Morphogenic Modeling of Corrosion Reveals Complex Effects of Intermetallic Particles

Abstract Corrosion processes are often discussed as stochastic events. Here, it is shown that some of these seemingly random processes are not driven by nanoscopic fluctuations but rather by the spatial distribution of micrometer‐scale heterogeneities that trigger fast reactions associated with corrosion. Using a novel excitable reaction‐diffusion model, corrosion waves traveling over the metal surface and the associated material loss are described. This resulting nonuniform corrosion penetration, seen as a height loss in modeling, exposes buried intermetallic particles, which depending on the local electrochemical state of the surface trigger or block new waves. Informed by quantitative experimental data for the Mg–Al–Zn alloy AZ31B, wave speeds, wave widths, and average material loss are accurately captured. Morphogenic mitigation based on wave‐breaking microparticles is also simulated. While AZ31B corrosion is identified as a process driven by rare‐wave events, this study predicts several other corrosion regimes that proceed via spots or patchy patterns, opening the door for new protection, design, and prediction strategies.