Erosion-corrosion Resistance Research Articles

Erosion-Corrosion: An Up-To-Date Review of Origin, Impacts, Affecting Factors, Occurrence Areas, Experimental Measuring Devices, and Research Advances

Abstract: An up-to-date review of erosion-corrosion from various literary sources, covering its origin, impacts, affecting factors, occurrence areas, experimental measuring devices, and research advances, is reported. From the review, erosion-corrosion is a mechanically caused action by impinging fluid, usually liquid, slurry abrasion, suspended particles in fast-flowing fluids, bubbles, droplets, cavitations, etc., under complex synergistic effects of the natural electrochemical corrosion. It is affected by many factors that still need to be fully understood, so it is very challenging to accurately find its rates for controlling it. It is a very costly problem that is common in power plants, water, oil, gas, metallurgy, mining, and other industrial sectors that utilize mechanical equipment as well as structural components in hydraulic environments. Its effects are predominant in petroleum pipelines and heat exchange industries, as well as marine equipment or structures. Its rates, time scale, and capacity to degenerate material components to failure are much more alarming than most other corrosion types. This corrosion type is highly detestable, so much attention has been drawn to it, as attested by many research outputs on it to date, with a pressing need for ways, including emerging technologies, of minimizing its impacts. Forty-six of the research outputs have been recapitulated and presented, and they focus on developing and/or testing alternative material components, coatings, measuring devices, and application of artificial intelligence, for better erosion-corrosion resistances or rate measurements and control under various fluid conditions. The paper provides integrated, up-to-date information on erosion-corrosion for easy accessibility for the needful basic knowledge for research progress towards reducing its impacts.

Regulating Sublayer Cu Distribution in TiAl(Cu)N Coating by Periodic Modulation of Cu Target Current for Enhanced Erosion-Corrosion Resistance

Regulating Sublayer Cu Distribution in TiAl(Cu)N Coating by Periodic Modulation of Cu Target Current for Enhanced Erosion-Corrosion Resistance

Effect of Impact Energy on High Temperature Erosion-Corrosion Behavior of Ni-xFe Alloys in Fluidized Silica Sand

An internally circulating fluidized-bed boiler is composed of a combustion chamber and a heat recovery cell. The heat exchange tubes are exposed to complex erosive and corrosive conditions due to impact of sand particles under high-temperature corrosion in chlorine containing atmospheres, which results in the severe degradation of the materials. In general, protective coatings are applied on the heat exchange tubes to improve an erosion-corrosion (E-C) resistance. In our previous study, high-temperature E-C resistance of Ni-xFe alloys (x = 0, 10, and 30 wt.%) was found to increase with increasing Fe content because of a formation of the Fe-rich oxide scale, which is harder than a Ni oxide scale. However, factors affecting an E-C behavior such as the impact energy of sand particles and the salt concentration have yet to be sufficiently evaluated. In this study, the effect of the impact energy of silica sand on the high-temperature erosion-corrosion of Ni-xFe alloys was investigated.Pure Ni, Ni-10Fe and Ni-30Fe (wt%) alloys were prepared by Ar arc melting. Samples with a thickness of approximately 1mm were cut from the homogenized ingots and polished down to a 1200 grit using SiC papers. Figure 1 shows the schematic of the E-C test rig. The sample holder with affixed samples was inserted into the quartz tube containing silica sand (average particle size 500μm). The silica sand was heated to 700°C, and fluidized by compressed air preheated to 400°C at a flow rate of 25 L/min. The impact angle of the sand to the surface was set to be 45°, and the sample temperature was maintained at 360-380°C by water cooling of the sample holder. The salt vapor of KCl-40 mol.%NaCl-20 mol.%CaCl2 was continuously supplied from the bottom of quartz tube into sand by a compressed air. The impact energy of sand particles was set at 540 J/m2 and 1150 J/m2, which were calculated by a fluidized bed analysis. The high-temperature E-C test was stopped every 25 h or 50 h to change the silica sand and salt crucible , and continued for up to 100 h. After the E-C tests, the samples were analyzed by XRD, FE-SEM, EDS, and STEM. The STEM samples were prepared by using FIB.Figure 2 shows the relationship between the impact energy of silica sand and the mass change of each sample after 50 h of E-C test. The mass change at 0 J/m2 was defined as the mass change after the embedded corrosion test for 50 h in silica sand with 0.01 wt.% of KCl-40 mol.%NaCl-20 mol.%CaCl2 salts. The slope of the graph decreased with increasing Fe content, suggesting that the effect of impact energy on the E-C resistance became less pronounced for the alloy with higher Fe content. Regardless of the impact energy, no oxide scale formation was observed on the pure Ni after the E-C test, which indicates that mass loss might be caused by the erosion of the metal substrate. In Ni-10Fe, a thin (Fe, Ni) spinel was remained on outermost surface of the oxide scale and NiO containing several percent of Fe was remained beneath the spinel layer after the test at 540 J/m2, but no oxide scale was remained after the test at 1150 J/m2, which indicates that the mode of high temperature E-C might have changed from erosion of the oxide scale to that of the metal substrate as impact energy increased. In Ni-30Fe, Fe3O4 and (Fe, Ni) spinel was remained on most of the alloy surface after the test at 540 J/m2, suggesting that the E-C is predominated by erosion of oxide scale. However, some scratches due to the impact of sand particles were observed after the test at 1150 J/m2, and EDS analysis confirmed that the signals from oxygen was very weak on the scratched area, which indicates that not only the erosion of oxide scale but also the erosion of alloy substrate could occur in Ni-30Fe. These results suggest that the influence of impact energy depends on the type of oxide scale formed, and the dependence of the erosion rate constant on impact energy could be smaller for the Fe-rich oxide scale. Figure 1

Microstructure, mechanical behavior, and cavitation erosion-corrosion resistance of the BCC/B2 strengthened FeNiCrMoAl-based multi-principal element alloys

The influence of disordered and ordered body-centered cubic (BCC-β and B2-β′) secondary phases on the mechanical properties and cavitation erosion-corrosion (CE-C) behavior of BCC/B2 strengthened FeNiCrMoAl-based multi-principal element alloy (MPEA) was systematically investigated. An increased β/β′ phases content enhanced the MPEAs’ strengths while maintaining good ductility. However, this increases also led to a higher proportion of loosely bound Al2O3 within the passivation film, resulting in a slight reduction in electrochemical corrosion performance. Remarkably, in a NaCl solution, the increased β/β′ phases significantly improved the MPEAs’ resistance to CE-C, attributed to the outstanding corrosion resistance and mechanical properties which could withstand elastic strain damage and plastic deformation.

Enhanced erosion-corrosion resistance of monolithic ENP coating on ductile cast iron by using electrochemical pretreatment and heat treatment

This research aims to enhance the erosion-corrosion durability of monolithic ENP coating used on ductile cast iron. The ENP coating does not usually adhere well to the cast iron surface due to the special characteristics and innertness of the graphite sphere so an electrochemical surface pre-treatment containing a cathodic treatment was implemented to ensure proper adhesion of the coating to the surface. A slurry pot erosion-corrosion test was performed at a linear velocity of 10 m/s for 16 h, and it verified the efficacy of the treatment. Three different heat treatments were carried out on coated samples at 200 °C, 400 °C, and 600 °C. The sample heat-treated at 600 °C exhibited a pseudo-passivation behavior and displayed the best corrosion resistance of 0.1407 μA/cm2. Nonetheless, in erosion-corrosion tests, it was outperformed by other coatings due to the removal of its oxide layer. The heat treatment at 400 °C resulted in the highest hardness of 871 Vickeres and the best erosion-corrosion resistance of 8.8 mpy compared to 11.74 mpy for the as-plated sample and 381.3 mpy for the cast iron substrate.

Erosion-corrosion behavior of Ni-Al-Cu coating on nickel-aluminium bronze alloy in 3.5 wt% NaCl solution

A Ni-Al-Cu coating was prepared on NAB alloy through electroplating and heat treatment, and the erosion-corrosion behaviors were investigated. The results demonstrated that Ni-Al-Cu coating exhibited higher erosion resistance compared to NAB alloy, with an average reduction of 63 % in material removal rate (MRR). It was revealed that deformation and cracks were observed in NAB, with loss of hard κ and β phases alongside deformation of ductile α phase. Meanwhile, Ni-Al-Cu coating experienced fatigue delamination and grain disintegration due to alternating stress. Taguchi design method showed that increasing flow velocity and sand concentration could enhance the intensity of gravel impact, while changes in the erosion angle affected gravel impact modes and energy transfer, thereby impacting corrosion performance. Additionally, empirical equations for the material removal rate were derived through regression analysis, which became possible to predict the MRR under different influencing factors and assess the erosion-corrosion resistance of materials.

Influence of sand particle size on the erosion-corrosion resistance of Ni2FeCrMo0.2 HEA in seawater: Particle-surface-electrochemistry interaction

The erosion-corrosion mechanism in rotary flowing seawater is hugely complicated due to the multiscale coupling processes of particle-surface impact, ion mass transfer, and interface electrochemistry. Therefore, developing erosion-corrosion resistant material and exploring the synergistic mechanism between sand erosion and electrochemical corrosion is vital. This study conducted the erosion-corrosion test on Ni2FeCrMo0.2 high-entropy alloy under the particle-seawater flow. Based on a coupled analysis of multi-component weight loss, electrochemical behavior, and microscopic damage morphology, the multiscale coupling processes of sand transportation, particle-surface impact, ion mass transfer, and interface electrochemistry were revealed. The present study found that with the increase of sand size, the energy carried by the particles promoted impact erosion. Additionally, particle movement enhanced ion mass transfer through turbulent effects, and the impact behavior disrupted the passivation film to promote electrochemical processes by reducing the thickness of the passivation film, leading to an increase in the erosion-corrosion rate. However, when the particle size continued to increase to a certain extent, the impact frequency decreased, reducing the erosion-corrosion rate. As the sand size grew, the dominant damage mechanism transitioned from pure corrosion (100 μm) to synergistic effects (200 μm, 400 μm) and then to pure erosion (800 μm). This study provides an in-depth understanding of the erosion-corrosion mechanism in seawater from the perspective of particle-ion-fluid-surface interaction by multi-element characterization.

Synergistic improvement of erosion-corrosion resistance and mechanical properties of nickel aluminium bronze alloy by the addition of Cr

Synergistic improvement of erosion-corrosion resistance and mechanical properties of nickel aluminium bronze alloy by the addition of Cr

Effect of heat treatment on corrosion resistance of Al2O3-TiO2 ceramic coating impregnated with aluminum phosphate

The atmospheric plasma spray process (APS) is a well-established and widely employed technology used to create various types of coating for the fabrication of numerous industrial applications. Speciallity, this process is considered as a suitable technique for fabricating ceramic coatings. However, the structure of thermal spray coatings consists of particles, semi-molten particles, oxides, pores, and cracks that significantly influence the coating properties, especially their erosion-corrosion resistance. In this study, the Al2O3-40TiO2 coating applied by APS was penetrated with aluminum phosphate (APP) by ultrasonic excitation method, and then, the effect of heat treatment after the sealing on corrosion protection of Al2O3-40TiO2 ceramic coating was investigated. The results show that, after being impregnated with APP, the heat treatment at 800 oC assures the coating a lower porosity and better corrosion resistance than heat treatments at 400 and 600 oC. The existence of the durable crystalline phases Al(PO3)3 (Cubic), Al2P6O18 (Monoclinic), and AlPO4 (Orthorhombic) on the surface of the sample heat-treated at 800 oC has contributed to enhancing the corrosion resistance of the Al2O3-40TiO2 coating.

Tribo-Corrosion Control with Molecules of Bio-Origin: Experimental Studies and Theoretical Insights

Tribo corrosion control of 6061 aluminum alloy was done by using naturally available Boswellia serrata (BWS) extract as green inhibitor. Studies were done in artificial sea water slurry containing 0.03% sand particles via a submerged jet impingement technique. Electrochemical studies were the majour techniques adopted for corrosion rate measurement in the absence and in the presence of inhibitor. Investigation was done at different flow rates and at different temperatures. Detailed surface study was done for sand particles before and after impingement using scanning electron microscope. Surface morphology of aluminum sample was done before and after the addition of inhibitor. For a given flowrate inhibition efficiency decreased with increase in temperature. This suggested the possibility of physical adsorption. Results were fitted into suitable adsorption isotherm. Mechanism of adsorption was supported and substantiated by quantum chemical calculations using Density Functional Theory (DFT). The best corrosion–erosion resistance was obtained at a concentration of 1000 ppm Boswellia serrata at 303 K under 4 L min−1. DFT studies supported the adsorption mechanism of the inhibitor on the surface of metal under tribological conditions. The outcome of this work will help in research that is focused on development on green inhibitors for corrosion inhibition under dynamic multi flow conditions.

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.

Constructing PANI@CF hybrids enhanced epoxy coatings with integrated functionalities of interfacial enhancement, erosion wear resistance and anti-corrosion

Factors such as sediment erosion and diffusion of corrosive ions in the splash zone result in a serious decrease in the protective performance of organic coatings. Carbon fiber (CF) reinforced polymer coatings have attracted much attention due to the impressive high mechanical strength and reliable chemical stability, but their protection period for steel structures is usually limited by the surface inertness and poor interfacial compatibility of the original CF. Herein, we created a composite coating with excellent erosion and wear resistance and corrosion resistance through simple self-polymerization of polyaniline on carbon fibers. The PANI layer not only helped to improve the interfacial compatibility between fibers/resin, but also exerted its corrosion inhibition effect. The interfacial shear strength (IFSS) value of the modified PANI4@CF monofilament and resin (60.63 MPa) was 46.73 % larger than that of the unmodified CF monofilament. In the simulated splash zone, PANI4@CF5/EP composite coating showed the best erosion resistance and corrosion resistance, and the mass loss and volume loss after erosion test were reduced by 53.39 % and 50.10 %, respectively, compared with pure epoxy coating. The local electrochemical impedance spectroscopy (LEIS) value of PANI4@CF5/EP coating with artificial defect was one order of magnitude higher than the epoxy coating after 48 h immersion. Finally, the environmental conditions of the splash zone were simulated to evaluate the anti-corrosion performance and erosion resistance of the CF reinforced composite coatings, and the protective mechanism was discussed in depth, which has great significance to the development of protective coatings for the splash zone under extreme marine environments.

Metal loss and corrosion attack of FeCrAl overlay welds on evaporator tube shields of a waste‐fired power plant

AbstractThree FeCrAl alloys (APMT, EF100 and EF101) from Kanthal® and the reference Ni‐Cr Alloy 625 were used as weld cladding materials on tube shields in the evaporator tube bank of a waste‐fired combined heat and power plant. For each alloy type, the overlay welded tube shields were placed in both roof and floor positions within the evaporator for 6 months. The metal‐loss rate, the microstructure and hardness of the overlay welds before and after exposure and the corrosion products were analysed. The results showed higher metal‐loss rates in the welds placed in the roof position, confirming heterogeneities in the evaporator bank environment. Alloys were ranked from higher to lower erosion–corrosion resistance as follows: APMT ≈ Alloy 625 > EF101 > EF100. The analysis of the corrosion attacks showed a significant variation among the alloys, from a primarily homogeneous corrosion attack on APMT to intergranular corrosion in EF100 and pit formation in EF101.

Laser-based fabrication of superwetting titanium alloy with enhanced corrosion and erosion-corrosion resistance

Titanium (Ti) alloy is vulnerable to erosion and corrosion effect of sea water in the application of marine equipment and prone to degradation and failure. In order to further enhance the erosion-corrosion resistance of Ti alloy, a laser-heat hybrid treatment is applied to fabricate superwetting Ti alloy surface. The surface morphology, chemical composition and surface wettability of Ti alloy before and after laser processing are characterized. The surface behaviors of the superwetting Ti alloy surface during corrosion and erosion-corrosion interaction are evaluated by electrochemical station and two-phase flow erosion equipment. The experimental results indicate that the periodic micro-bump structure induced by laser texturing and the low surface energy after heat treatment contribute to the surface wettability transformation into superhydrophobicity with the contact angle of 156.2°. Compared with the untreated Ti alloy surface, the laser-heat-treated superhydrophobic surface exhibits a smaller corrosion current density and a larger potential in NaCl solution, showing better corrosion resistance. The surface erosion-corrosion resistance has also been increased by 18% due to the decrease of solid-liquid contact area caused by air cavity of superhydrophobic surface. This can provide a solid laser-based fabrication method of Ti alloy for long-term and stable application in marine environment.

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%.

Interaction of erosion and corrosion on high-strength steels used for marine dredging engineering

In this work, the erosion–corrosion performances of three high-strength steel samples: high manganese austenitic steel (HMnS), dual-phase steel (D-PS), and martensitic steel (MS), which are potentially used to construct marine dredged pipelines were investigated in comparison to the Q235 carbon steel. The corrosion-enhanced erosion (C-E) and erosion-enhanced corrosion (E-C) were electrochemically studied in conjunction with surface and subsurface characterizations. Results showed that the fracture of the steel extrusions induced by micro-cutting was the main erosion-corrosion feature under normal sand impacts. The C-E played a significant role in the erosion–corrosion process, which resulted in the dissolution of the work-hardening layer and facilitated the subsurface crack propagation, particularly for D-PS and MS. Although the general E-C rate was low, the concentration of the major anodes at the highly eroded area significantly enhanced the erosion process. Evaluating erosion resistance solely based on hardness is significantly limited. The twinning deformation of the austenite grain in HMnS effectively hindered the crack propagation during the erosion–corrosion. The addition of Al and Cr elements improved the erosion–corrosion resistance of high-strength steels.

Effect of Pre-immersion Temperature on Corrosion Product Films and Their Erosion Corrosion Resistance on 90/10 and 70/30 Copper-Nickel Tubes in 1 wt.% NaCl Solution

Effect of Pre-immersion Temperature on Corrosion Product Films and Their Erosion Corrosion Resistance on 90/10 and 70/30 Copper-Nickel Tubes in 1 wt.% NaCl Solution

Protection of N80 steel from erosion-corrosion of geothermal water by nanoparticle-modified expoxy resin coatings

In order to investigate the erosion-corrosion resistance of nano-SiO2/EP composite coating and TiO2/EP composite coating in a geothermal environment, the coatings were subjected to potentiodynamic polarization curve tests, AC impedance tests, weightlessness tests, under different immersion time in geothermal water. The micro-morphology of the coating after erosion-corrosion was observed to evaluate the protective effect of the modified EP coating on N80 steel. The result showed that the addition of nanoparticles can improve the corrosion resistance of EP coatings to a certain extent, and the optimum addition amount of nanoparticles is 3%. In geothermal water containing sand, the corrosion inhibition efficiency of EP coatings modified by nanoparticles was above 99.99% except for the 1 wt% SiO2/EP composite coating. When the nanoparticle content is 1 wt%, the protective effect of nano-SiO2/EP composite coating is better than that of TiO2/EP composite coating, but the protective effect is opposite when the nanoparticle content is 3% and 5%, respectively.

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.

Influence of pre-immersion aeration conditions on corrosion product films and erosion-corrosion resistance of 90/10 and 70/30 copper-nickel tubes in 1 wt% NaCl solution

The influences of pre-immersion aeration conditions on the corrosion product films and their erosion-corrosion resistance of 90/10 and 70/30 copper-nickel tubes are investigated. Results show that sealed immersion inhibits the formation of protective films on 90/10 and 70/30 tubes and thus worsens the erosion-corrosion resistance, which is related to the nanosized Mn/O particles near the film/substrate interface. Aerated immersion promotes the formation of protective film on 90/10 copper-nickel tube and improve the film recovery ability of 70/30 copper-nickel tube. Moreover, the features of the corrosion product film with good erosion-corrosion resistance are identified.