-dependent and decoupling their effects on surface reactivity is challenging. Using low-energy electron microscopy to spatially and temporally resolve the oxide film growth during the oxidation of NiAl(100), we differentiate such coupled effects by monitoring oxide growth while simultaneously fine-tuning the surface structure and composition during oxidation. We demonstrate that the oxidation of chemically ordered surfaces results in compact oxide island growth whereas non-compact oxide growth during the surface phase transition. By incorporating the surface phase transition induced chemical disordering into kinetic Monte Carlo simulations, we illustrate that the non-compact oxide growth is induced bymore » the composition effect on the surface diffusion of oxygen, which can be described by the concept of “ant in the labyrinth”.« less

The high-temperature oxidation of NiAl is studied with dry oxygen and water vapor. The oxidation in H₂O results in a thicker Al₂O₃ oxide scale than that in O₂. The oxide scale formed initially is a single layer of γ-Al₂O₃ that subsequently transforms into a α-Al₂O₃/γ-Al₂O₃ bilayer structure, in which the inner α-Al2O3 layer formed in H2O has a higher porosity than that in O₂. Finally, further density functional theory calculations show that H protons derived from H₂O molecules penetrate into the oxide lattice and boost the formation of lattice vacancies in both α-Al₂O₃ and γ-Al₂O₃, thus enhancing the oxide scalemore » growth.« less

The nanoscale oxidation mechanisms and kinetics of a model β-NiAl system were investigated using in situ closed-cell gas reaction scanning transmission electron microscopy (STEM). Here, we directly visualize the dynamic structural and chemical changes that occur during high-temperature oxidation at a high spatial resolution of 50.3Ni–49.7Al (at.%) nanoparticles under static air conditions at 730 Torr with heating up to 750 °C at 5 °C/s. A MEMS-based gas cell system, with microfabricated heater devices and a gas delivery system, was used to reveal site-specific oxidation initiation sites. Through time-resolved annular dark-field STEM imaging, we tracked the nanoscale oxidation kinetics of Al₂O₃.more » After oxidation at 750 °C, nucleation of voids at the Ni/Al₂O₃ interface was observed along a NiAl grain boundary, followed by the formation of faceted NiO crystals. Small faceted cubic crystals of NiO were formed at the initial stage of oxidation at high PO₂ due to the outward self-diffusion of Ni²⁺ ions, followed by the formation of a mixture of metastable and stable α-Al₂O₃ at the oxide/metal interface that is attributed to a PO₂ decrease with oxidation time, which agreed with thermodynamic modeling calculations. Furthermore, the results from these in situ oxidation experiments in the β-NiAl system are in agreement with the established oxidation mechanisms; however, with in situ closed-cell gas microscopy it is now feasible to investigate nanoscale oxidation mechanisms and kinetics in real time and at high spatial resolution and can be broadly applied to understand the basic high-temperature oxidation mechanisms for a wide range of alloy compositions.« less

Ball milling motion has been previously studied through computationally expensive, off-line experimental video processing and numerical simulations by the discrete element method. Here, this research establishes a more efficient formulation of the ball energetics and kinetics similar to the Brownian kinetic theory of statistical mechanics. Based on assumptions of thermomechanical equilibrium, negligible gravitational, aerodynamic and surface condition effects, and decoupled impact interaction among balls and with milled particulates, this model proposes mono-parametric spectral energy and velocity probability density functions akin to Maxwell-Boltzmann statistics, along with uniformly distributed impact directionality. The model predictions are calibrated and validated by comparison with publishedmore » experimental measurements and computationally derived spectra. This descriptive Brownian-like motion model enables effective simulation of contact and impact, material deformation and micro-joining of ball milled bimetallic powders. A comprehensive simulation of the evolving internal fractal microstructure of the processed particulates is implemented at real-time computation speed, and its predictions are compared with experimental micrographs of ball milled Ni—Al particulates.« less

Atomic steps, a defect common to all crystal surfaces, can play an important role in many physical and chemical processes. However, attempts to predict surface dynamics under nonequilibrium conditions are usually frustrated by poor knowledge of the atomic processes of surface motion arising from mass transport from/to surface steps. Using low-energy electron microscopy that spatially and temporally resolves oxide film growth during the oxidation of NiAl(100) we demonstrate that surface steps are impermeable to oxide film growth. The advancement of the oxide occurs exclusively on the same terrace and requires the coordinated migration of surface steps. The resulting piling upmore » of surface steps ahead of the oxide growth front progressively impedes the oxide growth. This process is reversed during oxide decomposition. The migration of the substrate steps is found to be a surface-step version of the well-known Hele-Shaw problem, governed by detachment (attachment) of Al atoms at step edges induced by the oxide growth (decomposition). As a result, by comparing with the oxidation of NiAl(110) that exhibits unimpeded oxide film growth over substrate steps, we suggest that whenever steps are the source of atoms used for oxide growth they limit the oxidation process; when atoms are supplied from the bulk, the oxidation rate is not limited by the motion of surface steps.« less