Cavitation Erosion Corrosion Research Articles

Enhanced cavitation erosion and electrochemical corrosion properties of additively manufactured Hastelloy C276 coating by ultrasonic shot peening

Enhanced cavitation erosion and electrochemical corrosion properties of additively manufactured Hastelloy C276 coating by ultrasonic shot peening

Investigation into Morphology of Cavitation Erosion-Corrosion Pits on the Surface of Carbon Steel

Nano-sized films associated with the ring areasformed around micropits in cavitation erosion experimentswere investigated. The corrosion behavior and vibratory cavitation erosion tests of mild carbon steel in 3% NaCldistilled water were carried out. The results showed that thenano-sized films associated with the ring areas formedaround micropits in cavitation and free cavitation tests havea similar shape. The study proved that the nano-structure and the ring areas formed around micropits are the result ofcorrosion effects and not as a result of thermal effectsrelated to the collapse of the bubbles.

Cavitation erosion-corrosion properties of as-cast TC4 and LPBF TC4 in 0.6 mol/L NaCl solution: A comparison investigation

In this work study, a comparative analysis was undertaken to investigate investigation into the cavitation erosion (CE) and corrosion behavior of laser powder bed fusion (LPBF) TC4 and as-cast TC4 in 0.6 mol/L NaCl solution. Relevant results indicated that LPBF TC4 revealed a rectangular checkerboard-like pattern with a more refined grain size compared to as-cast TC4. Meanwhile, LPBF TC4 surpassed its as-cast counterpart in CE resistance, demonstrating approximately 2.25 times lower cumulative mass loss after 8 h CE. The corrosion potential under alternating CE and quiescence conditions demonstrated that both LPBF TC4 and as-cast TC4 underwent a rapid potential decrease at the initial stages of CE, while a consistent negative shift in corrosion potential was observed with the continuously increasing CE time, indicative of a gradual decline in repassivation ability. The initial surge in corrosion potential during the early CE stages was primarily attributed to accelerated oxygen transfer. As CE progressed, the significant reduction in corrosion potential for both LPBF TC4 and as-cast TC4 was attributed to the breakdown of the passive film. The refined and uniform microstructure in LPBF TC4 effectively suppresses both crack formation and propagation, underscoring the potential of LPBF technology in enhancing the CE resistance of titanium alloys. This work can provide important insights into developing high-quality, reliable, and sustainable CE-resistant materials via LPBF technology.

Exceptional combination of mechanical properties and cavitation erosion-corrosion resistance in a Fe23.7Co23.8Ni23.8Cr23.7Mo5 multi-principal element alloy

This study analyzed cavitation erosion (CE) and cavitation erosion-corrosion (CE-C) of single-phase face-centered cubic structured Fe23.7Co23.8Ni23.8Cr23.7Mo5 multi-principal element alloy (MPEA) with varying grain sizes obtained through post-deformation annealing (PDA). The average grain sizes of the samples after annealing at 1100 °C for 60 s, 1150 °C for 60 s, and 1100 °C for 200 s are 4.1 µm, 10.3 µm, and 15.2 µm, respectively. Among them, the 4.1 µm sample exhibits the best combination of high ultimate tensile strength (889 MPa) and large elongation (40.3%), as well as good electrochemical corrosion resistance in NaCl solution. Under the conditions of CE and CE-C for a duration of 10 h, the 4.1 µm specimen exhibits cumulative mass losses of approximately 1.4 mg and 2.6 mg, respectively. In contrast, under identical conditions, the 316 L SS registers cumulative mass losses of approximately 16.7 mg and 24.8 mg, respectively. Due to the excellent mechanical properties and work hardening ability of the 4.1 µm sample, it can effectively resist the plastic deformation caused by cavitation erosion, reducing mass loss. In addition, the stable passivation film enhances its resistance to Cl- destruction, thus demonstrating notable corrosion resistance. Ultimately, under conditions where cavitation erosion and corrosion coexist, these combined properties enable the 4.1 µm sample to exhibit the least mass loss and damage.

Advanced cavitation erosion-corrosion resistance of nickel-aluminum bronze prepared by directed energy deposition

The mechanical properties and cavitation erosion-corrosion behavior of directed energy deposition (DED) and as-cast nickel-aluminum bronze (NAB) alloys in 3.5 wt% NaCl solution were investigated. The DED-produced NAB alloy showed a finer microstructure, and the content of κ phases significantly decreased, improving yield strength (increased by 27.76%) and elongation (increased by 54.89%) of NAB alloy. The DED-produced NAB exhibited a more uniform microstructure, fewer high-angle grain boundaries (HAGBs), and twin boundaries (∑3), resulting in a weakened synergistic effect between corrosion and mechanical attack. Compared with the as-cast counterpart, the mass loss rate of DED-produced NAB decreased by 74.77%.

Effect of seawater temperature on the corrosion and cavitation erosion-corrosion resistance of Al10Cr28Co28Ni34 high-entropy alloy coating

The influence of temperature on the corrosion and cavitation erosion-corrosion (CE-C) behavior of Al10Cr28Co28Ni34 high-entropy alloy (HEA) coating in seawater was investigated. Interestingly, the corrosion resistance of the coating progressively diminished with an increase in seawater temperature, but the CE-C resistance demonstrated a trend of initial increase followed by a decrease. At higher seawater temperature, the resistance of the coating surface and the destructive force of the bubbles were respectively enhanced and weakened due to the increase in oxide film thickness, maximum bubble size, and collapse time, together leading to a reduction in the damage degree to the coating.

The influence of sulphide on the ultrasonic cavitation erosion-corrosion behaviors of HVOF-sprayed WC-Cr3C2-Ni coating

The present study emphasizes the role of sulphide on ultrasonic cavitation erosion-corrosion (UCE-C) behaviors of HVOF-sprayed WC-Cr3C2-Ni coating in 3.5 wt% NaCl solution with different sulphide concentrations. The results indicated that the ultrasonic cavitation erosion (UCE) resistance of the coating decreased significantly with increasing sulphide concentration. The coating reacted with oxygen and anion those transferred by UCE, and the cavitation impact force led to the lack of support for tungsten carbide particles, which resulted in the reduction in the mass of the coating. There were two main factors those affected the UCE-C mechanism, in which the passivation film helped to reduce the mass loss of the coating, while the impact force caused by cavitation destroyed the passivation film, led to the accelerated anion diffusion and ultimately accelerated the mass loss of the coating. Mechanical erosion dominated the UCE-C of the coating in all tested solutions.

Synergistic effect between cavitation erosion and corrosion of Monel K500 alloy in 3.5 wt% NaCl solution

Cavitation erosion-corrosion simultaneously damaged the material through mechanical attack and electrochemical corrosion. In this work, experiments were performed on Monel K500 alloy in deionized water and 3.5 wt% NaCl solution using an indirect ultrasonic vibration system to investigate the synergistic effect between cavitation erosion and corrosion. Mass loss measurement and surface topography observation were used to identify the different stages of cavitation erosion. The electrochemical properties at different cavitation stages were analyzed by EIS technique. Results showed that the synergistic effect between cavitation erosion and corrosion exacerbated cavitation damage, and the weight loss rate in 3.5 wt% NaCl solution was about 10% higher than that in deionized water. The increase in ion diffusion and oxygen supply caused by violent agitation accelerated the surface corrosion process, resulting in corrosion-enhanced erosion. Mechanical damage to the material surface during the cavitation process also accelerated the corrosion process, indicating that cavitation-enhanced corrosion was the primary synergistic mechanism. Pure cavitation accounted for 90.75% of total mass loss, suggesting that mechanical deterioration dominated the overall cavitation erosion and corrosion process. Cavitation-enhanced corrosion accounting for 96.12% of the synergistic effect，was the main synergistic mechanism.

Revealing the influence of zirconium content on the cavitation erosion-corrosion of a wear-resistant steel in sodium chloride solution

Wear-resistant steels with different zirconium contents were prepared to investigate the influence of zirconium on the cavitation erosion-corrosion behaviour in sodium chloride solution. To better understand the behaviour of these steels, the microstructure, mechanical properties and corrosion behaviour were also evaluated. It was found that the addition of appropriate amounts of zirconium to current steel could effectively improve its cavitation erosion-corrosion resistance, mainly attributed to the improved corrosion resistance, impact toughness and work-hardening capacity. However, excessive addition of zirconium caused the precipitation of large-sized zirconium compounds. The interface between the compounds and the matrix could be the origin of damage.

Effect of residual stress and phase constituents on corrosion-cavitation erosion behavior of 304 stainless steel by iso-material manufacturing of laser surface melting

Different from additive manufacturing and subtractive manufacturing, iso-material manufacturing (also named isovolumetric manufacturing) is applied to 304 stainless steel (304SS) by laser surface melting (LSM) at four energy density (51 J/mm2, 44 J/mm2, 39 J/mm2, 37 J/mm2), aiming at improving the resistance to corrosion and cavitation erosion without any addition of precious metals. The experimental results show that the microstructure presents the transformation from plane crystal → columnar crystal → equiaxed crystal from interface to top surface. All the samples exhibit austenite+martensite+Cr23C6, and the martensite content is increased from 9.3% to 40.8% with the energy density decreasing after iso-material manufacturing. In addition, low angle grain boundary is increased, and nano-mechanical properties also show an increasing trend. The decreasing of energy density also enhances the residual tensile stress of the melting layer. The sample obtained at energy density of 51 J/mm2 displays the highest corrosion resistance in 3.5 wt% NaCl solution, which can be attributed to its low galvanic corrosion degree and small residual tensile stress. The sample obtained at energy density of 39 J/mm2 exhibits the highest cavitation erosion resistance (Re) and its passivation film displays better self-repairing and re-passivation ability as indicated by synergistic cavitation erosion-corrosion behavior. The high cavitation erosion resistance can be attributed to the proper compromise of the constituent phases and higher self-repairing of the passivation film for the melting layer. Moreover, the 304 stainless steel prepared in this study exhibits a high or comparable corrosion and cavitation erosion resistance in comparison with the samples prepared by other fabrication method reported previously.

An investigation on wear and cavitation erosion-corrosion characteristics of the TiC modified Fe-based composite coating via laser cladding

Fe-based composite coating, modified with TiC ceramic particles, has been successfully manufactured on 304 stainless steel substrate by laser cladding technique in this paper. The phase distribution and microstructure of composite coating are carefully studied via some advanced techniques such as XRD, SEM, EDS and EBSD, meanwhile, the microhardness, wear resistance, electrochemical performance and cavitation corrosion resistance of composite coating and substrate are systematically tested. The obtained results reveal that the as-cladded composite coating is mainly composed of α-Fe, (Cr,Fe)7C3 and TiC. The introduction of TiC particles refined the microstructure inside the dendrites, at the same time the different forms of TiC particles are dispersively distributed in the composite coating. It is found the high microhardness is beneficial for the wear resistance of the coating. Compared with the matrix and some common engineering materials, although no obvious passivation zone is observed, the composite coating also exhibits superior electrochemical performance. Combining the excellent electrochemical and mechanical properties of the coating, the cavitation corrosion resistance of the composite coating has been significantly enhanced. A cavitation erosion resistance mechanism for composite coating has been proposed.

Effect of synergistic cavitation erosion-corrosion on cavitation damage of CoCrFeNiMn high entropy alloy layer by laser cladding

The CoCrFeNiMn high entropy alloy (HEAs) clad layer was prepared on the surface of 304 stainless steel using coaxial powder feeding laser cladding. The effects of laser energy density on the macroscopic residual stress, crystallographic characteristics, microhardness, corrosion resistance and cavitation erosion (CE) resistance of HEAs clad layer were studied. With the decrease of laser energy density from 45 J/mm2 to 36 J/mm2, pore defects and abnormal coarsening of microstructure in HEAs cladding layer can be effectively avoided, the average grain size can be refined to 74.3 ± 1.7 μm, the average Schmidt factor is 0.43, which also shows the highest dynamic passivation tendency and corrosion resistance in artificial seawater. After 10 h-CE, the carrier density ND in the passivation film of HEAs clad layer can be as low as 3.24 ± 0.08 × 1022 cm−3, and the lowest mean depth erosion rates (MDER) is 0.68 ± 0.07 μm/h, which is much lower than that of 304 stainless steel substrate (4.23 ± 0.13 μm/h). The excellent CE resistance of the HEAs clad layer is attributed to the fact that its grains can effectively resist the plastic deformation and the surface passivation film can maintain a relatively high degree of integrity and continuous level after long aging CE, which has a considerable application prospect in marine engineering.

Analysis of Mechanisms Affecting the Tool in Pulsed Electrochemical Machining

Electrochemical machining (ECM) is an important technology in machining difficult-to-cut materials. The contactless nature of ECM and anodic dissolution of the workpiece propound no tool ablation. Nevertheless, in a few studies, tool damages, namely the formation of pits and geometrical changes, have been observed, which is the investigative goal of this work. This study considers three hypotheses to investigate tool changes during pulsed electrochemical machining (PECM) which are hydrogen embrittlement, cavitation erosion, and cathodic corrosion. A systematic study of monitoring possible tool (1.4112 martensitic stainless steel) changes during ECM and PECM in aqueous NaNO3 electrolyte is performed. Experimental results of this study show that hydrogen embrittlement and cavitation erosion are not the reason for causing changes in the tool. Cathodic corrosion might be the reason for the changes in the tool in this study; however, more investigation is needed. The approach in this study is investigating the microstructure of the tool regarding different aspects before and after ECM and PECM, as the microstructure stores information regarding phenomena occurring during any process.

Cavitation erosion-corrosion behaviour of Fe-19Cr-15Mn-0.66 N high nitrogen austenitic stainless steel in sodium chloride solution

In this work, the cavitation erosion (CE)-corrosion behaviors of high nitrogen austenitic stainless steel (HNSS) Fe-19Cr-15Mn-0.66 N were investigated under both static and CE conditions in 0.5 mol l−1 NaCl solution. For the sample after 8 h CE, the cumulative mass loss increased by 15% in 0.5 mol l−1 NaCl solution compared to distilled water, indicating that the corrosive media promoted mass loss. The corrosion behavior of the samples under static and CE conditions was evaluated using electrochemical techniques. The results showed that compared with the samples under static conditions, the samples under CE had a higher corrosion rate, and the corrosion resistance of the samples gradually decreased with the prolongation of C E time.The open circuit potential and potentiodynamic polarization tests showed a higher corrosion rate under CE conditions. The electrochemical impedance spectroscopy results revealed a decrease in corrosion resistance with increasing CE time. The XPS results showed that CE has a significant effect on the composition of the passive film, promoting a notable increase in Cr2O3 and Fe2O3.

The effect of Ni201 transition layer on the corrosion, wear and synergetic cavitation erosion-corrosion behavior of CMT-Monel K500 coating

The Monel K500 modified coating with Ni201 as the transition layer was prepared on the 304 stainless steel substrate by cold metal transfer (CMT) technology. Different from the Monel K500 coatings with direct deposition, the Ni201 transition layer can effectively block the diffusion of Fe and other elements in the substrate and avoid the deterioration of corrosion resistance of Monel K500 coating caused by galvanic corrosion in artificial seawater, which showed the highest polarization resistance and the strongest passivation tendency. In addition, the diffusion of Ni atoms in the transition layer compensated and stabilized the alloy element composition of the Monel K500 coating, making it have a finer microstructure and show higher microhardness and wear resistance. After 10 h- cavitation erosion (CE), the Monel K500 coating with transition layer showed the lowest mean depth erosion rates (MDER) of 2.2 ± 0.09 μm/h as it maintains the highest self-healing ability and integrity of passive film during the long-term synergistic effect of cavitation erosion and corrosion (SCEC). The introduce of the Ni201 transition layer can effectively improve the corrosion-cavitation and wear properties of CMT-Monel K500 surface modified coating, and then effectively prolong the service life of seawater overflow components such as butterfly valves, pump bodies, hydraulic turbines and heat exchangers, which has great application potential in the field of tribo-corrosion in ocean engineering.

High-entropy carbides designed to resist cavitation erosion-corrosion in an acidic environment: Surface engineering guided by first-principles calculations and experiments

In this study, the influence of chemical composition on phase stability, mechanical and electronic properties of (TixZr0.2Nb0.2Ta0.2Mo0.4-x)C (x = 0.3, 0.2, 0.1) high entropy carbide ceramics (HECCs) were first explored by first-principles calculations. The results showed that the composition (Ti0.3Zr0.2Nb0.2Ta0.2Mo0.1)C has higher values of electron work function (EWF) value and theoretical hardness than that of the other HECCs with lower Ti concentrations. Following this investigation, a (Ti0.3Zr0.2Nb0.2Ta0.2Mo0.1)C HECC coating was deposited onto a commercially pure titanium substrate by a reactive-sputtering method. The as-prepared HECC coating had a uniform thickness of ∼17 μm and consisted of equiaxed nanocrystals with a mean diameter of ∼7 nm. The cavitation erosion-corrosion behavior of the HECC coating was studied by combining electrochemical impedance spectroscopy (EIS) and electrochemical noise (EN) measurements in a 0.05 M H2SO4 solution. The EIS results revealed that with increasing time of cavitation exposure, the resistance value of the HECC coating was an order of magnitude larger than that for uncoated CP-Ti for a given cavitation time. EN analysis indicated that under cavitation conditions, uncoated CP-Ti was more vulnerable to localized corrosive attack than the HECC coating in an acidic environment.

Microstructure and corrosion behaviour of WC-Co coating fabricated by plasma arc welding

ABSTRACT The WC-Co composite coating was prepared on SS 316L by plasma arc welding technology. The microstructure, phase composition, and microhardness of the WC-Co composite coating were thoroughly studied. The corrosion behaviour including electrochemical corrosion, cavitation erosion, and erosion corrosion was tested. The results showed that the WC-Co coating exhibited a good metallurgical bond with the substrate. The average microhardness of the WC-Co coating reached 1785 HV, which was 9.4 times that of the SS 316L. The corrosion current density of the WC-Co composite coating was one order of magnitude lower than that of the substrate. Meanwhile, the cumulative mass loss of cavitation erosion and erosion corrosion of the WC-Co composite coating was much lower than that of the SS 316L.

Cavitation erosion/corrosion synergy and wear behaviors of nickel-based alloy coatings on 304 stainless steel prepared by cold metal transfer

Inconel 625 and Hastelloy C-276 nickel-based alloy coatings were prepared on 304 stainless steels by cold metal transfer (CMT), aiming at improving the resistance to corrosion, cavitation erosion and wear. The synergistic cavitation erosion-corrosion (SCE-C) effect of the coatings was also revealed in 3.5 wt% NaCl solution. Experimental results show that the Inconel 625 coating was composed of γ-phase matrix and MC-type carbide precipitates dominated by NbC, while the Hastelloy C-276 coating exhibited γ-phase matrix and Mo-rich p phase. Both corrosion resistance and cavitation erosion resistance of the Hastelloy C-276 coating and Inconel 625 coating were higher than that of 304 substrate, and the Hastelloy C-276 coating possessed higher corrosion resistance and cavitation erosion resistance than Inconel 625 coating as indicated by higher polarization resistance (152.95 kΩ cm2) and lower mean depth erosion rates (1.3 ± 0.15 μm/h). The carrier concentration ND of passivation film for Hastelloy C-276 coating (4.05 ± 0.01 × 1022 cm−3) was lower after 10h-cavitation erosion compared to Inconel 625 coating, indicating its passive film showing a stronger passivation behavior and protective ability. The Hastelloy C-276 coating also exhibited a higher wear resistance, and the wear mechanism was adhesive-abrasive comprehensive wear dominated by adhesive wear in the linear reciprocating wear test with Al2O3 as the friction pair. The wear resistance of Inconel 625 coating and Hastelloy C-276 coating was about 1.3 and 1.5 times that of 304 substrate, respectively. The Hastelloy C-276 coating fabricated in the present study exhibited a great potential as flow-passing parts in marine engineering fields due to the desirable resistance to corrosion, cavitation erosion and wear.

ULTRASONIC CAVITATION EROSION-CORROSION BEHAVIOR OF NiTi CLADDINGS WITH Ni AND Cu INTERLAYER

The NiTi claddings by tungsten inert gas (TIG) with Ni and Cu interlayer were manufactured to resist the cavitation erosion-corrosion (CEC). The cavitation test, the open circuit potential and the potentiodynamic polarization measurements were used to study the synergistic effect among cavitation erosion (CE) and corrosion for the NiTi claddings. After the CEC test for 11[Formula: see text]h, the cumulative mass loss of 304 stainless steel is 5 and 1.15 times that of NiTi-Ni-TIG cladding and NiTi-Cu-TIG cladding, respectively. In NiTi-Cu-TIG cladding, the galvanic corrosion between the Cu-Ti intermetallics and the B2 phase causes the anodic dissolution of the Cu-Ti intermetallics, and results in the B2 phase losing support and spalling off during the CEC test. In contrast, NiTi-Ni-TIG cladding can be used against the CEC because of its uniform microstructure, no Cu-rich area and the effect of corrosion on CE of NiTi-Ni-TIG cladding is small.

Effect of compressive stress on cavitation erosion-corrosion behavior of nickel-aluminum bronze alloy

The effect of compressive stress on cavitation erosion-corrosion behavior of nickel-aluminum bronze alloy was investigated, and the results showed that the alloy exhibited selective phase corrosion of eutectoid “α + κiii” and its destruction was aggravated with more cavitation mass loss up to 1.74 times of the specimen without stress. It was mainly owing to the enhanced corrosion-induced erosion caused by compressive stress, which led to lattice distortion of the alloy and the resulting accelerated selective phase corrosion with increasing surface roughness, and then intensified the synergistic effect of electrochemical corrosion and mechanical erosion.