Erosion-corrosion of candidate HVOF aluminium-based marine coatings

This paper describes gravimetric results of HVOF sprayed commercially pure Al and Al/12% Si eutectic alloy coatings obtained under erosion-corrosion conditions. The performance of these coatings are compared to a hot-dipped zinc coating. These coatings have been applied to AISI 1020 carbon steel substrates and tested in a free jet impingement rig with a variety of fluids and slurries to enable the erosion and corrosion contributions to the total erosion-corrosion removal of the surface to be determined. Tests have been conducted at 30° and 90° jet impingement angles at jet velocities of 3.5 m/s.Erosion damage mechanisms are identified and the erosion-corrosion mass loss results discussed in terms of the contributions made by erosion and corrosion. Zinc was found to suffer severely from flow corrosion, while the other targets did not. All target materials under sand erosion lose mass in a way directly proportional to kinetic energy, and inversely related to hardness. Corrosion losses are relatively small while the generation of solid products sometimes results in net weight gains. There are greater mass losses at nominally normal incidence than at nominally oblique incidence, due to particle interference effects. Synergy is found to be both positive and negative and appears to be angle dependent, but is difficult to determine precisely.     

The slurry erosive wear of physically vapour deposited TiN and CrN coatings under controlled corrosion

The erosion-corrosion of mild steel (BS6323), in the presence and absence of physically vapour deposited (PVD) TiN and CrN coatings, was studied, in comparison with that of AISI 304 stainless steel, in an aqueous alkaline slurry solution containing alumina particles. The influence of applied potential and particle velocity on the total erosion-corrosion loss was examined, and the respective corrosion and erosion damage (both contributing to the overall weight loss) then assessed by means of microscopical investigation of the morphology of the damaged surface, and subsequently evaluated quantitatively. The superior erosion-corrosion resistance of both the coatings compared to that of the uncoated mild and stainless steels was shown to be due to their resistance to both wear and corrosion. According to the detailed corrosion mechanisms revealed and different responses to wear, schematic diagrams were proposed to outline the main features of the corrosion-erosion process and the individual roles of erosion and corrosion. Discrete differences, in terms of the respective erosion and corrosion processes, between the TiN and CrN coatings, and between the mild and stainless steels, were also investigated and discussed. This revised version was published online in August 2006 with corrections to the Cover Date.     

Full factorial investigation on the erosion-corrosion resistance of UNS S31603

The interactions that occur when erosion and corrosion act simultaneously are extremely complex and are often difficult to interpret. These interactions generate either a synergistic or antagonistic material loss effect for a particular material in a certain environment. The level of interaction between impact energy, number of impacts, fluid temperature, material properties, fluid flow and electrochemical properties severely complicates the analysis of erosion-corrosion wear rates. This paper investigates the interaction between the main parameters influencing erosion-corrosion. A combination of statistical analysis and interaction contour plots has been employed to obtain in-depth understanding of the variables influencing erosion-corrosion, namely particle velocity, sand size, sand concentration and fluid temperature. An empirical equation has been derived from test results to describe the relationship between the test parameters. Analysis of the residuals versus predicted erosion-corrosion shows a normalized distribution and thereby confirms the suitability of this model. Velocity was found to have the strongest influence on erosion-corrosion rate followed by sand concentration, temperature and finally sand size, which had the least significant effect. SEM surface features show that the increase in sand concentration causes the surface to be covered with a higher number of impact craters and lips indicating a linear relationship between the two. The SEM micrographs also show that the increase in sand size produces deeper craters and more prominent lips compared to fine sized particles where the particles tend to graze the surface without sufficient kinetic energy to plastically deform the material surface.     

Particle concentration and size effects on the erosion-corrosion of pure metals in aqueous slurries

In previous studies of erosion-corrosion, several different theories have been developed to produce a model which represents the relationship between particle erosion and chemical corrosion. Regimes in the models define how the two mechanisms behave relative to one another, whether it is erosion dominated, corrosion dominated. This paper investigates the effect of particle and target material on the erosion-corrosion mechanisms. The performance of Fe as the target material will be modelled when considering particle concentration and size. A comparison is made between the erosion-corrosion mechanisms of Fe, Ni, Al and Cu under different conditions of particle size and concentration. By producing several maps, the regimes and wastage rates predicted as functions of velocity and applied potential will be discussed.     

Electrochemical investigation of erosion-corrosion using a slurry pot erosion tester

The aim of this paper is to use a modified slurry pot erosion tester to perform in-situ electrochemical measurements during solid particle impingement to investigate the effects of velocity, sand size and sand concentration on a passive metal (UNS S31603). Samples are subjected to a set of erosion-corrosion experiments. The electrochemical response of UNS S31603 to the test parameters is plotted and compared to develop an understanding of the erosion-corrosion process. The current trend with variation of test parameters has been explained by an erosion enhanced corrosion synergistic effect. The current transients associated with depassivation and repassivation during solid particle impingement are observed through electrochemical noise measurements. It was observed that the increase in velocity and sand concentration increased the current levels during erosion-corrosion. However, the increase in sand size had a more complex response. Single particle impact experiments conducted revealed that the peak corrosion current and the repassivation time increased with increase in velocity. A linear trend was seen between the peak current and the kinetic energy. A second-order exponential decay was fitted to the repassivation kinetics of the single particle impact. SEM has been used to develop a mechanistic understanding of erosion-corrosion. The surface scars reveal that the depth of the craters and the length of the lips increase with increase in velocity. Micro-cracks also appear on these lips, believed to be due to corrosive action attacking the roots of these lips.     

Erosion-corrosion mapping of Fe in aqueous slurries: some views on a new rationale for defining the erosion-corrosion interaction

In studies of erosion-corrosion of materials in aqueous conditions, there have been various attempts to define regimes of interaction. Such regimes indicate whether erosion or corrosion may dominate the wastage mechanism. However, intermediate regimes in which corrosion and erosion interact with each other may lead to situations where the wastage is far greater than the sum of the processes acting separately.A common method of defining erosion-corrosion interactions has been to distinguish between the regime in which erosion enhances the corrosion rate (the so called “additive effect” because the corrosion contribution can be measured electrochemically and thus added to the erosion contribution to assess the overall wastage rate) and the regime where corrosion enhances erosion (the so-called “synergistic” effect). However, regimes of erosion-corrosion, where corrosion impedes the erosion are also of great importance mechanistically, and usually these are termed as exhibiting “negative synergism”. Defining the conditions in which a transition from “positive” to “negative synergism” occurs, is useful in order to optimize the parameters to minimize the wastage rate.This paper reviews the rationale that has been used to define erosion-corrosion regimes in aqueous conditions as part of a study of the erosion-corrosion of Fe at various pHs. The mathematical definitions are discussed in relation to practical erosion-corrosion problems. In addition, a new “antagonistic” erosion-corrosion regime is proposed to properly define the concept of “negative synergism”.     

Relationship between the effects of velocity and alloy corrosion resistance in erosion-corrosion environments at elevated temperatures

Erosion-corrosion by either solid particle or liquid impact occurs in a wide variety of industrial environments which range from coal conversion processes to steam turbines in nuclear power generation. The effects of erosion-corrosion depend on properties of the particle, the target and the nature of the corrosion environment. Various regimes of erosion-corrosion interaction have been identified, ranging from “erosion-dominated” (erosion of the substrate) to “corrosion-dominated” (erosion of the corrosion product).

In studies of erosion-corrosion, the effects of impact velocity are generally not well understood. In some environments in which corrosion occurs, high velocity exponents have been reported, while, in others, the values are close to 1. In addition, the effects of alloy corrosion resistance in environments of different velocities have been puzzling with differences in the exponents reported, as alloy corrosion resistance is increased.

This paper considers the effect of velocity for various erosion-corrosion studies from the literature. The effects of alloy corrosion resistance for such results are evaluated. Some general provisos for the interpretation of the effects of velocity will be made for alloys of different corrosion resistance in erosion-corrosion environments. It is shown that relative erosion-corrosion resistance of alloys in one environment cannot be used arbitrarily to predict resistance in other environments, particularly if parameters such as velocity are varied significantly.     

冲击形式产生的冲蚀、空蚀和腐蚀联合磨损试验研究

舰船等海洋运输装备在海水中行驶时,船体表面受到含沙海水的冲蚀磨损,舰船行驶速度变化引起的空蚀磨损,以及海水的腐蚀磨损,因此舰船表面材料的破坏形式是冲击式的冲蚀、空蚀和腐蚀联合磨损。为了研究联合磨损的影响因素,研制冲蚀、空蚀和腐蚀联合磨损试验台,并实验研究沙粒浓度、沙粒尺寸、含盐浓度以及冲蚀速度对45钢试件的联合磨损影响规律。实验结果表明:冲蚀、空蚀和腐蚀联合磨损程度强于冲蚀和空蚀交互磨损或单纯腐蚀磨损,在较低的沙粒浓度和较低的含盐浓度条件下,金属材料联合磨损质量损失与沙粒浓度、沙粒尺寸、含盐浓度和冲蚀速度均成正比关系。磨损面形貌分析表明:随着沙粒浓度、沙粒尺寸、含盐浓度、冲蚀速度的增加,试件表面的冲蚀沟和空蚀孔的磨痕深度和面积增大,而在人造海水中,试件表面不仅存在冲蚀沟和空蚀孔,还产生了腐蚀坑。     

Mapping erosion-corrosion of carbon steel in oil exploration conditions: Some new approaches to characterizing mechanisms and synergies

Erosion by solid particles in oil/water slurries is a technologically important area. In such conditions, it is necessary to distinguish between the effects of the sand, aqueous environment, and the oil. Erosion-corrosion maps provide a means of identification between erosion-corrosion regimes as a function of erosion and corrosion parameters. However, there has been no work carried out to map the effects of parameters in oil/water slurries. This paper investigates the effect of erosion-corrosion on carbon steel in oil field production and maps the results. Distinctions between “synergistic” and “additive” erosion-corrosion behaviour are superimposed on the maps in the various environments.     

Electro-mechanical interactions during erosion–corrosion

This study aims to understand the physical processes invoked when solid particle erosion occurs in a corrosive media. The literature on wear-corrosion shows some effort has been placed in qualifying the interactions between erosion and corrosion leading to ‘synergistic’, ‘additive’ and ‘antagonistic’ terms. These terms are difficult to quantify experimentally with multiple experiments being required and generate considerable errors often suggesting these interactive terms are negligible. Hence the current work seeks to investigate these interactions, the errors associated with their measurement and gain understanding of the processes involved by careful examination of microstructural and mechanical property changes of surfaces subjected to erosion–corrosion. Cast nickel–aluminium bronze/NaCl solution has been chosen to study as this system has been studied at Southampton for several years. In situ electrochemical, gravimetric and topographical analyses have been evaluated and discussed using microstructural and hardness measurements.