Corrosive wear of carbon and austenitic stainless steels in NaCl solution

The wear rates of an AISI 52100 carbon steel and a type 316 austenitic stainless steel and the corrosion current I from the rubbing steels were measured in NaCl solution to study the interrelationship between the corrosion and wear of the steels. An on-off cyclic loading test was also conducted to examine the effect of static corrosion during an unloading period on the corrosive wear of the steels.

It was found that the wear rates of the carbon steel and the type 316 stainless steel reach a maximum at NaCl concentrations of about 3% and 0.1% respectively. The on-off cyclic test has shown that corrosive wear of the steels is influenced by static corrosion during an unloading period. The increment †I of the corrosion current due to sliding was associated with the corrosive wear rate of the steels.     

Corrosion and wear of 6082 aluminum alloy

The corrosion and corrosive wear resistance of 6082 wrought aluminum alloy against 410 stainless steel counterface in 0.01 M NaCl solution with different concentrations of sodium molybdate dihydrate solution (0, 0.01, 0.1 and 0.5 M), were studied. The experimental results indicated that the increase in sodium molybdate dihydrate acted as an inhibitor in the 0.01 M NaCl solution resulting in a significant decrease in the corrosion current, meaning improved corrosion resistance. During the corrosive wear under free corrosion conditions of 6082 aluminum alloy specimens against 410 stainless steel counterface, the addition of sodium molybdate dihydrate inhibitor, leads to a decrease in friction coefficient of the examined pair of materials. The dominant wear mechanisms of the aluminum alloy were mainly observed to be plastic deformation and abrasion. These wear mechanisms coexisted with pitting corrosion phenomena, on the surface of this alloy.     

Tribocorrosion behavior of Ni-17.5Si-29.3Cr alloy in sulfuric acid solution

The tribocorrosion property of a Ni-17.5Si-29.3Cr alloy against a Si₃N₄ ball was studied in comparison with AISI321 stainless steel using a ball-on-disk reciprocating tribotester in 1 M sulfuric acid (H₂SO₄) solution. The effects of load and sliding speed on the tribocorrosion properties of the alloy were investigated. The results indicated that the wear rate of the alloy increased while the friction coefficient decreased with increasing load. The wear rate of the alloy increased linearly with increasing sliding speed and the friction coefficient increased in the initial stages and then remained constant with increasing sliding speed. The wear mechanisms were mainly microploughing, uniform corrosion and pitting corrosion. Under the experimental conditions of the present study, the Ni-17.5Si-29.3Cr alloy showed excellent corrosion-resistence and anti-wear ability compared with AISI321 stainless steel.     

Surface degradation of ductile metals in elevated temperature gas-particle streams

The mechanisms and rates of erosion and combined erosion-corrosion of 9Cr-1Mo steel (where the composition is in approximate weight per cent) and type 310 stainless steel at elevated temperatures were investigated to understand better the behavior of piping steels in fluidized bed combustor environments. Tests were performed in a partially inert gas atmosphere to study erosion behavior and in an air atmosphere to study combined erosion-corrosion behavior. It was determined that the erosion rate remained constant or decreased with increasing temperature in nitrogen until a temperature was reached at which the tensile strength started to decrease more rapidly with increasing test temparature. Above this temperature the erosion rate increased rapidly with temperature.In an erosion-corrosion environment, corrosion was the dominant mechanism at all test conditions. At higher temperatures and velocities the material loss mechanism changed from low loss rate chipping of the scale to high loss rate periodic spailing. The continuous scale formed on 9Cr-1Mo steel in air appeared to protect the metal surface, decreasing its loss rate in α = 30° tests compared with that of type 310 stainless steel tested in the same conditions in nitrogen where a continuous scale did not form.     

Wear and corrosion wear of medium carbon steel and 304 stainless steel

Wear and corrosive wear involve mechanical and chemical mechanisms and the combination of these mechanisms often results in significant mutual effects. In this paper, tribological behavior, X-ray peak broadening, and microstructure changes of carbon steel AISI 1045 and stainless steel AISI 304 samples under simultaneous wear and corrosion were investigated and the results were compared with those obtained from dry wear tests. 3.5 wt.% NaCl solution was used as the corrosion agent and a pin-on-disk tribometer was employed to perform wear and corrosive wear tests.X-ray diffraction measurements have shown that by increasing the applied load, the worn surfaces of carbon steel samples reached a constant strain at which fracture and wear occurred. Whereas in 304 stainless steel samples, by increasing the applied load, broadening of X-ray diffraction peaks was decreased.Wear tests of carbon steel and stainless steel samples have shown smaller weight losses and lower friction coefficient in the presence of corrosive environment. Study of worn surfaces suggested that depending on wear environment and applied load, different features of wear mechanisms were involved.     

Corrosion–erosion wear behaviors of 13Cr24Mn0.44N stainless steel in saline–sand slurry

The corrosion–erosion wear behaviors of austenitic stainless steels, 316L and 13Cr24Mn0.44N, were investigated in water–sand slurry and saline–sand slurry, respectively. The corrosion–erosion wear mass-loss was measured to evaluate the influence of medium and materials. The worn surface and corrosion–erosion wear mechanism were analyzed using a scanning electron microscopy and a non-contact optical profilometer. Results show that the corrosion–erosion wear mass-loss of 13Cr24Mn0.44N is lower than that of 316L in both the slurries. The relative wear resistance increases with the increasing of the impingement velocity and arrives at maximum of 1.6. The dominant wear mechanism of 13Cr24Mn0.44N is abrasive wear in the water–sand slurry, whereas it becomes abrasive wear associated with little corrosive pitting in the saline–sand slurry. As the impingement velocity increased all the synergism ratios exhibit a tendency of increase, among which the synergism ratio of 13Cr24Mn0.44N is always lower than that of 316L at any given velocity. The results indicate that 13Cr24Mn0.44N possesses a predominant anti-corrosion–erosion wear property.     

A review of the performance of engineering materials under prevalent tribological and wear situations in South African industries

The wear of materials used on machinery operating in a wide range of industrial situations such as mining, energy production and agriculture can cause serious inefficiencies, sudden breakdowns and consequential financial losses. Our work over two decades has concerned industrial problems encountered in South African industry, and laboratory simulations of abrasion, abrasion plus corrosion, adhesive wear, impact wear, cavitation, solid particle erosion and erosion plus corrosion situations have been successfully undertaken. Materials investigated include plain carbon and alloy steel, stainless steels, aluminium alloys, cast irons, tungsten carbide cermets, ceramics, polymers, composites and various surface treated and coated materials. The paper reviews the investigations carried out in our laboratories and conclusions we have made.     

Wear mechanisms of laser-hardened martensitic high-nitrogen-steels under sliding wear

High-nitrogen tool steels (Fe, 15% Cr, 1% Mo, 0.3% C, 0.3% N) are applied, e.g. in bearings and gears in aeronautics and space technology. Their advantage compared to conventional, nitrogen-free tool steels is a superior corrosion resistance, which can be attributed to Cr, Mo, and N dissolved within the solid solution. In order to gain a sufficient toughness for application, these steels are tempered above 600°C bringing about precipitated carbides and nitrides, which bind Cr and N and, therefore, deteriorate the chemical properties. Within a DFG (German Research Council)-funded research project the authors show, that by means of laser hardening it is possible to dissolve a part of these precipitates — mainly nitrides resulting in improved properties under fatigue, wear and corrosion. This is brought about by a newly generated martensite with compressive residual stresses (fatigue, sliding wear), dissolution of Cr and N (corrosion) and a higher mechanical stability of the surfaces (sliding wear). This contribution focuses on the acting wear mechanisms under dry sliding wear. The investigations are carried out with pin-on-disk tests, with the disk as the actual specimen and a pin made of conventionally hardened 52100 bearing steel (100Cr6). It can be shown, that the wear properties of the high-nitrogen-steel are better than those of comparable conventional tool steels and that a laser treatment leads to a further improvement. Due to the fact that there is a tempered zone between overlapping laser-hardened areas, there is a change of acting mechanisms and, thus a distinct difference in wear rates. For the conventional corrosion resistant martensitic tool steel the difference between the tempered and the hardened zone is not as marked. Neither the wear mechanisms nor the wear rates differ distinctly. These effects and their influence on the wear behaviour is correlated with the microstructure of both steels before and after laser-hardening.     

Experimental study of grinding fluids for abrasive-belt grinding of stainless steel

A number of ferritic stainless steels with high corrosion resistance have recently been developed, but these steels are known to be difficult to grind in coated abrasive-belt grinding operations. In order to formulate or select an optimum oil-based grinding fluid with which such stainless steels can be successfully ground, an optimum base oil was first experimentally selected, and then additives were evaluated for their effect in improving abrasive-belt grinding performance. A paraffinic mineral oil having a certain viscosity was found to be suitable for the base oil. Chemical grinding oil additives were found markedly effective in improving the abrasive-belt grinding performance for both 19Cr-2Mo ferritic stainless steel and SUS 304 austenitic steel, with those containing sulphur or chlorine being superior to those containing phosphorus, fatty acid or alcohol. Among all the additives tested, chemically active oils, such as sulphurized mineral oil, exhibited the best performance. Effects of chlorinated paraffins on the grinding performance could be perceived but were not so great as those of sulphur-series additives. The addition of TCP (tricresyl phosphate) to the grinding oil containing sulphur reduced metal removal in the case of 18Cr-2Mo ferritic stainless steel (SUS 444). In the case of SUS 430 ferritic stainless steel, however, TCP increased metal removal for a comparatively low sulphur concentration, but, above an optimum concentration of 0.4 wt% S, metal removal was reduced by TCP addition. A comparison of sulphur-series additives added to a sulphurized paraffinic mineral oil showed that nonyl polysulphide was superior to any other additives for improving the grinding performance in 19Cr-2Mo steel (SUS 444) and SUS 430. Excess addition of sulphurized fatty oil to a grinding fluid lowered the cutting ability of abrasive grains.     

On the synergistic effects of abrasion and corrosion during wear

The interactive effects of abrasion and corrosion were studied as a function of abrasive load, corrosion time and the frequency of abrasive and corrosive treatments. The initial rate of corrosion is independent of abrasive load but the percentage contribution to wear of corrosion decreases with increasing abrasive load. It has also been found that increasing the frequency of exposure to abrasion and corrosion increases the wear loss for a constant total amount of abrasion and corrosion. These effects are discussed in terms of the nature of the work-hardened surface layer and the chemical activity of this layer.     

Corrosive Wear Behaviors of Carbon Steels in Oil-Water Fluid

Carbon steel (CS) is the most common material used in oil production. Based on surface wetting state, the corrosive wear behavior of CS in oil-water fluid was investigated. The surface wetting state of the metal in oil-water fluids with different water cut and flow velocity was measured using a specially constructed device. Wear loss, corrosion loss, and corrosive wear loss of the CS samples in different oil-water fluids were measured by a reciprocating corrosive wear tester. The damage morphology of the CS samples was observed using scanning electron microscopy (SEM) and the element distribution on the surface was detected by energy-dispersive X-ray spectroscopy (EDS). The results indicated that the surface water wetting rate of the metal increased with water cut and decreased with flow velocity in the oil-water fluid. Wear, corrosion, and corrosive wear behavior of the CS was related to the surface wetting film and surface reaction film. In this test range, the synergetic action is negative and chlorine embrittlement occurs in the fluid with high water cut and low velocity. The damage mechanism of the CS was abrasive wear with selective corrosion.     

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.     

碳钢奥氏体不锈钢材料在水电工程中应用的局限性

通过对水电站典型应用材料(55钢、1Cr18Ni9Ti、0Cr13Ni5Mo)在冲蚀磨损过程中电化学腐蚀及抗冲蚀磨损性能研究,区分出纯磨损、纯腐蚀、磨损对腐蚀的促进分量及腐蚀对磨损的促进分量等在材料失效过程中各占的比例,考察了试验材料的抗冲蚀磨损特性及其磨损与腐蚀间的交互作用,分析了其失效机制。结果表明:不同的冲蚀速度下,0Cr13Ni5Mo不锈钢的冲蚀磨损失重率最小,55钢最大;纯磨损是材料失去的主要方式:55钢虽然纯磨损量较小,但腐蚀及其磨损与腐蚀的交互作用失去量大,1Cr18Ni9Ti不锈钢虽然纯腐蚀量小,但纯磨损量大,因而都有应用的局限性。     

The abrasive-corrosive wear of stainless steels

Laboratory abrasive and abrasive-corrosive testing has been carried out on a range of ferritic, austenitic and martensitic stainless steels and the results compared with the testing of similar materials in situ in the abrasivecorrosive conditions of a gold mine. All grades were found to have better abrasive-corrosive resistance than proprietary abrasion-resistant alloys.The austenitic grades derive their outstanding properties from their capacity to resist unstable fracture of microshear lips on the abraded surface. This is due to the strain capacity afforded by the mechanical inducement of the martensitic phase transformations and the high work-hardening characteristics of the transformation product. The influence of this transformation has been studied as a function of prior cold work and velocity of abrasion on a range of austenitic grades of stainless steels.Notwithstanding these advantages of the austenitic grades, the ferritic grades are superior in terms of cost per unit volume lost and the new duplex ferritic-martensitic steel designated 3CR12 has potential as an abrasionresisting material in corrosive environments.     

Wear of low temperature nitrided steels under different wear processes

A programme of tests has been carried out to assess the wear resistance of three low temperature nitriding treatments when compared with the untreatedv steel and a standard cyanide case-hardening treatment, under conditions of scuffing, abrasion, fretting and corrosion. The main conclusion is that low temperature nitriding is most suited to applications where scuffing and corrosion are the main wear mechanisms and that the resistance to abrasion and fretting is poorer in general than that of traditional case-hardening. Therefore, care should be taken in assessing the wear process in any application in which these treatments are used. Reference is also made to the wear mechanisms in the different tests.     

An examination of the electrochemical characteristics of two stainless steels (UNS S32654 and UNS S31603) under liquid-solid impingement

The erosion-corrosion resistance of high alloy stainless steel UNS S32654 and standard stainless steel UNS S31603 has been assessed under liquid-solid impingement conditions. The electrochemical characteristics of the two stainless steels have been examined via free corrosion potential measurements, anodic polarisation, linear polarisation and potentiostatic control in erosion-corrosion.It has been shown in this paper that high alloy stainless steel UNS S32654 exhibits better corrosion and erosion-corrosion performance than lower grade alloy UNS S31603. A general linear relationship between two electrochemical parameters (E_corr and R_p) has been shown in this study. A critical solid loading between 60 and 100 mg/l, at which there is a transition from corrosion to erosion-corrosion for the two stainless steels under different conditions, has been determined.     

Wear behaviour of hardfaced Fe-Cr-C alloy and austenitic steel under 2-body and 3-body conditions at elevated temperature

Fe-based hardfacing alloys are widely used to protect machinery equipment exposed to different loading situations where abrasives play a dominant role in restricting lifetime of tools. Wear at elevated temperatures is superposed by the effect of oxidation of the wearing surface. In view of the above, two hardfacing alloys based on Fe-Cr-C incorporating Nb, Mo and B to ensure improved performances at elevated temperature were deposited onto mild steel under optimised gas metal arc welding (GMAW) condition. 2-body erosive wear behaviour was evaluated from room temperature up to 650 °C under 30° and 90° impact angle. For 3-body impact/abrasion conditions tests were done with a specially designed cyclic impact abrasion tester (CIAT) at room temperature and 600 °C. The wear behaviour of the hardfacings was compared with austenitic stainless steel. Results indicate that 2-body erosive wear rate of the hardfacing increases with test temperature and with increase in impact angle, whereas wear behaviour of the austenitic stainless steel is non-sensitive to the testing temperature at normal impact. In 3-body impact abrasion testing similar behaviour can be seen; cyclic tests in CIAT at enhanced temperatures result in breaking of coarse carbides, whereas wear mechanisms of the austenitic steel result in massive abrasion and formation of a mechanically mixed layer (MML).     

Erosion of elevated-temperature corrosion scales on metals

Combined erosion-corrosion poses a considerable problem to the design of long-lifetime metallic components in energy conversion systems. To gain some insight into this problem, scales were formed on stainless steel at elevated temperature and were subsequently eroded at room temperature to determine the nature of the erosion rates and the mechanism of scale removal. Thin corrosion scales were formed on stainless steel 310 and on an experimental Fe-18Cr-5Al-1Hf alloy at high temperatures (900 and 980°C) in gas mixtures with various levels of oxygen and combined O₂-S₂. The corroded specimens were eroded at room temperature in an air-solid particle stream using SiC particles 50 μm in size at a velocity of 60 m s^?1. The conditions of the corrosive exposures, the rates of erosion of these scales and the microscopic appearance of the eroded surface were correlated to determine the mechanism of thin scale erosion.     

Abrasive wear resistance of some commercial abrasion resistant steels evaluated by laboratory test methods

The aim of the present study is to evaluate the abrasive wear resistance of some potential abrasion resistant steels exposed to different types of abrasive wear contact conditions typical of mining and transportation applications. The steels investigated, include a ferritic stainless steel, a medium alloyed ferritic carbon steel and a medium alloyed martensitic carbon steel.The abrasive wear resistance of the steels was evaluated using two different laboratory test methods, i.e. pin-on-disc testing and paddle wear testing that expose the materials to sliding abrasion and impact abrasion, respectively. All tests were performed under dry conditions in air at room temperature. In order to evaluate the tribological response of the different steels post-test characterization of the worn surfaces were performed using optical surface profilometry, scanning electron microscopy and energy dispersive X-ray spectroscopy. Besides, characterization of the wear induced sub-surface microstructure was performed using optical microscopy.The results show that depending on the abrasive conditions a combination of high hardness and toughness (fracture strain) is of importance in order to obtain a high wear resistance. In the pin-on-disc test (i.e. in sliding abrasion) these properties seem to be controlled by the as-rolled microstructure of the steels although a thin triboinduced sub-surface layer (5–10 μm in thickness) may influence the results. In contrast, in the paddle wear test (i.e. in impact abrasion), resulting in higher forces acting perpendicular to the surface by impacting stones, these properties are definitely controlled by the properties of the active sub-surface layer which also contains small imbedded stone fragments.     

Abrasion and corrosion resistant cobalt base alloys for hardfacing

Previous investigations carried out at CRM have shown that adding Mo, singly or in combination with Ni and/or Cu, enhances greatly the corrosion and abrasion resistance of high-carbon Co-Cr-W-C cast alloys.On account of these improvements, coatings of several Mo-, Ni- and/or Cu-modified grades of a Co-2.2% C-13% W-32% Cr alloy were prepared either by oxyacetylene welding with cast electrodes or by plasma spraying with prealloyed powders. The abrasion/corrosion behavior of the experimental deposits was compared with that of commercial alloys. The test data reported in this paper reveal the particularly good behaviour of the 18.2% Ni-4% Cu-8.7% Mo modified grade.