Corrosion Damage Mechanisms Research Articles

Investigation of calcium–magnesium-alumino-silicate (CMAS) resistance and hot corrosion behavior of YSZ and La2Zr2O7/YSZ thermal barrier coatings (TBCs) produced with CGDS method

Thermal barrier coatings (TBCs) commonly expose to oxidation, hot corrosion, and CaO-MgO-Al2O3-SiO2 (CMAS) attacks during the service condition. All of these attacks cause the spallation or delamination of TBCs from the bond coat. In this study, the effect of these attacks on YSZ and La2Zr2O7/YSZ TBC systems was investigated. YSZ and double layer La2Zr2O7/YSZ topcoats were deposited using electron beam physical technique (EB-PVD) on CoNiCrAlY bond coat produced by cold gas dynamic spray (CGDS) technique. CMAS tests at 1225 °C for 4, 8, 12, 16, 20, 24, 28, and 32 h and 5 h cyclic hot corrosion tests at 1000 °C were carried out on TBCs. Before and after the tests, TBCs were characterized using scanning electron microscopy (SEM), energy dispersive spectrometer (EDS), x-ray diffraction (XRD) and image analysis software program. At the end of the tests, the formed phases, microstructural changes, and general failure mechanisms were investigated in detail for each test. The general result shows that double-layered TBCs provide significant contributions and durability against high-temperature corrosive attacks of conventional YSZ TBC. In addition, in this study, hot corrosion damage mechanism and CMAS attack significantly damaged the column morphology of the EB-PVD method, reducing the thermal insulation properties and strain tolerance of TBCs. As a result of the tests, spallation and phase changes occurred in the damaged TBC systems.

Mechanical properties and damage mode of cemented tailings backfill in an acidic environment

The properties and deterioration in strength of cemented tailings backfill (CTB )in the underground acidic environment under oxidizing conditions were studied. X-ray diffraction analysis and scanning electron microscopy of the surface of the CTB was carried out, and the sulphuric acid corrosion mechanism elucidated. The properties tested included compressive strength, elastic modulus, cohesion, internal friction angle, variation in the hydrogen ion concentration, and stress-strain relationship in different corrosion periods. The damage model of the CTB was established considering the effects of parameters such as corrosion time and strain on the damage evolution. It was found that the compressive strength, elastic modulus, cohesion (binder effect), and internal friction angle increased at first and then decreased with exposure time. In the long term, the peak stress decreased with corrosion time while the peak strain increased; elastic modulus, and deformation modulus also decreased. The damage caused by corrosion and by load were related by means of a mathematical model, which revealed the relationships between sulphuric attack, load, and damage to backfill in complex underground environments. During corrosion, the expansion of gypsum and ettringite caused microfractures in the CTB. With increasing corrosion time, micro-cracks developed and proliferated. The mechanism of corrosion damage was found to be the dissolution of hydrogen ions and a sulphate ion reaction that produces an expansive substance, resulting in deterioration of the strength of CTB.

Effect of Flow Rate on Erosion Corrosion Damage and Damage Mechanism of Al5083-H321 Aluminum Alloy in Seawater Environment

In this study, erosion tests and erosion-corrosion tests of Al5083-H321 aluminum alloy were conducted at various flow rates in seawater. The erosion tests were conducted at a flow rate of 0 to 20 m/s, and erosion-corrosion tests were performed by potentiodynamic polarization method at the same flow rate. Characteristic evaluation after the erosion test was conducted by surface analysis. Characteristic evaluation after the erosion-corrosion test was performed by Tafel extrapolation and surface analysis. The results of the surface analysis after the erosion test showed that surface damage tended to increase as the flow rate increased. In particular, intermetallic particles were separated due to the breakdown of the oxide film at 10 m/s or more. In the erosion-corrosion test, the corrosion current density increased as the flow rate increased. Additionally, the surface analysis showed that surface damage occurred in a vortex shape and the width of the surface damage tended to increase as the flow rate increased. Moreover, damage at 0 m/s, proceeded in a depth direction due to the growth of pitting corrosion, and the damaged area tended to increase due to acceleration of the intermetallic particle loss by the fluid impact.

MAGNESIA CORROSION OF GROUTING MATERIALS

The issue of magnesia corrosion of grouting materials in oil and gas wells is very relevant in the construction of oil and gas wells since magnesia salts can lead to the destruction of Portland cement-based cement stone within few months. When fastening powerful intervals of salt deposits represented by magnesium salts, the use of magnesia cements is effective. However, individual layers and interlayers containing dissolved magnesium salts are not individually cemented, but overlap over the entire interval of the open hole with cement Portland cement, which can be destroyed due to magnesia corrosion. The main aim of the paper is to analyze the corrosion of Portland cement stone in aggressive environments of magnesia. As the quantitative indicators characterizing the degree of stone damage, the thickness of the damaged layer and the stone resistance coefficient are taken, characterized by the ratio of the compressive strength or bending strength of stone samples after being in an aggressive environment to the strength of control samples at the same hardening time. The corrosion resistance of cement stone was assessed after 8 weeks in an aggressive magnesia environment. Also, the role of MgCl2 concentration on the mechanism of corrosion damage to cement stone was studied. The use of reducing the water-cement ratio and adding palygorskite clay to reduce the porosity of cement stone and reduce the rate of corrosion damage is proposed. The kinetics and the main factors affecting the corrosion process were considered, an X-ray diffraction analysis of corrosion products and unaffected cement stone was carried out.

CORROSION OF WELDED CARBON STEEL PIPES IN OIL PRODUCTION FIELDS IN EGYPT

In oil production fields, corrosion of welded carbon steel pipes frequently occurs in areas near welds. Corrosion in other areas may take place at a lower frequency and with a lower detrimental effect. In this paper, a field survey is conducted of eight oil petroleum fields over a period of seven years. Testing of specimens of carbon steel welded joints is carried out under simulated conditions. This study investigates the predominated corrosion damage mechanisms in welded carbon steel pipes. It examines the critical factors triggering corrosion mechanisms and the techniques for corrosion monitoring and mitigation. Flow-induced corrosion and preferential weld corrosion were found to be the most effective mechanisms compared to pitting and microbiologically induced corrosion. Detrimental factors of corrosion mechanisms include flow rates and changes in process parameters of pH, fluid resistivity, and some anion concentrations. The corrosion mitigation was achieved by increasing the dosage of injected corrosion inhibitors.

Research on the Corrosion Damage Mechanism of Concrete in Two Freeze–Thaw Environments

This study aims to investigate the effects of two freeze–thaw environments (i.e., maintenance freeze‐thaw (MFT) environment and immersion freeze‐thaw (IFT) environment) on the durability performance, deterioration rules, and mechanisms of concrete. In MFT, the concrete specimens were firstly cured in the standard curing environment (temperature, 20 ± 3, humidity, not less than 95%, and ages, 28 d) and then were carried out in freeze–thaw environment, while in IFT, the concrete specimens were firstly cured in the salt (NaHCO3, NaCl, and Na2SO4) immersion environment for 90 d and then were carried out in freeze–thaw environment. In this study, the damage features, relative dynamic elastic modulus, mass changes, and erosion‐resistance coefficient of concrete have been measured. Thereafter, using the scanning electron microscopy (SEM) and the mercury intrusion porosimetry (MIP), the air‐void structure parameters and the microstructures have been measured, respectively. The results show that the relative dynamic elastic modulus and the erosion‐resistance coefficient of the compressive strength of the concrete in the IFT environment are, respectively, 14.3% and 21.0% higher than those of the concrete in the MFT environment. In addition, the results of the microstructure analyses show that the corrosion damages of the concrete are mainly caused by the combined action of the corrosion products of ettringite and freeze–thaw environment. However, the damage to the concrete in the MFT environment is more serious than that in the IFT environment. The results of the MIP analysis show that the harmful pore value for the concrete in the MFT environment is almost two times larger than that for the concrete in the IFT environment.

Damage mechanism and evaluation model of compressor impeller remanufacturing blanks: A review

The theoretical and technological achievements in the damage mechanism and evaluation model obtained through the national basic research program “Key Fundamental Scientific Problems on Mechanical Equipment Remanufacturing” are reviewed in this work. Large centrifugal compressor impeller blanks were used as the study object. The materials of the blanks were FV520B and KMN. The mechanism and evaluation model of ultra-high cycle fatigue, erosion wear, and corrosion damage were studied via theoretical calculation, finite element simulation, and experimentation. For ultra-high cycle fatigue damage, the characteristics of ultra-high cycle fatigue of the impeller material were clarified, and prediction models of ultra-high cycle fatigue strength were established. A residual life evaluation technique based on the “β-HV-N” (where β was the nonlinear parameter, HV was the Vickers hardness, and N was the fatigue life) double criterion method was proposed. For erosion wear, the flow field of gas-solid two-phase flow inside the impeller was simulated, and the erosion wear law was clarified. Two models for erosion rate and erosion depth calculation were established. For corrosion damage, the electrochemical and stress corrosion behaviors of the impeller material and welded joints in H2S/CO2 environment were investigated. KISCC (critical stress intensity factor) and da/dt (crack growth rate, where a is the total crack length and t is time) varied with H2S concentration and temperature, and their variation laws were revealed. Through this research, the key scientific problems of the damage behavior and mechanism of remanufacturing objects in the multistrength field and cross-scale were solved. The findings provide theoretical and evaluation model support for the analysis and evaluation of large centrifugal compressor impellers before remanufacturing.

Corrosion Electrochemical Behavior of Nickel in the LiCl–KCl Melt Containing Lanthanum Trichloride

The effect of temperature on the corrosion of nickel (N1) in the range from 500 to 800°C during testing in the salt melt of the eutectic mixture of lithium and potassium chlorides with the addition of lanthanum trichloride in the amounts from 0.5 to 2 mol % is studied. The nickel corrosion rate increases with temperature, and lanthanum chloride additives decrease the corrosion rate at 500–650°C (inhibition of the shielding type due to the subsequent chemical reaction). The corrosion potential of nickel is approximately –0.5 V relative to the silver chloride electrode at 500°C, insignificantly decreases with temperature, and is independent of the concentration of lanthanum chloride. To specify the mechanism of corrosion damage, current–voltage curves are recorded at lanthanum chloride contents of 0.5 and 2 mol % and sweep speeds of 10 and 20 mV/s. X-ray diffraction analysis and X-ray spectral microanalysis are used. The sweep speed exerts no effect on the irreversible electrochemical oxidation process, and the addition of lanthanum chloride increases the current density in the anodic region tenfold or more. A comparison of the corrosion rates obtained by gravimetric and chemical analytical methods suggests an electrochemical corrosion mechanism.

A review study on Corrosion Fatigue and its related testing methodologies

Corrosion Fatigue is the mechanical degradation of a material under the joint action of damage mechanisms corrosion and fatigue. Corrosive nature of the seawater puts severe durability requirements on materials of which are often exposed to corrosion fatigue and abrasive conditions simultaneously. Therefore, identification of the combined effects of both corrosion and fatigue damage mechanisms is necessary to improve predictive models for the corrosion fatigue phenomenon. Present article is the result of a desktop study (scientific literature and standards) with the aim of study the feasibility of designing and manufacturing of a corrosion fatigue testing set-up that would allow the designer to compare the performance of different materials exposed to corrosion fatigue, permitting also the comparison with results from dry fatigue testing. The corrosion fatigue mechanism is described in more detail and a short presentation of some typical lab-scale corrosion fatigue test setups is given. This is followed by illustration of international standards and guidelines which will be used to design a new corrosion fatigue test set-up for evaluating the fatigue behavior of material in seawater environment. Finally the experimental techniques for corrosion fatigue crack detection and propagation along with the fundamental basic of corrosion fatigue modeling are illustrated.

Corrosion Damage Behavior of Prestressed Rock Bolts under Aggressive Environment

The corrosion of prestressed rock bolts (PRBs) has become a serious problem threatening the durability of prestressed anchorage structures during their service. This paper aims to investigate the corrosion damage mechanisms of the free lengths of PRBs subjected to an aggressive environment. During the experiment period, the corrosion behavior of the rock bolts was analyzed considering the influence of prestress under different pH (4, 5, 6, 7, and 8) amounts and several oxygen flow rates (OFR, 0 cm3/min, 40 cm3/min, 80 cm3/min, 120 cm3/min, and 160 cm3/min). Based on the electrochemical analysis, a corrosion rate (CR) development model of the PRBs related to the OFR was developed. The results indicated that the prestress had a great influence on the corrosion of the rock bolts. In the process of corrosion, the PRBs were in an activated state, and no passivation region was formed all the time. The corrosion degree of PRBs increased remarkably with an OFR ranging from 0 cm3/min to 80 cm3/min, and then it reached a threshold value. Additionally, the CR increment was insensitive to the OFR when the pH value was constant. It was observed that the loss rate of the ultimate elongation was larger than the other mechanical properties such as the ultimate tensile load loss rate and the elastic modulus. The effective stress loss of the PRBs under different conditions indicated that more attention is needed to be given to the specimens immersed in solutions with an OFR greater 40 cm3/min and pH lower than 6.

RESEARCH OF CORROSIVE DAMAGE TO THE PURPOSE OF FOOD PRODUCTION

Chemical and food processing environments contain chemically active ingredients such as oxygen, carbon dioxide (СО2), carbon monoxide (CO), sulfur, hydrogen, carbon acid ion and sulfuric acid ion, chlorine ions, impurities of calcium carbonate, iron, and hydrochloric acid, etc. All these factors lead to intensive corrosion of the equipment, reducing its reliability and durability. The corrosion-mechanical resistance of metal equipment, such as chemical and sugar plants, is of great importance for environmental and sanitary requirements that make it impossible to contaminate the product with metal ions. First of all, the tubes of evaporation stations, diffusion apparatuses and steam boilers of chemical and agro-processing (sugar) enterprises are exposed to corrosive damage caused by the negative influence of high-temperature and corrosive-active steam under high pressure. Significantly worsens this negative situation and deposition of sediments of salts, carbonates, acids, and others. The analysis of corrosives damages suggests that predominantly point and pitting corrosion predominate, which are exacerbated by internal or external loads. Unlike uniform corrosion, finding and slowing down which is not a particular difficulty, these types of corrosion are usually detected only after they are caused by emergency failures or fractures. Therefore, the main reasons for failures of technical facilities, among which the important placeis the destruction or operation of corrosion and corrosion and mechanical damage, must be carefully investigated and, if possible, eliminated on time. The complex of investigations of the damaged metal of evaporator tubes (steel 20 and 06X1) with a life time (from 0 to 20 years) included, along with standard, also special types of research, in particular: various variants of X-ray spectral analysis using a raster electron microscope "JSM-35CF" (Jeol, Japan),"SEM-515" with Philips microinalyzer "Link" scanning Auger electron spectroscopy (micro-analyzer "AES-2000"). In addition, the content and character of the distribution in the metal of pipes of water heaters of hydrogen, sulfur and oxygen were determined by the method of local mass spectral analysis with a laser microprobe, as well as by the method of melting of metal samples in the flow of carrier gas using the installation of the firm "Leco". With the help of high-precision metallographic experimental equipment, the mechanism of corrosion damage to the surfaces of evaporator tubes and the proposed measures for further research on methods for reducing the corrosion activity of the process environment and the adhesion of salt and carbonate sediments to the surface of the tubes of steam generators of food production is investigated. In particular, it has been shown that in order to eliminate metal corrosion and deposits of salt sediments in the form of scale on the surface of pipes of water heaters, it is necessary simultaneously to reduce the chemical activity of the water-vapor environment using different reagents, and to cover the tube with anticorrosive protective.

Effects of ‘impact’ and abrasive particle size on the performance of white cast irons relative to low-alloy steels in laboratory ball mills

In mineral grinding mills, media and liners are consumed by abrasion, corrosion, and fracture-related damage mechanisms. White cast irons (carbide-reinforced composites) can provide substantially greater wear life than martensitic steels of comparable bulk hardness, but the magnitude of benefit depends on abrasive mineral characteristics. Their performance might also be influenced by mill operating parameters. Since increasing mill rotation speed increases the proportion of high-angle impingement compared to sliding, and since ‘impact’ is commonly expected to promote fracture-related damage mechanisms in brittle materials, it might be assumed that increasing speed will degrade white cast iron performance. However, such assumptions require scrutiny. Using the laboratory ball mill abrasion test (BMAT), the effects of impact severity on relative performance of white cast irons were quantified. Contrary to intuitive expectations, increasing impact severity appeared to improve white iron relative performance. Micro-fracture is known to be influenced by the abrasive's mineral constitution; but the results demonstrate an influence from abrasive particle size — fine particles being less capable of damaging the eutectic carbide network. The observed effects of mill operating parameters were all explicable in terms of their effect on particle size; hence were manifestations of simple abrasive wear processes, not impact-related damage mechanisms.

Accelerated Corrosion Tests of a New Class of Multilayer Metallic Materials with an Internal Protector

The problems of estimating the corrosion resistance of novel multilayer metallic materials with an internal protector, where the principle of protector-assisted pitting protection is applied, are considered. An electron-microscopic method is used to experimentally substantiate the mechanism of corrosion damage of the material layers. Electrochemical and chemical methods are proposed for accelerated tests to determine the rate of corrosion damage. The electrochemical method can be used to reveal the rate-controlling step of the process, to calculate the mass corrosion index, and to substantiate the choice of a protector for a certain aggressive medium. The chemical method can quantitatively estimate the efficiency of an internal protector and can determine the relative corrosion resistance index of a multilayer material in comparison with the corresponding monometallic material.

A Fuzzy Logic-Possibilistic Methodology to Analyze the Main Corrosion Damages Mechanisms in Pipes and Equipment Installed in an Oil and Gas Platform

Industrial accidents in recent years, particularly in the 1980s, have contributed significantly to the attention of government authorities, industry and society as a whole, in order to seek mechanisms to prevent such episodes that compromise safety of people and the quality of the environment. Currently one of the most discussed topics in various industries is process safety. Not all hazards and risks are the same or can have the same consequences. Process hazards and risks can cause major accidents, involving the release of potentially hazardous materials, fires, and explosions, or both. Accident studies have shown that equipment malfunctions are one of the major causes of unexpected and undesirable events, and so the inspection has been a technique to examine the actual condition of equipment exposed to corrosion damage mechanisms. One of the outputs from the inspection process is the observation of which damage mechanism is acting more intensely on the equipment or the piping. Having this information can help in forecasting the corrosion rates, which consequently assists in the design of a better inspection and maintenance plan. This work presents a methodology based on the Fuzzy logic, to analyze which are the corrosion damages mechanisms that contribute most to the deterioration of the equipment and pipes in an oil platform.

The corrosion damage mechanisms of the gas pipelines in the Republic of Sakha (Yakutia)

The article provides examples of critical damage to a long-running gas pipeline on the territory of the Republic of Sakha (Yakutia), which arose as a result of the development of corrosion processes, discusses the mechanisms and scenarios for the development of corrosion damage in the cryolithozone conditions. Considering the processes and mechanisms, they continue for a long period of time., an increase in the number of damages to a gas main pipeline due to corrosive degradation is expected in the near future. The stage of diffuse damage during long-term operation is confirmed by the increasing loss of working capacity due to corrosion damage in the last 25 years of the pipeline operation.

The corrosion damage mechanisms of the gas pipelines in the Republic of Sakha (Yakutia)

The article provides examples and analysis of critical damage to a long-term gas pipeline in the Republic of Sakha (Yakutia) resulting from the development of corrosion processes. This is the accident in August 2006 at the gas pipeline branch to the city of Pokrovsk and the accident in December 2018 at the «Taas-Tumus-Yakutsk» gas pipeline. The mechanisms and scenarios of the development of corrosion damage in the permafrost zone are discussed. The studied gas pipeline was put into operation in 1967 and is still in operation. The construction and operation of the gas pipeline in the permafrost zone was of both industrial and experimental nature. Wherein, over 50 years of operation, damage and accidents caused by corrosion processes have occurred extremely rarely. But, taking into account the duration of the development of corrosion processes in the permafrost zone, an increase in the number of damages to the long-running main gas pipeline due to corrosion wear is expected in the near future. The stage of diffuse damage during long-term operation is confirmed by an increase in loss of efficiency due to corrosion damage over the last 25 years of operation of the main gas pipeline.

Corrosion Damage Mechanism of TiN/ZrN Nanoscale Multilayer Anti-Erosion Coating

TiN/ZrN multilayers can effectively improve the erosion resistance of metals, particularly titanium alloys employed in aero engines. To explore the corrosion damage mechanism of TiN/ZrN nanoscale multilayers (nanolaminate), a novel [TiN/ZrN]100 nanolaminate coating was deposited on Ti-6Al-4V alloys by multi-arc ion plating method. Salt spray corrosion tests and hot corrosion experiment were carried out to evaluate the corrosion resistance of the coating. The corrosion and damage mechanisms were explored with the help of detailed microstructure, phase composition and element distribution characterizations. The salt spray corrosion tests showed that the [TiN/ZrN]100 nanolaminate coating possessed good corrosion resistance, which protected substrate against the corrosion. The low temperature hot corrosion tests showed that the oxidation occurred on the surface of the coating, which improved the oxidation resistance of the sample. However, the oxidized droplets squeezed the coating, and destroyed the oxidized layers. As a result, the coating was peeled off from the substrate. The research highlights the corrosion resistance of the novel TiN/ZrN nanolaminate coating and offers a support for their application in engine compressor blade.

Stress corrosion damage evolution analysis and mechanism identification for prestressed steel strands using acoustic emission technique

Stress corrosion is a major failure type of prestressed steel strands damage. Currently, no effective monitoring method exists. This paper is an analysis of the acoustic emission (AE) characteristic signal from the stress corrosion damage to prestressed steel strands using the ant colony optimization and self-organizing feature mapping. First, AE characteristic signals at the different stages of the stress corrosion were obtained through the stress corrosion experiments on prestressed steel strands, which can primarily present the corrosion mechanism and different corrosion sources. Subsequently, the ant colony optimization was applied to analyze the AE characteristic signals of stress corrosion. This resulted in the identification of the four main types of AE sources of stress corrosion on prestressed steel strands. The AE ant colony optimization cluster analysis, based on the principal component analysis technology, can separate the four types of damage sources totally and judge the evolution process of corrosion damage and broken wires signal easily. Finally, the self-organizing feature mapping neural network technology applied to the pattern recognition of stress corrosion on prestressed steel strands. The AE characteristic parameter distribution of different clusters can be realized.

Corrosion Damage and Wear Mechanisms in Long-Term Retrieved CoCr Femoral Components for Total Knee Arthroplasty

BackgroundMetal debris and ion release has raised concerns in joint arthroplasty. The purpose of this study was to characterize the sources of metallic ions and particulate debris released from long-term (in vivo >15 years) total knee arthroplasty femoral components. MethodsA total of 52 CoCr femoral condyles were identified as having been implanted for more than 15 years. The femoral components were examined for incidence of 5 types of damage (metal-on-metal wear due to historical polyethylene insert failure, mechanically assisted crevice corrosion at taper interfaces, cement interface corrosion, third-body abrasive wear, and inflammatory cell–induced corrosion [ICIC]). Third-body abrasive wear was evaluated using the Hood method for polyethylene components and a similar method quantifying surface damage of the femoral condyle was used. The total area damaged by ICIC was quantified using digital photogrammetry. ResultsSurface damage associated with corrosion and/or CoCr debris release was identified in 51 (98%) CoCr femoral components. Five types of damage were identified: 98% of femoral components exhibited third-body abrasive wear (mostly observed as scratching, n = 51/52), 29% of femoral components exhibited ICIC damage (n = 15/52), 41% exhibited cement interface damage (n = 11/27), 17% exhibited metal-on-metal wear after wear-through of the polyethylene insert (n = 9/52), and 50% of the modular femoral components exhibited mechanically assisted crevice corrosion taper damage (n = 2/4). The total ICIC-damaged area was an average of 0.11 ± 0.12 mm2 (range: 0.01-0.46 mm2). ConclusionAlthough implant damage in total knee arthroplasty is typically reported with regard to the polyethylene insert, the results of this study demonstrate that abrasive and corrosive damage occurs on the CoCr femoral condyle in vivo.

Investigation of the impact of rain and particle erosion on rotor blade aerodynamics with an erosion test facility to enhancing the rotor blade performance and durability

During their operational life span of around 20 years, the individual components of a wind turbine, especially the rotor blades, are exposed to extreme environmental influences. This is the result of the continuous exposure of wind turbines to the elements and of particularly high rotor blade tip speeds, which exceed a velocity of 90 m/s. These effects result in leading edge erosion. Rotor blades are therefore protected by special coating systems, e.g. varnishes and foils. The durability of those surface coatings varies depending on the location of the wind turbine and often proves to be insufficient. Additionally, there is no standardised test procedure for the evaluation of the durability and protective effect of the coating materials under the highly erosive conditions at the location of the wind turbines. In the course of this project, we will develop a testing procedure to evaluate the erosion of coating materials on actual leading edges of rotor blades, which will be applied in a test facility. The test rig will be capable of simulating a realistic application of rain and sand to gauge the effects of erosion. During the application, two test objects can be tested simultaneously. The geometry of the test objects will be adapted to represent that of real rotor blade tips. In order to generate comparable and transferable results, several challenges have to be met during the implementation, especially the realistic reproduction of environmental influences and the corrosion damage mechanism. In this regard, the duration of the test procedure is very important because a time lapse factor of 100-260 is intended. An operation of 20 years can thereby be simulated within 4 to 10 weeks.