Search results for: corrosion properties

Authors: Mandlenkosi G. R. Mahlobo, Peter A. Olubambi

Abstract:

Cathodic protection (CP) has been widely considered as a suitable technique for mitigating corrosion of steel structures buried in soil. Plenty of efforts have been made in developing techniques, in particular non-destructive techniques, for monitoring and quantifying the effectiveness of CP to ensure the sustainability and performance of buried steel structures. This study was aimed at using a specifically modified voltammetry approach as a non-destructive tool to monitor and quantify the effectiveness of CP of steel in simulated soil. Carbon steel was subjected to electrochemical tests with NS4 solution used as simulated soil conditions for four days before applying CP for further 11 days. A specifically modified voltammetry technique was applied at various time intervals of the experiment to monitor the corrosion behaviour and therefore reflect CP effectiveness. The voltammetry results revealed that the application of CP reduced the corrosion rate from the highest value of 410 µm/yr to 8 µm/yr between days 5 and 14 of the experiments. The microstructural analysis of the steel surface performed using x-ray diffraction identified calcareous deposit as the dominant phase protecting the surface from corrosion. It was deduced that the formation of calcareous deposits was linked with the effectiveness of CP of steel.

Keywords: carbon steel, cathodic protection, NS4 solution, voltammetry, XRD

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Authors: S. Zouari, H. Ghorbel, H. Liao, R. Elleuch

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Research is increasingly moving towards the use of surface treatment processes to limit environmental effects. Electrolytic plating has traditionally been seen as a way to protect brass products, especially faucets, from mechanical and chemical damage. However, this method was not effective industrially, economically and ecologically. The aim of this work is to develop non-usual polymer coatings for brass faucets in order to improve the performance of brass and to replace electrolytic chromium coatings, thereby reducing environmental impact. Fluorinated-Ethylene-Propylene polymer (FEP) was chosen for its excellent mechanical and chemical properties and its good environmental performance. This coating was developed by spraying (painting) process onto brass substrates. The coatings obtained were characterized using a scanning electron microscope to evaluate the morphology of the deposits and their porosity rate. Grid adhesion, surface energy and corrosion tests (salt spray) were also performed to evaluate the mechanical and chemical behavior of these coatings properly. The results show that the deposits obtained have a homogeneous microstructure with a very low porosity rate. The results of the grid adhesion test prove the conformity of the test according to the NF077 standard. The coatings have a hydrophobic character following the low values of surface energy obtained and a very good resistance to corrosion. These results are interesting and may represent real technological issues in the industrial field.

Keywords: FEP coatings, spraying process, brass, adhesion, surface energy, corrosion resistance

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Authors: Asma Lamin, Anna H. Kaksonen, Ivan Cole, Paul White, Xiao-Bo Chen

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Microbiologically influenced corrosion (MIC) is a process in which microorganisms initiate, facilitate, or accelerate the electrochemical corrosion reactions of metallic components. Several reports documented that MIC accounts for about 20 to 40 % of the total cost of corrosion. Biofilm formation due to the presence of microorganisms on the surface of metal components is known to play a vital role in MIC, which can lead to severe consequences in various environmental and industrial settings. Quorum sensing (QS) system plays a major role in regulating biofilm formation and control the expression of some microbial enzymes. QS is a communication mechanism between microorganisms that involves the regulation of gene expression as a response to the microbial cell density within an environment. This process is employed by both Gram-positive and Gram-negative bacteria to regulate different physiological functions. QS involves production, detection, and responses to signalling chemicals, known as auto-inducers. QS controls specific processes important for the microbial community, such as biofilm formation, virulence factor expression, production of secondary metabolites and stress adaptation mechanisms. The use of QS inhibitors (QSIs) has been proposed as a possible solution to biofilm related challenges in many different applications. Although QSIs have demonstrated some strength in tackling biofouling, QSI-based strategies to control microbially influenced corrosion have not been thoroughly investigated. As such, our research aims to target the QS mechanisms as a strategy for mitigating MIC on metal surfaces in engineered systems.

Keywords: quorum sensing, quorum quenching, biofilm, biocorrosion

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Authors: K. N. Kipreou, E. Efthmiadou, G. Kordas

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Biofouling represents one of the most crucial problems in the present maritime industries when its control still challenges the researchers all over the world. The present work is referred to the synthesis and characterization CeMo and Cu2O nanocontainers by using a wide range of techniques including scanning electron microscopy (SEM), X-ray diffraction (XRD) and thermogravimetric analysis (TGA) for marine applications. The above nanosystems will be loaded with active monomers and corrosion rendering healing ability to marine paints. The objective of this project is their ability for self-healing, self-polishing and finally for anti-corrosion activity. One of the driving forces for the exploration of CeMo, is the unique anticorrosive behavior, which will be confirmed by the electrochemistry methodology. It has be highlighted that the nanocontainers of Cu2O with the appropriate antibacterial inhibitor will improve the hydrophobicity and the morphology of the coating surfaces reducing the water friction. In summary, both novel nanoc will increase the lifetime of the paints releasing the antifouling agent in a control manner.

Keywords: marinepaints, nanocontainer, antifouling, anticorrosion, copper, electrochemistry, coating, biofouling, inhibitors, copper oxide, coating, SEM

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Authors: Naveed Ejaz, Liaqat Ali, Amer Nusair

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Thermal barrier coatings (TBCs) serve as thermal barriers against the high temperature of the hot regions of the aircraft turbine engines keeping the surface of the turbine blades, vanes and combustion chamber at comparatively lower temperature. The life of these coatings depends on many in-service environmental factors. Among these factors, the behavior of the bond coat as well as the top coat at high temperature aggravated by the corrosive environments having S, V, Na and Cl plays a key role. The incorporation of the 5-15% CaZrO3 in YSZ coatings was studied after hot corrosion in vanadium oxide environment. It was observed that the reactivity of the V gradually switched from Y to Ca making CaV2O4 instead of YVO4; the percentage of CaV2O4 increased with the increase of CaZrO3 in YSZ. It eventually prevented leaching out of the Y from YSZ leaving the YSZ without any harmful phase change. The thermal insulation was found to be improved in case of CaZrO3 incorporated YSZ coatings as compared to only YSZ coating.

Keywords: hot corrosion, thermal barrier coatings, yttria stabilized zirconia, calcium zirconate

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Authors: S. K. Ghosh, C. Srivastava, P. K. Limaye, V. Kain

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Electroplated hard chromium is widely known in coatings and surface finishing, automobile and aerospace industries because of its excellent hardness, wear resistance and corrosion properties. However, its precursor, Cr+6 is highly carcinogenic in nature and a consensus has been adopted internationally to eradicate this coating technology with an alternative one. The search for alternate coatings to electroplated hard chrome is continuing worldwide. Various alloys and nanocomposites like Co-W alloys, Ni-Graphene, Ni-diamond nanocomposites etc. have already shown promising results in this regard. Basically, in this study, electroless Ni-P alloys with excellent corrosion resistance was taken as the base matrix and incorporation of tungsten as third alloying element was considered to improve the hardness and wear resistance of the resultant alloy coating. The present work is focused on the preparation of Ni–W–P coatings by electrodeposition with different content of phosphorous and its effect on the electrochemical, mechanical and tribological performances. The results were also compared with Ni-W alloys. Composition analysis by EDS showed deposition of Ni-32.85 wt% W-3.84 wt% P (designated as Ni-W-LP) and Ni-18.55 wt% W-8.73 wt% P (designated as Ni-W-HP) alloy coatings from electrolytes containing of 0.006 and 0.01M sodium hypophosphite respectively. Inhibition of tungsten deposition in the presence of phosphorous was noted. SEM investigation showed cauliflower like growth along with few microcracks. The as-deposited Ni-W-P alloy coating was amorphous in nature as confirmed by XRD investigation and step-wise crystallization was noticed upon annealing at higher temperatures. For all the coatings, the nanohardness was found to increase after heat-treatment and typical nanonahardness values obtained for 400°C annealed samples were 18.65±0.20 GPa, 20.03±0.25 GPa, and 19.17±0.25 for alloy coatings Ni-W, Ni-W-LP and Ni-W-HP respectively. Therefore, the nanohardness data show very promising results. Wear and coefficient of friction data were recorded by applying a different normal load in reciprocating motion using a ball on plate geometry. Post experiment, the wear mechanism was established by detail investigation of wear-scar morphology. Potentiodynamic measurements showed coating with a high content of phosphorous was most corrosion resistant in 3.5wt% NaCl solution.

Keywords: corrosion, electrodeposition, nanohardness, Ni-W-P alloy coating

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Authors: Ibrahim R. Elomari, Fin O'Flaherty, Ibrahim R. Elomari, Paul Lambert

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Cathodic protection (CP) is a technique commonly used to arrest corrosion of steel in infrastructure. However, it is not generally used on high strength, pre-stressed tendons due to the risk of hydrogen generation, leading to possible embrittlement. This paper investigates its use in such circumstances where the applied protection potential is varied to determine if CP can be safely employed on pre-stressed tendons. Plain steel tendons measuring 5.4 mm diameter were pre-stressed in timber moulds and embedded in sand/cement mortar, formulated to represent gunite. Two levels of pre-stressing were investigated (400MPa and 1200MPa). Pre-corrosion of 0% (control), 3% and 6% target loss of cross-sectional area was applied to replicate service conditions. Impressed current cathodic protection (ICCP) was then applied to the tendons at two levels of potential to identify any effect on strength. Instant-off values up to -950mV were used for normal protection with values of -1100mV or more negative to achieve overprotection. Following the ICCP phase, the tendons were removed from the mortar, cleaned and weighed to confirm actual percentage of corrosion. Tensile tests were then conducted on the tendons. The preliminary results show the influence of normal levels and overprotection of CP on the ultimate strength of the tendons.

Keywords: pre-stressed concrete, corrosion, cathodic protection, hydrogen embrittlement

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Authors: Abdulrahman Sumayli

Abstract:

Natural Zinc has many significant biological functions, including developments and sustainable of bones and wound healing. Metallic zinc has recently been explored as potential biomaterials that have preferable biodegradable, biocompatible, and mechanical properties. Pure metal zinc has a preferable physical and mechanical properties for biodegradable and biocompatible applications such as density and modulus of elasticity. The aim of the research is to make different Zn-based metallic alloys and test them effectively to be used as biocompatible and biodegradable materials in the field biomedical application. Microstructure study of the as-cast alloys will be examined using SEM (scanning electron microscope) followed by X-ray diffraction investigated so as to evaluate phase constitution of the designed alloys. After that, immersion test and electrochemical test will be applied to the designed alloys so as to study bio corrosion behaviour of the proposed alloys. Finally, in vitro cytocompatibility well conducted to study biocompatibility of the made alloys.

Keywords: Zn-based alloys, biodegradable and biocompatible materials, cytotoxicity test, neutron synchrotron imaging

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Authors: Lenka Markovičová, Viera Zatkalíková, Tomasz Garbacz

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The development of composite materials and the related design and manufacturing technologies is one of the most important advances in the history of materials. Composites are multifunctional materials having unprecedented mechanical and physical properties that can be tailored to meet the requirements of a particular application. Some composites also exhibit great resistance to high-temperature corrosion, oxidation, and wear. Polymers are widely used indoors and outdoors, therefore they are exposed to a chemical environment which may include atmospheric oxygen, acidic fumes, acidic rain, moisture heat and thermal shock, ultra-violet light, high energy radiation, etc. Different polymers are affected differently by these factors even though the amorphous polymers are more sensitive. Ageing is also important and it is defined as the process of deterioration of engineering materials resulting from the combined effects of atmospheric radiation, heat, oxygen, water, micro-organisms and other atmospheric factors.

Keywords: composites with glass fibers, mechanical properties, polyamides, UV degradation

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Authors: Nadia Hammouda, Kamel Belmokre

Abstract:

Organic coatings are widely employed in the corrosion protection of most metal surfaces, particularly steel. They provide a barrier against corrosive species present in the environment, due to their high resistance to oxygen, water and ions transport. This study focuses on the evaluation of corrosion protection performance of epoxy paint on the carbon steel surface in sea water by Electrochemical Impedance Spectroscopy (EIS). The electrochemical behavior of painted surface was estimated by EIS parameters that contained paint film resistance, paint film capacitance and double layer capacitance. On the basis of calculation using EIS spectrums it was observed that pore resistance (Rpore) decreased with the appearance of doubled layer capacitance (Cdl) due to the electrolyte penetration through the film. This was further confirmed by the decrease of diffusion resistance (Rd) which was also the indicator of the deterioration of paint film protectiveness.

Keywords: epoxy paints, carbon steel, electrochemical impedance spectroscopy, corrosion mechanisms, seawater

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Authors: Saad A. Bakheet, Salah M. Elkoum, Asharaf A. Almaghribi

Abstract:

Pre-stressed wire is considered the most important in manufacturing pre-stressed concrete pipes, this is because the life of the mentioned pipes depends on the integrity of the wire. When the wire is wrapped around the concrete core, it provides a compressive strength that enables the concrete cores to withstand internal and external pressures. Since LIBYA has constructed different stages of man-made river projects using pre-stressed concrete pipes in different diameters (1.6, 2.2, 3.6 and 4.0 m) to transport water from the south part of the country to the north-populated area, pipe failures due to corrosion have occurred after several years of operation at different locations of the pipeline route. The PC wire is corroded and, in the end, breaks and becomes unable to withstand internal water pressure. The wire breaks recorded using the hydrophone technique added extra pressure on the project management staff and engineers to resolve and study the possible main cause of wire break and pipe failure. Information regarding the PC wire used will be provided in this paper which includes specifications, manufacturing etc. In this paper, the causes of wire corrosion and wire breaks after several years of PCCP operation will be discussed and explained, in addition to that, the correlation between wire breaks and pipe potential will be addressed and highlighted.

Keywords: wire technical specification, wire break, corrosion causes, potential measurement, failure concrete pipe

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Authors: Chen Jiang, Eric Jordan, Maurice Gell, Balakrishnan Nair

Abstract:

Nuclear fusion, one of the most promising options for reliably generating large amounts of carbon-free energy in the future, has seen a plethora of ground-breaking technological advances in recent years. An efficient and durable “breeding blanket”, needed to ensure a reactor’s self-sufficiency by maintaining the optimal coolant temperature as well as by minimizing radiation dosage behind the blanket, still remains a technological challenge for the various reactor designs for commercial fusion power plants. A relatively new dual-coolant lead-lithium (DCLL) breeder design has exhibited great potential for high-temperature (>700oC), high-thermal-efficiency (>40%) fusion reactor operation. However, the structural material, namely reduced activation ferritic-martensitic (RAFM) steel, is not chemically stable in contact with molten Pb-17%Li coolant. Thus, to utilize this new promising reactor design, the demand for effective corrosion-resistant coatings on RAFM steels represents a pressing need. Solution Spray Technologies LLC (SST) is developing a double-layer ceramic coating design to address the corrosion protection of RAFM steels, using a novel solution and solution/suspension plasma spray technology through a US Department of Energy-funded project. Plasma spray is a coating deposition method widely used in many energy applications. Novel derivatives of the conventional powder plasma spray process, known as the solution-precursor and solution/suspension-hybrid plasma spray process, are powerful methods to fabricate thin, dense ceramic coatings with complex compositions necessary for the corrosion protection in DCLL breeders. These processes can be used to produce ultra-fine molten splats and to allow fine adjustment of coating chemistry. Thin, dense ceramic coatings with chosen chemistry for superior chemical stability in molten Pb-Li, low activation properties, and good radiation tolerance, is ideal for corrosion-protection of RAFM steels. A key challenge is to accommodate its CTE mismatch with the RAFM substrate through the selection and incorporation of appropriate bond layers, thus allowing for enhanced coating durability and robustness. Systematic process optimization is being used to define the optimal plasma spray conditions for both the topcoat and bond-layer, and X-ray diffraction and SEM-EDS are applied to successfully validate the chemistry and phase composition of the coatings. The plasma-sprayed double-layer corrosion resistant coatings were also deposited onto simulated RAFM steel substrates, which are being tested separately under thermal cycling, high-temperature moist air oxidation as well as molten Pb-Li capsule corrosion conditions. Results from this testing on coated samples, and comparisons with bare RAFM reference samples will be presented and conclusions will be presented assessing the viability of the new ceramic coatings to be viable corrosion prevention systems for DCLL breeders in commercial nuclear fusion reactors.

Keywords: breeding blanket, corrosion protection, coating, plasma spray

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Authors: Jana Rejková, Marie Kudrnová

Abstract:

This paper deals with the research of materials for one of the types of reactors IV. generation - reactor with molten salts. One of the advantages of molten salts applied as a coolant in reactors is the ability to operate at relatively low pressures, as opposed to cooling with water or gases. Compared to liquid metal cooling, which also allows lower operating pressures, salt melts are less prone to chemical reactions. The service life of the construction materials used is limited by the operating temperatures of the reactor and the content of impurities in the salts. For the research of corrosion resistance, an experimental device was designed and assembled, enabling exposure at high temperatures without access to oxygen in a flowing atmosphere of inert gas. Nickel alloys Inconel 601, 617, and 625 were tested in a mixture of chloride salts LiCl – KCl (58,2 - 41,8 wt. %). The experiment showed high resistance of the materials used and based on the results and XPS analysis, other construction materials were proposed for the experiments.

Keywords: molten salt, corrosion, nuclear reactor, nickel alloy

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Authors: Nadia Hammouda, K. Belmokre

Abstract:

Organic coatings are widely employed in the corrosion protection of most metal surfaces, particularly steel. They provide a barrier against corrosive species present in the environment, due to their high resistance to oxygen, water and ions transport. This study focuses on the evaluation of corrosion protection performance of epoxy paint on the carbon steel surface in sea water by Electrochemical Impedance Spectroscopy (EIS). The electrochemical behavior of painted surface was estimated by EIS parameters that contained paint film resistance, paint film capacitance and double layer capacitance. On the basis of calculation using EIS spectrums it was observed that pore resistance (Rpore) decreased with the appearance of doubled layer capacitance (Cdl) due to the electrolyte penetration through the film. This was further confirmed by the decrease of diffusion resistance (Rd) which was also the indicator of the deterioration of paint film protectiveness.

Keywords: epoxy paints, carbon steel, electrochemical impedance spectroscopy, corrosion mechanisms, sea water

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Authors: Tejinder Singh Sidhu

Abstract:

Hot corrosion has been recognized as a severe problem in steam-powered electricity generation plants and industrial waste incinerators as it consumes the material at an unpredictably rapid rate. Consequently, the load-carrying ability of the components reduces quickly, eventually leading to catastrophic failure. The inability to either totally prevent hot corrosion or at least detect it at an early stage has resulted in several accidents, leading to loss of life and/or destruction of infrastructures. A number of countermeasures are currently in use or under investigation to combat hot corrosion, such as using inhibitors, controlling the process parameters, designing a suitable industrial alloy, and depositing protective coatings. However, the protection system to be selected for a particular application must be practical, reliable, and economically viable. Due to the continuously rising cost of the materials as well as increased material requirements, the coating techniques have been given much more importance in recent times. Coatings can add value to products up to 10 times the cost of the coating. Among the different coating techniques, thermal spraying has grown into a well-accepted industrial technology for applying overlay coatings onto the surfaces of engineering components to allow them to function under extreme conditions of wear, erosion-corrosion, high-temperature oxidation, and hot corrosion. In this study, the hot corrosion performances of Ni-20Cr and Cr₃C₂-NiCr coatings developed by High Velocity Oxy-Fuel (HVOF) process have been studied. The coatings were developed on a Fe-based superalloy, and experiments were performed in an actual industrial environment of a coal-fired boiler. The cyclic study was carried out around the platen superheater zone where the temperature was around 1000°C. The study was conducted for 10 cycles, and one cycle was consisting of 100 hours of heating followed by 1 hour of cooling at ambient temperature. Both the coatings deposited on Fe-based superalloy imparted better hot corrosion resistance than the uncoated one. The Ni-20Cr coated superalloy performed better than the Cr₃C₂-NiCr coated in the actual working conditions of the coal fired boiler. It is found that the formation of chromium oxide at the boundaries of Ni-rich splats of the coating blocks the inward permeation of oxygen and other corrosive species to the substrate.

Keywords: hot corrosion, coating, HVOF, oxidation

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Authors: N. Boshkova, K. Kamburova, N. Tabakova, N. Boshkov, Ts. Radeva

Abstract:

Coatings based on polyaniline (PANI) can improve the resistance of steel against corrosion. In this work, the preparation of stable suspensions of colloidal PANI-SiO₂ particles, suitable for obtaining of composite anticorrosive coating on steel, is described. Electrokinetic data as a function of pH are presented, showing that the zeta potentials of the PANI-SiO₂ particles are governed primarily by the charged groups at the silica oxide surface. Electrosteric stabilization of the PANI-SiO₂ particles’ suspension against aggregation is realized at pH>5.5 (EB form of PANI) by adsorption of positively charged polyelectrolyte molecules onto negatively charged PANI-SiO₂ particles. The PANI-SiO₂ particles are incorporated by electrodeposition into the metal matrix of zinc in order to obtain composite (hybrid) coatings. The latter are aimed to ensure sacrificial protection of steel mainly in aggressive media leading to local corrosion damages. The surface morphology of the composite zinc coatings is investigated with SEM. The influence of PANI-SiO₂ particles on the cathodic and anodic processes occurring in the starting electrolyte for obtaining of the coatings is followed with cyclic voltammetry. The electrochemical and corrosion behavior is evaluated with potentiodynamic polarization curves and polarization resistance measurements. The beneficial effect of the stabilized PANI-SiO₂ particles for the increased protective ability of the composites is commented and discussed.

Keywords: corrosion, polyaniline-silica particles, zinc, protective ability

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Authors: Gurpreet Singh, Hazoor Singh, Kulbir Singh Sandhu

Abstract:

Friction Stir Welding Process emerged as promising solid-state welding and eliminates various welding defects like cracks and porosity in joining of dissimilar aluminum alloys. In the present research, Friction Stir Welding (FSW) is carried out on dissimilar aluminum alloys 2000 series and 6000 series this combination of alloys are highly used in automobile and aerospace industry due to their good strength to weight ratio, mechanical, and corrosion properties. The joints characterized by applying various destructive and non-destructive tests. Three critical welding parameters were considered i.e. Tool Rotation speed, Transverse speed, and Tool Geometry. The effective range of tool rotation speed from 1200-1800 rpm and transverse speed from 60-240 mm/min and tool geometry was studied. The two-different difficult to weld alloys were successfully welded. All the samples showed different microstructure with different set of welding parameters. It has been revealed with microstructure scans that grain refinement plays a crucial role in mechanical properties.

Keywords: aluminum alloys, friction stir welding, mechanical properties, microstructure

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Authors: I. M. B. Omiogbemi, D. S. Yawas, I. M. Dagwa, F. G. Okibe

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This work present the effects of some gas metal arc welding parameters on the corrosion behavior of austenitic stainless steel, exposed to 0.5M sodium hydroxide at ambient temperatures (298K) using conventional weight loss determination, together with surface morphology evaluation by scanning electron microscopy and the application of factorial design of experiment to determine welding conditions which enhance the integrity of the welded stainless steel. The welding variables evaluated include speed, voltage and current. Different samples of the welded stainless steels were immersed in the corrosion environment for 8, 16, 24, 32 and 40 days and weight loss determined. From the results, it was found that increase in welding current and speed at constant voltage gave the optimum performance of the austenitic stainless steel in the environment. At a of speed 40cm/min, 110Amp current and voltage of 230 volt the welded stainless steel showed only a 0.0015mg loss in weight after 40 days. Pit-like openings were observed on the surface of the metals indicating corrosion but were minimal at the optimum conditions. It was concluded from the research that relatively high welding speed and current at a constant voltage gives a good welded austenitic stainless steel with better integrity.

Keywords: welding, current, speed, austenitic stainless steel, sodium hydroxide

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Authors: Hikmet Cicek

Abstract:

Transition metal nitrides are widely used as protective coatings on machine parts and cutting tools to protect the surfaces from abrasion and corrosion for decades. In this study, the ternary TiNbVN thin coatings were produced with closed field unbalanced magnetron sputtering system and their structural, mechanical and fatigue-like (multi-pass scratch test) properties were investigated. Two different substrates (M2 and H13 steels) were used to explore substrates effects. X-Ray diffractometer, scanning electron microscope, and energy dispersive spectroscopy were used for the structural and chemical analysis of the coatings. Nanohardness tests were proceed for mechanical properties. The fatigue-like properties of the coatings obtained from the multi-scratch test under three different cycle passes. The results showed that TiNbVN films have excellent fatigue resistance and the coatings deposited on M2 steel substrate have higher hardness and better fatigue resistance.

Keywords: physical vapor deposition, fatigue, metal nitride, multipass scratch test

Procedia PDF Downloads 210

Authors: Mandlenkosi George Robert Mahlobo, Tumelo Seadira, Major Melusi Mabuza, Peter Apata Olubambi

Abstract:

Cathodic protection (CP) has been widely considered a suitable technique for mitigating corrosion of buried metal structures. Plenty of efforts have been made in developing techniques, in particular non-destructive techniques, for monitoring and quantifying the effectiveness of CP to ensure the sustainability and performance of buried steel structures. The aim of this study was to investigate the evolution of the electrochemical processes at the steel/soil interface during the application of CP on steel in simulated soil. Carbon steel was subjected to electrochemical tests with NS4 solution used as simulated soil conditions for 4 days before applying CP for a further 11 days. A previously modified non-destructive voltammetry technique was applied before and after the application of CP to measure the corrosion rate. Electrochemical impedance spectroscopy (EIS), in combination with mathematical modeling through equivalent electric circuits, was applied to determine the electrochemical behavior at the steel/soil interface. The measured corrosion rate was found to have decreased from 410 µm/yr to 8 µm/yr between days 5 and 14 because of the applied CP. Equivalent electrical circuits were successfully constructed and used to adequately model the EIS results. The modeling of the obtained EIS results revealed the formation of corrosion products via a mixed activation-diffusion mechanism during the first 4 days, while the activation mechanism prevailed in the presence of CP, resulting in a protective film. The x-ray diffraction analysis confirmed the presence of corrosion products and the predominant protective film corresponding to the calcareous deposit.

Keywords: carbon steel, cathodic protection, NS4 solution, voltammetry, EIS

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Authors: S. Hehni Meidani Behzad, Mokhtari Karchegani Amir, Mabodi Samad

Abstract:

There are some TLE (Transfer Line Exchanger) that their lifetime reduced to 4 years instead of 30 years and after 4 years, we saw corroded area on one part of those T.L.E. that named Oval header and this happened in condition that other parts of those TLE were safe and perfect. By using of thickness measurement devices, we find that thickness reduces unusually on that part and after research and doing computer analysis with fluent software, it was recognized that on that part, we have high temperature and when this out of range temperature adds to bad quality of water, corrosion increased with high rate on that part and after more research it became obviously that it case by more excess air in furnace that located before this T.L.E. that this more air case to consuming more fuel to reach same furnace temperature so it concluded that inner coil fluid temperature increased and after received to T.L.E, this case happened and deflector condition, creep in coil and material analysis confirmed that condition.

Keywords: Transfer Line Exchanger (TLE), CFD, corrosion, erosion, tube, oval header

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Authors: Kamil Dydek, Szymon Demski, Kamil Majchrowicz, Paulina Kozera, Bogna Sztorch, Dariusz Brząkalski, Zuzanna Krawczyk, Robert Przekop, Anna Boczkowska

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Thanks to their excellent properties, i.e. high stiffness and strength in relation to their weight, corrosion resistance, and low thermal expansion, Carbon Fiber Reinforced Polymers (CFRPs) are a group of materials readily used in many industrial sectors, e.g. aviation, automotive, wind energy. Conventional CFRPs also have their disadvantages, namely, relatively low electrical conductivity and brittle cracking. To counteract this, a thermoplastic acrylic resin was proposed, which was further modified by the addition of organosilicon compounds and multi-walled carbon nanotubes (MWCNTs). The addition of the organosilicon compounds was aimed at improving the dispersion of the MWCNTs and obtaining good adhesion between the resin and the carbon fibre, where the MWCNTs were used as a conductive filler. In addition, during the fabrication of laminates using the infusion method, thermoplastic nonwovens doped with MWCNTs were placed between the carbon reinforcement layers to achieve a synergistic effect with an increase in electrical and mechanical properties.

Keywords: CFRP, acrylic resin, organosilicon compounds, mechanical properties, electrical properties

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Authors: S. S. Sravanthi, Swati Ghosh Acharyya

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Automotive light weighting is of major prominence in the current times due to its contribution in improved fuel economy and reduced environmental pollution. Various arc welding technologies are being employed in the production of automobile components with reduced weight. The present study is of practical importance since it involves preferential substitution of Zinc coated mild steel with a light weight alloy such as 6061 Aluminium by means of Gas Metal Arc Welding (GMAW) – Brazing technique at different processing parameters. However, the fabricated joints have shown the generation of Al – Fe layer at the interfacial regions which was confirmed by the Scanning Electron Microscope and Energy Dispersion Spectroscopy. These Al-Fe compounds not only affect the mechanical strength, but also predominantly deteriorate the corrosion resistance of the joints. Hence, it is essential to understand the phases formed in this layer and their crystal structure. Micro area X - ray diffraction technique has been exclusively used for this study. Moreover, the crevice corrosion analysis at the joint interfaces was done by exposing the joints to 5 wt.% FeCl₃ solution at regular time intervals as per ASTM G 48-03. The joints have shown a decreased crevice corrosion resistance with increased heat intensity. Inner surfaces of welds have shown severe oxide cracking and a remarkable weight loss when exposed to concentrated FeCl₃. The weight loss was enhanced with decreased filler wire feed rate and increased heat intensity. 

Keywords: automobiles, welding, corrosion, lap joints, Micro XRD

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Authors: Fadwa Jewilli

Abstract:

A sudden leak of a 6-inch gas line pipe after being in service for one year was observed. The pipe had been designed to transport dry gas. The failure had taken place in 6 o’clock position at the stage discharge of the flow process. Laboratory investigations were conducted to find out the cause of the pipe rupture. Visual and metallographic observations confirmed that the pipe split was due to a crack initiated in circumferential and then turned into longitudinal direction. Sever wall thickness reduction was noticed on the internal pipe surface. Scanning electron microscopy observations at the fracture surface revealed features of ductile fracture mode. Corrosion product analysis showed the traces of iron carbonate and iron sulphate. The laboratory analysis resulted in the conclusion that the pipe failed due to the effect of wet fluid (condensate) caused severe wall thickness dissolution resulted in pipe could not stand the continuation at in-service working condition.

Keywords: gas line pipe, corrosion prediction ductile fracture, ductile fracture, failure analysis

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Authors: Milad Alizadeh Galdiani, Navid Sabet, Mohamad Ali Mohit, Fatemeh Palizdar

Abstract:

Railway as one of the most important transportation modes, passes through ‎various areas with different conditions ‎inevitably, and in many countries such as ‎China, United States, Australia, and Iran, it passes through sandy ‎desert areas. One ‎of the main problems in these areas is the movement of sand, causing various ‎damages ‎to ballasted railway track such as corrosion in the railway fastening system. ‎The soil composition of some desert areas like Fahraj in Iran consists of sand ‎and ‎salt. Due to the movement of sand and corrosive ions of salt, the fastening system ‎of the railway is ‎corroded, which, in turn, reduces the thickness of the components ‎and their life span.‎ In this research, the Nano-coating for fastening system of ‎the railway is ‎introduced, and its performance has been investigated in both ‎laboratory and field tests. The Nano-coating of ‎the fastening system consists of zinc-rich, epoxy, polyurethane, and additive, which is produced through ‎Nano ‎technology. This layer covers the surface of the fastening system and ‎prohibits the chemical reactions, which result in ‎corrosion. The results of ‎Electrochemical Impedance Spectroscopy (EIS) ‎indicate that corrosion resistance ‎increases 315 times by using nano-coating, salt spray test results demonstrate that ‎nano-coated components remained intact after 1000 hours.‎

Keywords: ballasted railway, Nano-coating, railway fastening system, sandy desert

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Authors: Santiranjan Shannigrahi, Mohit Sharma, Ivan Tan Chee Kiang, Yong Anna Marie

Abstract:

Polymer-ceramics composites are gaining importance due to their high specific strength, corrosion resistance, and high mechanical properties, as well as low cost. As a result, polymer composites are suitable for various industrial applications, like automobiles, aerospace, and biomedical areas. The present work comprises the development of polymer-ceramic composite films and is tested for the harsh environment including weatherability and UV barrier property. The polymer composite films are kept in weather chamber for a fixed period of time followed by tested for their physical, mechanical and chemical properties. The composite films are fabricated using compounding followed by hot pressing. UV-visible spectroscopy results reveal that the pure polymer polyethylene (PE) films are transparent in the visible range and do not absorb UV. However, polymer ceramic composite films start absorbing UV completely even at very low filler loading amount of 5 wt.%. The changes in tensile properties of the various composite films before and after UV illuminations for 40 hrs at 60 degC are analyzed. The tensile strength of neat PE film has been observed 8% reduction, whereas the remarkable increase in tensile strength has been observed (18% improvement for 10 wt. % filled composites films). The UV exposure leads to strengthen the crosslinking among PE polymer chains in the filled composite films, which contributes towards the incremented tensile strength properties.

Keywords: polymer ceramic composite, processing, harsh environment, mechanical properties

Procedia PDF Downloads 385

Authors: S. M. A. Al-Qawabah, A. I. O. Zaid

Abstract:

Aluminum and its alloys are versatile materials which are widely used in industrial and engineering applications due to their good and useful properties e.g. high strength to weight ratio, high thermal and electrical conductivities and good resistance to corrosion. However, against these favorable properties they have the disadvantage they solidifying large grain columnar structure which negatively affects their mechanical properties and surface quality. Aluminum alloys are normally grain refined by some alloying elements, such as Ti, Ti-B or Zr. In this paper, the effect of zirconium addition to Al grain refined by Ti after extrusion on its wear resistance is investigated under different loads and sliding speeds namely at 5,10 and 20 N loads and sliding speeds ranging from m/min. and m/min. the results are presented in three-dimensional wear mode. To the best the authors' knowledge, the wear of aluminum in 3-dimensions has never been tackled before. In this work, the wear resistance of by presenting the results of wear are presented and discussed on the time, load and speed plots.

Keywords: aluminum grain refined, addition of titanium, wear resistance, titanium

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Authors: Khalid H. Abass

Abstract:

Al-Ni-Cr alloy contains different ratios of Ni and Cr was prepared by mixing Al, Ni and Cr at 800oC under an argon atmosphere. The prepared alloys were heated for 1300 hr to 560oC, and then cooled rapidly by water at the ambient temperature. Surface morphology for alloys is studied by scanning electron microscope (SEM). The resultant homogeneous surface is a result of heat treatment. The X-ray diffraction patterns showed (111), (200), and (220) diffraction lines from cubic Al crystal structure, and suggested that the intensity of peak (111) orientation is predominant. Three binary phases were observed and grown in alloys: Al3Ni (Orthorhombic, a = 6.598Ǻ, b = 7.352 Ǻ, c = 4.802 Ǻ), Cr9Al17 (Rhombohedra, a = 12.910 Ǻ, c = 15.677), and Ni2Cr3 (Tetragonal, a = 8.82 Ǻ, c = 4.58 Ǻ). The average crystallite sizes of the prepared samples were found to be from 3000 to 3094 nm by SEM, which is much smaller than that estimated from XRD data. Corrosion resistance increases with increasing Ni-Cr content in Al alloys. The electrical volume resistivity decreased with increasing Ni-Cr content at low frequency. This behavior can be seen generally at 50Hz, where the electrical volume resistivity reached the value of 3.98×10-8Ω.cm for the ratio Al-1.8 at.%Ni-0.18at.%Cr.

Keywords: Al-Ni-Cr alloy, corrosion current, electrical volume resistivity, binary phase, homogeneous surface

Procedia PDF Downloads 399

Authors: Jana Petru, Marie Kudrnova

Abstract:

The use of technologies working with molten salts is conditioned by finding suitable construction materials that must meet several demanding criteria. In addition to temperature resistance, materials must also show corrosion resistance to salts; they must meet mechanical requirements and other requirements according to the area of use – for example, radiation resistance in Molten Salt Reactors. The present text describes an experimental device for studying the corrosion resistance of candidate materials in molten mixtures of salts and is a partial task of the international project ADAR, dealing with the evaluation of advanced nuclear reactors based on molten salts. The design of the device is based on a test exposure of Inconel 625 in the mixture of salts Hitec in a high temperature tube furnace. The result of the pre-exposure is, in addition to the metallographic evaluation of the behavior of material 625 in the mixture of nitrate salts, mainly a list of operational and construction problems that were essential for the construction of the new experimental equipment. The main output is a scheme of a newly designed gas-tight experimental apparatus capable of operating in an inert argon atmosphere, temperature up to 600 °C, pressure 3 bar, in the presence of a corrosive salt environment, with an exposure time of hundreds of hours. This device will enable the study of promising construction materials for nuclear energy.

Keywords: corrosion, experimental device, molten salt, steel

Procedia PDF Downloads 119

Authors: Kourosh Kosari

Abstract:

This study is engineering the properties of concrete containing natural nano zeolite as supplementary cementitious material in the blended Portland-cement based binder in amounts of 5,7 and 10% by mass. Crashing of clinoptilolite zeolite is performed by means of planetary ball mill. Two types of concrete along with water to cementitious material ratio (W/(C + P)) in 0.45 and 0.4 at the ages of 7, 28 and 90 days and were compared with each other. The effect of these additives on mechanical properties (compressive and tensile strength) and durability has been investigated by Electrical Resistivity (ER) and Rapid Chloride Penetration Test (RCPT) at the ages 28 and 90 days. Scanning Electron Microscopy (SEM) and X-Ray Diffraction (XRD) revealed that nanoparticles of natural clinoptilolite could improve quality of concrete. As a result of the tests, decrease in penetration of chloride ion and increase electrical resistivity significantly that are appropriate option for controlling of corrosion in reinforced concrete structures but increase of mechanical characteristics is not considerable.

Keywords: ball mill, durability, mechanical properties, nano zeolite

Procedia PDF Downloads 320