Erosion Of Steel Research Articles

3D digital holography for measuring particle impact crater morphology and in-situ analysis of oxidation healing on steel surfaces

Deformation and erosion of steel due to particle impacts in high-temperature environments are common issues in industrial applications. Under high-temperature conditions, an oxide layer forms that affects the deformation and erosion of the steel surface following particle impacts. Studying the interaction mechanism of oxidation and deformation (erosion) is of considerable significance. Traditional research methods primarily involve ex-situ measurements on samples post-erosion and oxidation, which cannot capture the morphological changes of the steel surface immediately following particle impact. Utilizing 3D digital holography (DH) technology, this paper develops a measurement system to investigate the surface morphological changes in steel induced by single particle impacts. We utilized this experimental system to measure the impact crater morphology of 500 μm zirconia particles impacting Q690 steel sheets. Our findings indicate that Hertzian ring cracks formation is significantly affected by heating temperature and impact angle. Notably, oxide layer peeling and erosion occurred at an impact angle of 30°. Additionally, impact crater depths at a 90° angle and impact speeds ranging from 1 to 20 m/s varied between 0.66 and 4.25 μm, with crater depths showing a correlation to the thickness of the oxide layer. Concurrently, in-situ measurements of the impact crater healing process during heating revealed that the crater formed at a 30° impact angle, which had numerous microcracks, exhibited significantly better healing compared to the crater formed at a 90° impact angle. The thickening process of the oxide layer were also analyzed, leading to the derivation of the oxide layer growth kinetic equation based on the measurement data: . This study is the first to use DH technology to measure the surface morphology of steel and to conduct in-situ analysis of the oxide layer thickening process following particle impact and during heating. This approach provides a novel perspective for understanding the erosion-oxidation interaction mechanism.

Numerical simulation of high-temperature erosion of heat-resistant steel considering surface scale evolution

A study was conducted on heat-treated, heat-resistant steel S51740 to understand the issues surrounding gas turbine compressors. The study included high-temperature cyclic oxidation and high-temperature erosion tests at 400 °C, 600 °C, and 800 °C. We used the oxidation test data to establish dynamic erosion models using Ansys LS-DYNA software. We focused on the target's surface morphology, stress-strain, transient temperature, and failure characteristics during high-temperature erosion after high-temperature oxidation to reveal the erosion mechanism of oxidized steel. During cyclic oxidation, the specimen's microstructure was refined at 400 °C, with a 10 μm oxidation-affected zone emerging. At 600 °C, austenite appeared, forming a 20 μm oxidation-affected zone. Performance declined at 800 °C due to decarburization and segregation, resulting in a 50 μm oxidation-affected zone. High-temperature erosion on the oxidized specimens featured cutting and a chip-like morphology at 400 °C and 600 °C. At 800 °C, the specimen experienced a notable increase in mass loss and extensive plastic deformation on the surface. Erosion simulations revealed that rising temperatures increase the target's stress distribution, strain, and temperature zones. Reduced material strength leads to lower resistance to impact particles, converting high-speed kinetic energy to internal energy during erosion. Temperature spikes in impacted zones accelerate wear and adversely affect local mechanical properties. Lower ambient temperatures exacerbate the temperature increase from erosion, significantly influencing material erosion and wear resistance.

Effect of water jet erosion parameters on erosion rate of WC10Ni5Cr HVOF coated 35CrMo steel

Abstract This research work aims for developing the water jet erosion (WJE) prediction equation and analyzing the optimum water jet erosion parameters such as impingement angle (degree), water jet velocity (m s−1), stand-off distance (mm), and erodent discharge rate (g min−1) for minimizing the water jet erosion of 35CrMo steel coated with WC10Ni5Cr coating. The optimized high velocity oxy fuel (HVOF) process parameters were employed for developing the coating of WC10Ni5Cr on 35CrMo steel. The WJE prediction equations were checked for its validity employing analysis of variance (ANOVA). The water jet erosion was measured as the loss of mass (g) after water jet erosion testing for noncoated and coated 35CrMo steel substrates. From the results it was analyzed that the noncoated and coated 35CrMo steel substrates when subjected to the impingement angle of 60°, water jet velocity of 15 m s−1, stand-off distance of 40 mm, and erodent discharge rate of 1500 g min−1 displayed lower mass loss of 0.0177 g and 0.0079 g. The coated 35CrMo steel substrate showed 55.36 % decrement in erosion compared to noncoated 35CrMo steel substrate. These findings support the employability of WC10Ni5Cr HVOF coating for 35CrMo steel to improve its water jet erosion resistance in engineering applications.

Wear behavior of bare and coated 18Cr8Ni turbine steel exposed to sediment erosion: A comparative analysis

Hydropower plant components are exposed to sediment erosion due to the impact of hard particles flowing along with the water. As a consequence, significant material loss and substantial reduction in efficiency are encountered during plant operation. This work investigates the sediment erosion problem in hydraulic turbines using a slurry erosion tester. Experiments are performed on bare and coated 18Cr8Ni turbine steel at three impact velocities i.e. 6, 8, and 12 m/s, and two impact angles 30° and 90°. The size of impacting particles varies between 50 to 350 µm with a slurry concentration of 2500 ppm. The erosion rate is found to be maximum at 30° impact angle and minimum at 90° impact angle. With an aim to minimize the erosion of turbine steel, the test samples were coated with in-house formulated ceramic-based coating material using the high-velocity oxygen-fuel thermal spray technique. Vickers hardness test was performed to determine the hardness of the coatings. For metallurgical characterization, scanning electron microscopy, X-ray diffraction, and energy-dispersive X-ray spectroscopy techniques were used. A comparison of both bare and coated samples is carried out to observe the erosion-resistant aspects. A higher erosion resistance has been detected for the coated material as compared to the bare turbine material. The reduction in the erosion rate for coatings is 13.4% at 30° and 17.62% at 90° impingement angles. The obtained results are related to the tested materials’ microstructural, mechanical, and metallurgical aspects.

Corrosion studies of various salt solutions on metals and alloys

Corrosion studies of various salt solutions on metals and alloys

Experimental and numerical simulation study on the erosion behavior of the elbow of gathering pipeline in shale gas field

During the production period of shale gas, proppant particles and rock debris are produced together, which will seriously erode the elbows of gathering pipelines. In response to this problem, this paper takes the elbow of the gathering pipeline in the Changning Shale Gas Field as an example to test the erosion rate and material removal mechanism of the test piece at different angles of the elbow through experiments and compares the four erosion models with the experimental results. Through analysis, it is found that the best prediction model for quartz sand-carbon steel erosion is the Oka model. Based on the Oka model, FLUENT software was used to simulate and analyze the law of erosion of the elbow of the gas gathering pipeline under different gas flow velocities, gas gathering pressure, particle size, length of L1, and bending directions of the elbow. And a spiral pipeline structure is proposed to reduce the erosion rate of the elbow under the same working conditions. The results show that this structure can reduce erosion by 34%.

ANALYSIS OF CORROSION RATE AND REMAINING LIFE OF STEEL ON PIPELINES AT PKS PTPN 1 TANJUNG SEUMANTOH

Corrosion is a major cause of early failure in palm oil mill infrastructure in Aceh, Indonesia. Therefore, the aim of this study is to analyze the corrosion rate of steel used in the palm oil mill industry and determine the remaining life of the steel. Round bars and plates made of steel were used as exposure samples. This sample was cleaned of impurities and ground with sandpaper to obtain a 600 grating, then washed with clean water and rinsed with strong liquid, then presented to the climate at the PTPN 1 Tanjung Seumantoh palm oil mill so that it could see the rate of steel erosion due to corrosion. For exposure, steel specimens are placed on racks, and weight measurements are taken once a month to determine corrosion rate values using the ASTM G50 standard. In addition, steel thickness measurements were also carried out in 2021 and 2022 to calculate the corrosion rate using the Standard API 570 standard. Research results of the remaining life of the pipe on the wall tube is about 32 years. the remaining life for the generating pipe is about 29 years, and the remaining life for the heater pipe is about 11 years. from the calculation results obtained the longest remaining life is obtained on the wall pipe while the shortest remaining life of the pipe is found in the heater pipe because the pipe is always heated.

Influence of laser texturing along with PTFE topcoat on slurry and cavitation erosion resistance of HVOF sprayed VC coating

This research investigates the slurry and cavitation erosion resistance of a polytetrafluoroethylene (PTFE) top-coat applied to standalone high velocity oxy-fuel (HVOF) sprayed and laser textured Vanadium Carbide (VC) coating over SS316 steel. The static contact angle, microstructural characterization, EDS mapping, microhardness, fracture toughness, elastic modulus, slurry erosion, and cavitation erosion of all the samples namely SS316, HVOF sprayed VC, Laser textured VC, and PTFE modified VC were evaluated. Results demonstrate that the inclusion of a PTFE top-coat significantly enhances the erosion resistance over HVOF sprayed and laser textured VC coatings. Further, the laser textured VC surface was also found to be successful in reducing the slurry and cavitation erosion of SS316 steel, which could be attributed to its higher microhardness, presence of circular textures, and higher H/E ratio. When the failure mechanism was examined using SEM images, it was found that brittle failure occurred on hard surfaces while ductile failure occurred on soft surfaces.

Understanding the interaction between erosion and corrosion of pipeline steel in acid solution of different pH

The pure corrosion, erosion-corrosion and pure erosion behaviors of X65 pipeline steel in acid NaCl solution of different pH levels (ranging from 1.5 to 5.0) were studied using a rotation disc system, aiming to understand the interaction between erosion and corrosion of pipeline steel operating in acid slurry. The corrosion and erosion-corrosion performances of the steel were electrochemically measured in conjunction with surface characterizations. The pure erosion performance was studied by applying cathodic protection to eliminate the corrosion component. The propagation of the localized erosion-corrosion at different pH levels were probed using wire beam electrode. Results show that pH = 3.5 is a critical value for the transition of cathodic reaction under erosion-corrosion. In the acid fluids of pH < 3.5, the reduction of H+ is the main cathodic reaction, leading to a general erosion-corrosion feature with scattered small pits, which are initiated from the inclusions. Negative erosion-enhanced corrosion (E-C) is found at pH < 3.5 due to the wear of Fe3C networks. The oxygen reduction becomes the main cathodic reaction in the acid slurry of pH ≥ 3.5, resulting in the formation of erosion-corrosion pits and craters. The removal of the rust layer would result in positive E-C performance at pH > 3.5. Significant localized erosion-corrosion would occur at pH ≥ 3.5, where fixed major anodic sites are visualized. Obvious erosion-corrosion pits and craters would form with the occurrence of oxygen reduction. More serious corrosion-enhanced erosion (C-E) prefers to occur at the pitting areas where high macro-cell currents are registered.

A Review of Corrosion Behavior of Structural Steel in Liquid Lead–Bismuth Eutectic

Liquid lead–bismuth eutectic alloy is one of the candidate coolants for fourth-generation nuclear power systems because of its good physical and chemical properties, neutron economic performance, and safety. However, the compatibility between the coolant and structural steel is still the main factor restricting its large-scale industrial application in the nuclear energy field. Structural steel in a liquid lead–bismuth eutectic alloy for a long time would cause severe corrosion. The erosion of structural steel by high-flow-rate liquid lead–bismuth alloy will lead to a more complex corrosion process. This paper mainly reviews the corrosion characteristics of liquid lead–bismuth and the corrosion behavior of structural steel in liquid lead-bismuth eutectic. The main methods of inhibiting liquid lead–bismuth corrosion are summarized, and future research directions are suggested.

Mitigation of erosion and corrosion of steel using nano-composite coating: Polyurethane reinforced with SiO2-ZnO core-shell nanoparticles

In the present study, we developed a multifunctional surface coating with silica-ZnO (SiO2-ZnO) core-shell nanoparticles. The idea behind the synthesis of core-shell nanoparticles was to utilize the mechanical strength of silica and the hydrophobicity of ZnO together in a single coating structure. Coating formulations were developed with solvent-based polyurethane binder containing silica-ZnO core-shell nanoparticles at various concentrations (1–4 wt%) on the steel substrate. These nanoparticles were characterized via X-ray diffraction (XRD), field emission scanning electron microscopy (FESEM), energy-dispersive X-ray spectroscopy (EDS), transmission electron microscopy (TEM) etc. Further, developed coatings were characterized for their surface wettability through measuring water contact angle. The erosion behaviour of the developed coatings has been analyzed through an air-jet solid particle erosion tester. Electrochemical impedance spectroscopy (EIS) and potentiodynamic polarization study are used to analyze the corrosion response of the substrate and the coatings. The coatings exhibited lesser Vickers and scratch hardness values then the substrate. The best erosion and corrosion resistant, and nearly superhydrophobic surface was achieved by nanocoating developed with 4 % (wt.) of silica-ZnO core-shell nanoparticles on the substrate material. The erosion performance was significantly improved in this coating as compared to the uncoated substrate (at 30° impact angle, erosion reduction ≈ 98 % and at impact angle 90°, erosion reduction ≈ 96 %). Lowest current density and the highest corrosion potential in polarization tests, and the highest impedance in EIS studies were also observed in the nanocoating developed with 4 % (wt.) SiO2-ZnO core-shell nanoparticles. Based on the coatings' performance evaluation, they can be used as protective layers for structural marine components.

Effect of carbon content on resistance to cavitation erosion of Cr-C coatings deposited by Arc PVD method

The aim of the study is a comparative analysis of effect of the carbon content in the range from 2 to 25 at.% on the resistance to cavitation erosion of Cr-C coated samples by means of the rotating disk method. The effect of carbon concentration in the range from 2 to 25 at % on the structure, properties and cavitation resistance of Cr-C vacuum-arc coatings deposited in argon with toluene at a pressure of 0.08 to 0.23 Pa on 12Cr18Ni10Ti stainless steel samples has been studied. It has been established that the application of coatings leads to a decrease in the rate of cavitation erosion of steel from 4 to 6 times. Chromium coatings with a two-phase structure containing carbide Cp7C3 show maximum durability.

Study the erosion of Eurofer-97 steel with the linear plasma device GyM

This work reports on the investigation of Eurofer-97 erosion behaviour when exposed to the deuterium plasma of the linear device GyM. The erosion dependence of Eurofer-97 on the deuterium ion fluence, Φ≤2.3×1025 m−2, and temperature of the samples, T = 600 K and 990 K, was addressed. A bias voltage of −200 V was applied to GyM sample holder during the experiments. Samples were deeply characterised by: profilometry, scanning electron microscopy, atomic force microscopy, energy-dispersive X-ray spectroscopy, time-of-flight secondary ion mass spectrometry, Rutherford backscattering spectroscopy and particle-induced X-ray emission.The behaviour of Eurofer-97 erosion rate with the ion fluence strictly depends upon temperature. At 600 K, it was ∼0.14 nm/s after 4.7 × 1024 m−2, then decreased, reaching a steady state value of ∼0.01 nm/s from 8.0 × 1024 m−2. At 990 K instead, the erosion rate was roughly constant around 0.019 nm/s for Φ≤1.24×1025 m−2. The value at 2.35 × 1025 m−2 was slightly lower. The erosion rate at 990 K was greater than that at 600 K for every ion fluence.Microscopy and surface analysis techniques showed that Eurofer-97 erosion rate dependence on Φ at 600 K was primarily determined by the preferential sputtering of iron and other mid-Z elements of the alloy, leading to a surface rich in W and Ta difficult to be sputtered. The erosion behaviour at 990 K was dominated by the morphology dynamics, instead. The different properties of the morphology developed at the two temperatures can explain the higher erosion rate at 990 K for all the ion fluences.

The effect of VC content on the scouring erosion resistance of tool steels

This work investigates the effect of vanadium carbide (VC) content and bulk hardness on the low angle impingement/scouring erosion of tool steels. Five grades of CPM xV (x = 1, 3, 9, 10, and 15) tool steels have been studied using a Coriolis erosion tester with a slurry of 10 wt% AFS 50–70 silica sand in water. The results showed that the scouring erosion resistance of the steels increases with increase in VC volume fraction and the increase is much more rapid when the volume fractions of VC are greater than ∼12%. On the other hand, the erosion resistance is mostly independent of material hardness. Wear scars were examined using scanning electron microscopy and laser profilometry. It was found that the standout wear protection effect of the fine VC carbides became more pronounced in steels with VC volume fractions higher than ∼12%. In these steels, the contribution of the microcutting mechanism decreased drastically with increase in VC volume fraction, with the grooving depth being reduced by about 4 times in CPM 15V as compared with the steel containing the lowest VC volume fraction (CPM 1V).

DEPOSITION OF Al2O3/Cr2O3 CERAMICS HVOF SPRAYED COATINGS FOR PROTECTION AGAINST SILT EROSION

Hydro turbines are one of the most vital and essential components for the production of hydroelectric power. Since the hydro turbine is always operating under the influence of water and the silt transported by the water from the hilly region, it poses a lot of threat and damage to the turbine blades working constantly under the action of silt laden water. Erosion wear is the most common type of damage, and drastically affects the life of turbine runners and blades. The introduction of thermal spray coatings, namely high-velocity oxy-fuel (HVOF) technique, has resulted in a major improvement in stainless steel erosion resistance. Ceramic coating powders primarily Al2O3, Cr2O3, and a composite mixture of composition 55% Cr2O[Formula: see text] Al2O3 were deposited on stainless steel substrates of grade 304. The thorough experiments utilizing silt slurry are conducted at different particle size of silt in the range 212–250, 150–212 and 53–106[Formula: see text][Formula: see text]m. The silt concentration has been varied in the range 12–42% by weight, and the substrate was rotated at a rotational speed in the range 600–1500[Formula: see text]rev/min for the test time of 4[Formula: see text]h. SEM images were used to assess the surface morphology of the required testing samples. The erosion observance and the material removal mechanism were investigated and discussed on the basis of microstructure studies. Cr2O3 coating is found to be more resistant to erosion than other coatings under all test conditions.

Antikorozivna svojstva leka ropinirol (ERN sistem) sa isteklim rokom trajanja kao inhibitora za meki čelik u 1M HCl

Ropinirole is utilized to forestall sickness and spewing brought about by disease chemotherapy and radiation treatment. It works by hindering serotonin, a characteristic substance in the body that causes queasiness and retching. After lapse, they can be utilized as consumption added substances or inhibitors. The consumption obstruction activity of terminated Ropinirole drug (ERN) on the erosion of mild steel in 1M HCl medium has been assessed by the weight reduction strategy. The weight reduction estimations showed that erosion restraint effectiveness expanded with expanding the convergence of the inhibitor, with greatest security productivity at 0.001 M. The temperature influences the pace of erosion; at high temperatures, the consumption restraint effectiveness diminishes, and erosion is noticed. The robotic parts of consumption obstruction have been concentrated by the potentiodynamic polarization method and electrochemical impedance spectroscopy (EIS). The potentiodynamic polarization strategy uncovers that the inhibitor framework capabilities as a cathodic kind of inhibitor, controlling cathodic responses. An inhibitor can decrease corrosion current due to inhibited reaction rate and increase Linear polarization resistance due to the formation of a barrier on the electrode surface. time., since, within the sight of an inhibitor framework, the charge moves opposition esteem increments and the twofold layer capacitance esteem diminishes. The surface morphology of repressed gentle steel was dissected by filtering electron microscopy (SEM). The natural constituents on the gentle steel surface have been portrayed by energy dispersive X-beam spectroscopy (EDAX). The harshness of the gentle steel surface in cleaned MS, clear MS, and inhibitor frameworks has been described by nuclear power microscopy (AFM). The outcomes have obviously shown that ERN has a repressing limit with regards to decreasing the erosion of gentle steel submerged in hydrochloric corrosive medium.

Surface Damage Analysis on the Application of Abrasion and Slurry Erosion in Targeted Steels Using an Erosion Test Rig

The research focuses on slurry abrasion and erosion of martensitic steels used in the mining and agricultural industries. A traditionally constructed slurry pot tester with corundum abrasives in slurry form was used for wear characterisation. Wear testing was performed on each specimen for 180 h. Every 20 h, pauses were taken to characterise the specimen size, weight, hardness, and surface roughness. The worn zone’s damage progression was studied using optical microscopy. As the test period rose, the mass loss due to the wear, which was governed by the impact angle of the slurry flow, followed a linear pattern. The impact of specimen orientation on the wear rate was more pronounced than that of abrasive flow velocity. High-speed video recordings highlighted the varied contact conditions that caused the wear mechanism to shift from abrasion to slurry erosion. Slurry abrasion was seen at the bottom of the specimen as a result of pure sliding conditions, while pitting was observed at the top of the specimen as a result of fatigue from particle impact. Studies of 3D surfaces demonstrated a decrease in wear rate while transitioning from the abraded zone, which witnessed polishing and minor hardness, to the pitting zone. The wear performance of the materials was rated, with tempered martensitic steel coming out on top.

Evaluation of newly synthesized phosphoramide derivatives as mild steel anti-corrosions using experimental and theoretical approaches

Three new phosphoramide derivatives with the general formula of (R)2P(O)[C9H21N2] (R= Ph, A), (R= OPh, B) (R= OEt, C) were synthesized and characterized by using spectroscopy methods. The inhibition effectiveness of synthesized compounds was inspected using potentiodynamic polarization (PDP), impedance measurement spectroscopy (EIS) and scanning electron microscopy (SEM). The synthesized compounds demonstrated acceptable protection power for the erosion of mild steel in 1 M HCl at room temperature. The PDP studies illustrated that the new phosphoramide derivatives behaved as mixed-type inhibitors. Density functional theory and molecular dynamics (MD) simulations were employed to support experimental results. The molecular electrostatic potential plot, the highest occupied molecular orbital and the lowest unoccupied molecular orbital profiles, thermochemical parameters, and quantum chemical descriptors such as electronic electronegativity, chemical hardness of the ground state, and electrophilicity index were calculated and discussed from a corrosion inhibition view point. With the aim of identifying the most stable configuration of inhibitor-HCl, the HCl molecule was approached to all probable reactive sites of inhibitors determined by MEP plots. The molecule A with the most inhibition efficiency (87.25%) and negative inhibitor-HCl interaction energy (-2.56 kcal mol−1) was chosen to study its adsorption behavior on the Fe (1 1 0) using MD simulations at T = 298, 308, and 318 K and in the presence of n = 1-4 inhibitor molecules. The corrosion behavior was investigated with the help of binding energies, radial distribution function analysis, equilibrated configurations, and mean square displacement (MSD) analysis. The theoretical results were in good accordance with the experimental results.

Latest developments in the protection of steels from corrosion and erosion

This Special Issue entitled “Surface coatings: latest developments in the protection of steels from corrosion and erosion” focuses on significant advancements and developments in coating technologies in the protection of steels from corrosion and erosion in different operative environments. This Special Issue intends to cover original research and critical review articles on recent advances in various techniques to combat corrosion and erosion of steels.

Experimental study on erosion-corrosion of carbon steel in flowing NaCl solution of different pH

The pure corrosion, pure erosion and erosion-corrosion behaviours of X65 carbon steel in corrosive fluid and slurry of different pH were studied at low flow velocity. Results show that the corrosion pattern changed from general corrosion to pitting damage along with the occurrence of erosion in pH = 3 solution and it is postulated that this feature might be associated with changes in the cathodic reaction. The sand impacts would cause the transient of main cathodic reaction from hydrogen evolution to oxygen reduction. Density and connected small pits generated in pH = 7 solution containing sand particles. While, the increase of the solution pH from 7 to 11 resulted in more scattered and serious pitting damage, which is caused by more focused initial anodes. The occurrence of pitting damage has complicated the analysis of the electrochemical results. The sand impacts in pH = 13 solution could cause the local breakdown of passive film, leading to a significant decrease of pitting resistance.