突扩管条件下材料的冲刷腐蚀机理研究Ⅱ不锈钢

利用新近研制的双相流冲刷腐蚀激光多普勒实验装置,通过失重测试、表面形貌观察、局部流速流态测试和典型部位的电化学测试,研究了突护管条件下不锈钢ＡＩＳＩ３１６Ｌ在单相及含砂人工海水介质中的冲刷腐蚀机理。结果表明：冲刷腐蚀峰值发生在距突扩位置约３．０Ｄ的部位（Ｄ为粗管直径）,与切向流速扰动度的峰值位置相同。在３．０Ｄ和５．５Ｄ的部位,冲刷作用是主要的,而在回流区（１．５Ｄ）,则为氧扩散控制,不同部位的冲     

流体力学因素对冲刷腐蚀的影响机制

综述了流速流态,攻角以及颗粒性质等流体力学因素对冲刷腐蚀的影响机制,讨论了流体力学的因素的重要性、流体力学条件的描述、关键的流体力学参数以及扰流条件下局部流速流态的获取,并论述了如何从流体力学方面控制冲刷腐蚀。     

流场环境中AZ31镁合金的腐蚀行为研究

采用自主构建的体外模拟流场环境实验平台,通过电化学阻抗谱(EIS)测量、拉伸实验、模拟体液pH值变化测试、SEM观察等方法,对AZ31镁合金在流场环境中的腐蚀行为进行了研究。从腐蚀电化学角度探究了流场中镁合金腐蚀速率与流速的定量关系,并采用ANSYS有限元分析研究了流态与剪切力作用对镁合金不同部位腐蚀差异的影响。结果表明,流场会加速AZ31镁合金的腐蚀,在腐蚀初期,腐蚀电流密度i_(corr)与流场平均流速n之间存在i_(corr)~(-1)=i_c~(-1)+Aν~(-1/2)的关系,其中,ic为不考虑扩散影响时的腐蚀电流密度,A为常数。腐蚀速率随流速增加而增大,且随着腐蚀时间延长,由于腐蚀产物的影响而逐渐偏离i_(corr)~(-1)~n~(-1/2)的线性关系。有限元分析表明,样品不同部位表面流体流态及剪切应力分布不同,局部传质系数K存在显著差异,不同流速下试样边缘部位的传质系数是中间的4~5倍,试样局部腐蚀形貌与剪切应力分布及流态差异相对应。     

单相流条件下90°水平弯管冲刷腐蚀行为研究

通过自行设计的管流式实验装置,采用失重测量、表面分析等方法,研究了单相流条件下90°水平弯管不同部位的冲刷腐蚀行为。结果表明:单相流条件下,90°水平弯管不同部位的冲刷腐蚀速率主要集中在2.11~3.29 mm/a,弯管的内侧及出口处的外侧冲刷腐蚀比较严重。流动条件下的冲刷腐蚀速率远远大于静止条件下的纯腐蚀速率,机械冲刷对腐蚀过程起到促进作用,介质流动是引起冲刷腐蚀速率大大增加的主要原因。试样表面存在面积较大的冲刷腐蚀坑点和沟槽,沟槽具有明显的方向性,沟槽的方向与局部流体流动的方向一致。     

焊缝余高对铜镍合金管材腐蚀行为的影响

海水管道焊缝下游区是发生腐蚀的热点区域.为探究B30管道焊缝余高对与其下游区腐蚀行为的影响,利用原位电化学测试装置和自制循环海水冲刷装置,在3天、7天、15天、30天4个冲刷节点进行试验.测试了3种模拟焊缝余高(0 mm;0.5 mm;1.5 mm)在紧邻热影响区和下游30 mm处母材区的电化学阻抗谱,用扫描电镜观察了试样表面的腐蚀形貌,结合COMSOL软件建立了有限元仿真流态模型,探讨了余高对介质流态的影响.结果表明,在有焊缝情况下,热影响区和母材区阻抗值均小于无焊缝结构,焊缝结构会加速下游区的腐蚀,且余高越大,腐蚀倾向也越大;热影响区腐蚀速率均大于母材区;流态模型显示出在热影响区位置出现了涡流,涡流加速了热影响区的腐蚀.     

CO_2驱高温高盐油藏井筒用P110套管的腐蚀规律

研发了生产系统多相流二氧化碳腐蚀仿真模拟装置,通过模拟注入井、采出井和地面集输管道的多相流状态腐蚀环境,实现多种流态、不同CO_2分压与温度条件下的材料腐蚀评价和缓蚀剂性能评价。在此基础上,研究了矿化度、温度、CO_2分压和流速等多种腐蚀因素对CO_2驱生产井中P110套管的腐蚀影响规律,建立了高CO_2分压局部腐蚀预测模型,并绘制CO_2驱采出井管材局部腐蚀预测图板。结果表明:CO_2驱采出井中P110套管的关键防腐蚀部位为高CO_2分压采出井、井筒中下部、动液面附近管柱。现场应用结果表明,该预测图板的预测符合率达到了80%,能快速、准确预测井筒的腐蚀规律与腐蚀情况。     

加氢裂化空冷器管束失效的多相流数值分析

对加氢裂化空冷器换热管内流体进行了多相流数值计算.分析了衬管尾部结构对管束失效的影响,结果表明,衬管尾部直角结构在流体下游诱发涡流,产生高剪应力区,易发生冲刷腐蚀,而45°倒角结构和1:10锥角结构较为合理,同时对管内垢物的分布对流动状态的影响进行了分析,发现垢物沿轴向分布的不均匀改变了管内流体的流速.在垢物层最厚位置之后形成高剪应力区.产生冲刷腐蚀.计算结果与在役空冷器更换下来的换热管束腐蚀泄露位置吻合.     

螺旋流和缓蚀剂协同作用抑制管道冲刷腐蚀

目的 探讨螺旋流和缓蚀剂协同作用下的减蚀机理,为开发基于螺旋流的新型冲刷腐蚀控制方法提供理论支撑。方法 利用循环式管流冲刷腐蚀试验装置,结合失重测试法、电化学测试法、形貌分析、高速摄像和XPS腐蚀产物分析开展非螺旋流和螺旋流条件下加入水溶性咪唑啉缓蚀剂的管道冲刷腐蚀对比试验研究。结果 失重法和电化学测量结果一致表明:在非螺旋流和螺旋流条件下缓蚀剂对20号钢冲刷腐蚀的纯冲刷速率、纯腐蚀速率、腐蚀促进冲刷速率和冲刷促进腐蚀速率均具有有效的抑制作用,但对纯冲刷的缓蚀率均小于对其他三者的缓蚀率。螺旋流和缓蚀剂协同作用对纯冲刷速率、纯腐蚀速率、腐蚀促进冲刷速率和冲刷促进腐蚀速率4个分量的协同缓蚀率均高于缓蚀剂单独作用对4个分量的缓蚀率。其中对冲刷促进腐蚀分量的缓蚀率最高,达到93.75%。高速摄像结果表明扭带产生的螺旋流使砂粒切向速度增大,产生砂粒悬浮效应,改善了砂粒的分布状态。从形貌观察来看,螺旋流和缓蚀剂协同作用下工作电极表面腐蚀产物层最为完整致密且蚀坑数量最少。XPS分析证明了螺旋流和非螺旋流条件下缓蚀剂在电极表面的吸附且螺旋流促进了氧气和缓蚀剂的传质。结论 螺旋流产生的砂粒悬浮效应和传质增强效应进一步促进缓蚀剂对纯冲刷速率、纯腐蚀速率、腐蚀促进冲刷速率和冲刷促进腐蚀速率4个分量的抑制,更充分地发挥了缓蚀剂的缓蚀效果。螺旋流与缓蚀剂的协同作用在降低管道冲刷腐蚀方面具有潜在的优势。     

柴油机喷油嘴内流体冲刷腐蚀的数值模拟分析

根据流体流动的基本规律,建立了冲刷腐蚀和空化流相变的数学模型,利用Fluent软件对喷油嘴内部流体进行数值模拟分析。结果表明:冲刷腐蚀引起材料损坏的严重位置为喷孔入口拐角处。然而当出现"超空穴"现象时,流体最大剪切应力位置会移至喷孔出口处附近;当腐蚀介质一定时,冲刷腐蚀程度随着燃油粘度、流体流速、进口压力、入口圆角的增大而增大,随着背压增大而减小;在进口压力和流速一定的情况下,降低燃油粘度和背压,减小入口圆角既能减缓流体冲刷腐蚀作用又有利于燃油雾化。     

迪那2凝析气田集输管线腐蚀机理与防护技术

迪那2凝析气田在投产3个月后内部集输和处理厂集气装置陆续发生管线刺漏、管线壁厚减薄、阀门和设备腐蚀等问题。通过对现场腐蚀部位打开、测厚、观察和实验室分析,对生产工况取样和实验室模拟研究,表明支线来气造成主管线介质流态突变,在靠近支线一侧存在低速涡流区、且支线无缓蚀剂从而造成缓蚀剂保护膜断层,当介质流经低速涡流区时腐蚀性组分和水分聚集,形成酸性腐蚀环境,加上高温高压下CO2联合Cl-导致的局部腐蚀速率加剧,以及高流速下的冲刷腐蚀是造成迪那2区块内部集输管线腐蚀的主要原因。据此提出腐蚀对策,并建议对采集气管线材质提高防腐蚀等级,采用合金钢以解决腐蚀问题。     

凝析气田集输管道弯管冲刷腐蚀数值计算

凝析气田集输管道中介质的流态和成分比较复杂,容易引起管道弯管发生冲刷腐蚀,导致管道事故。针对这一现象,将计算流体的方法引入到弯管的冲刷腐蚀的研究中,根据流体流动的规律,建立了弯管冲刷腐蚀的数学模型。根据气田集输管道中的实际运行参数,模拟三种工况下管道弯管中流体的运动。结果显示,管道中确实存在最大剪切应力和最大含液率的区域,并且气相介质流速越大,冲刷腐蚀越严重;弯管结构的改变,引起管道内介质流速和湍流强度等参数发生改变。研究成果可为研究流体力学因素对管道冲刷腐蚀的影响提供指导依据,还可以用以指导实际管道的腐蚀检测和结构的优化,减少气田事故的发生。     

Modelling of erosion-corrosion in practical geometries

The limiting factor in certain instances of erosion-corrosion of steel is the presence of dissolved oxygen in the solution and the transfer of this oxygen to the reacting surface. Computational Fluid Dynamics (CFD) can be used to calculate oxygen diffusion throughout the flow and its transfer to the reacting surface. This was used in a computational model to calculate wear and validated against experimental results, for the first time, of erosion-corrosion wear in a contracting-expanding geometry. It was found that in order to correctly predict erosion-corrosion wear, Sherwood number independent grids were required providing a new metric to evaluate turbulent erosion-corrosion modelling. The predicted wear profile matched very closely with experimental results and overall matching was very good. Downstream of the flow expansion, erosion-corrosion wear was under-predicted. The disparity is due to detached flow for most of this sector where under-predicted radial velocities decrease transfer of oxygen to the reacting surface. This under-prediction is apparent in the downstream section due to the larger relative magnitude of the radial velocity in this sector.     

Effects of Rare Earth Metal addition on the cavitation erosion-corrosion resistance of super duplex stainless steels

Austenitic stainless steels such as AISI 316L have been used in equipment in which fluid flows at high speeds which can induce cavitation erosion on metallic surfaces due to the collapse of cavities, where the collapse is caused by the sudden change of local pressure within the liquid. Usually AISI 316L is susceptible to cavitation erosion. This research focuses on developing a better material to replace the AISI 316L used in equipment with high speed fluid flow, such as impellers. The effects of Rare Earth Metal (REM) additions on the cavitation erosion-corrosion resistance of duplex stainless steels were studied using metallographic examination, the potentiodynamic anodic polarization test, the tensile test, the X-ray diffraction test and the ultrasonic cavitation erosion test. The experimental alloys were found to have superior mechanical properties due to interstitial solid solution strengthening, by adding high nitrogen (0.4%), as well as by the refinement of phases and grains induced by fine REM oxides and oxy-sulfides. Corrosion resistance decreases in a gentle gradient as the REM content increases. However, REM containing alloys show superior corrosion resistance compared with that of other commercial alloys (SAF 2507, AISI 316L). Owing to their excellent mechanical properties and corrosion resistance, the alloys containing REM have high cavitation erosion-corrosion resistance.     

Rates of mass transfer to patch electrodes in disturbed flows using oxygen reduction under limiting current conditions

The cases of a sudden pipe expansion and a sudden pipe contraction are simulated within a flow loop-based test section designed to approximate disturbed conduit flow. Mass transfer rates to patch electrodes at selected positions within the test section have been measured using a limiting current methodology applied to oxygen reduction at copper in 3.5% wt./vol. NaCl. Using both large-scale polarisation linear sweep voltammetry and a potential step current transient technique with hydrodynamic steps, absolute and relative rates of oxygen mass transfer have been examined as a function of Reynolds number and location within the test section. The highest rates of oxygen transfer were observed both within the high velocity area of the test section and close to known regions of flow disturbance. Under the flow conditions used, patch electrode mass transfer relates to wall shear stress, which allowed areas of high mean and high fluctuating wall shear stress to be identified.     

碳钢在液/固双相管流中磨损腐蚀的电化学行为

利用自行研制的管流动态模拟试验装置，研究了碳钢在液／固双相流中的磨损腐蚀．结果表明：碳钢在含有5％河砂的双相流动3．5％NaCl溶液中。磨损腐蚀速度随流速的增加而显著增大。没有像单相流中出现磨损腐蚀速度显著降低的流速区段，其磨损腐蚀过程仍主要受阴极氧扩散控制．对碳钢施加阴极电流，由于抑制了腐蚀电化学因素，从而大幅度削弱了与流体力学因素间的协同效应，使碳钢的磨损腐蚀大大减轻。     

船用焊接B10铜镍环失效分析

采用化学成分、宏观形貌、金相组织、微观及能谱分析等方法,分析了某船舶海水管路中的B10铜镍环的腐蚀失效原因。结果表明,在该铜镍环的腐蚀坑底部、冲刷腐蚀区、冲蚀坑内以及腐蚀穿孔的减薄区,都普遍存在着“冰糖块”状的晶间腐蚀形貌;优先腐蚀的晶界形成一个回路,被包围的晶粒发生了明显的脱镍和溶解;表层腐蚀产物及冲刷腐蚀区暴露出的晶粒上都存在S。该B10铜镍环的腐蚀破坏过程是含硫介质中的晶间腐蚀、脱成分腐蚀和冲刷腐蚀综合作用的结果。     

Effect of preferential dissolution on erosion-corrosion for chromium steel in alkali slurry

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The effect of post-treatment of a high-velocity oxy-fuel Ni-Cr-Mo-Si-B coating part 2: Erosion-corrosion behavior

In this paper, a study of the erosion-corrosion characteristics of a Ni-Cr-Mo-Si-B coating applied by the high-velocity oxy-fuel (HVOF) process on to an austenitic stainless steel (UNS S31603) substrate are reported. The coatings were studied in the as-sprayed condition, after vacuum sealing with polymer impregnation and after vacuum furnace fusion. The erosion-corrosion characteristics were assessed in an impinging liquid jet of 3.5% NaCl solution at 18 °C at a velocity of 17 m/s at normal incidence in two conditions: (1) free from added solids and (2) containing 800 ppm silica sand. The methodology employed electrochemical control and monitoring to facilitate the identification of the separate and interrelated erosion and corrosion contributions to the erosion-corrosion process. The rates of erosion-corrosion damage were drastically accelerated in the presence of the suspended solids. The application of cathodic protection significantly reduced the deterioration process. The study showed the effect of sealing with polymer impregnation did not significantly alter the erosion-corrosion behavior of the sprayed coating. However, there was a significant improvement in erosion-corrosion durability afforded by the postfusion process. The mechanisms by which the improved performance of vacuum-fused coatings is achieved are discussed.