Abstract
The main objective of this study was to assess the influence of salt concentration on the corrosion behaviour, including the role of hydrodynamic conditions, of two broad classes of ferrous engineering materials. These are comprised of alloys, typified by a low-alloy steel (UNS G43400) that corrodes actively in aqueous conditions and a range of passive-film-forming stainless steels (UNS S31600, UNS S15500 and UNS S32760). Corrosion monitoring employed electrochemical (potentiodynamic polarisation) techniques. Three concentrations of aerated sodium chloride were utilised: 0.05 wt% NaCl, 3.5 wt% NaCl and 10 wt% NaCl. In quiescent, liquid impingement and solid/liquid impingement conditions, the corrosion rate of the low-alloy steel was observed to peak at 3.5 wt% NaCl, followed by a reduction in 10 wt% NaCl solution. These findings expand the range of previously reported trends, focused on static conditions. Such corrosion rate/salinity trends were observed to be dictated by the progress of the anodic reaction rather than influence on the cathodic reaction. Detailed studies were undertaken using segmented specimens to facilitate comparisons of the influence of hydrodynamic variations on corrosion behavior; these revealed that such variations influence the corrosion rates of low-alloy steel to a much lesser extent than the effect of changes in salinity. For the stainless steels, in quiescent and flowing conditions, when surface passive films are stable, there was a constant increase in corrosion rate with salinity. In solid-liquid conditions, however, the periodic film-destruction/repassivation events resulted in a similar corrosion rate/salinity trend to that displayed by the low-alloy steel, but with a much larger effect of hydrodynamic conditions. Additonally, the study revealed an underlying influence of stainless steel composition that mirrored, to an extent, the corrosion behaviour in pitting/re-passivation situations
Highlights
Natural and process waters, which are used in many industries, can be of variable nature in terms of chemical constitution and physical characteristics
This study has revealed that the influence of NaCl concentration on corrosion rates is quite different between low alloy steel and stainless steel in that the relationships are more dependent upon the type of corrosion–active or passive–than on the type of steel
An increase in corrosion rate was observed at moderate salt concentrations followed by a reduction in corrosion rate at higher salt concentrations
Summary
Natural and process waters, which are used in many industries, can be of variable nature in terms of chemical constitution and physical characteristics. One relevant feature of water is the total amount of dissolved salts (TDS)–often referred to as the salinity. This can vary between extremely low levels in many freshwaters, through concentrations of around 3% for ocean seawater. More saline conditions (5–10 wt% or more) are found in some local seas (Persian Gulf) and water after some industrial operations is even more saline (e.g., up to 30 wt% in the oil/gas [1] and mining sectors). Global demand for freshwater is constantly increasing, which means that industrial applications, such as fluid transport equipment, will be required to operate in more saline environments. The Chilean Copper Commission [5] in 2018 predicted a 230 wt% increase in the use of seawater in the decade–it is expected that all new and extended Chilean mines will need to use seawater or treated seawater
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