A general strategy for the ultrafast surface modification of metals

Surface modification is an essential step in engineering materials that can withstand the increasingly aggressive environments encountered in various modern energy-conversion systems and chemical processing industries. However, most traditional technologies exhibit disadvantages such as slow diffusion kinetics, processing difficulties or compatibility issues. Here, we present a general strategy for the ultrafast surface modification of metals inspired by electromigration, using aluminizing austenitic stainless steel as an example. Our strategy facilitates the rapid formation of a favourable ductile surface layer composed of FeCrAl or β-FeAl within only 10 min compared with several hours in conventional processes. This result indicates that electromigration can be used to achieve the ultrafast surface modification of metals and can overcome the limitations of traditional technologies. This strategy could be used to aluminize ultra-supercritical steam tubing to withstand aggressive oxidizing environments. Surface modification techniques can allow metals to be used in aggressive environments for emerging applications. Here authors demonstrate an ultrafast process for aluminizing austenitic stainless steels and propose an electromigration-assisted mechanism suggesting generalizability of the method.