Erosion-Corrosion Performance of EH36 Steel Under Sand Impacts of Different Particle Sizes
ZHANG Qiliang1, WANG Yuchao2, LI Guangda3, LI Xianjun3, HUANG Yi1, XU Yunze1()
1School of Naval Architecture and Ocean Engineering, Dalian University of Technology, Dalian 116024, China 2CGN New Energy Offshore Wind Power Co., Ltd., Shanwei 516600, China 3China Nuclear Power Design Co. Ltd., Shenzhen 518000, China
Cite this article:
ZHANG Qiliang, WANG Yuchao, LI Guangda, LI Xianjun, HUANG Yi, XU Yunze. Erosion-Corrosion Performance of EH36 Steel Under Sand Impacts of Different Particle Sizes. Acta Metall Sin, 2023, 59(7): 893-904.
Marine carbon steels are constantly subjected to active corrosion due to significant amounts of aggressive agents in seawater. Once sand particles are entrained in seawater, the relative movement between the seawater and marine structures could further lead to erosion-corrosion of marine carbon steels. The size of the sand particles would play an important role in the synergy of erosion and corrosion. In this work, the erosion-corrosion performances of the EH36 marine carbon steel at sand impacts of different particle sizes were studied in 3.5%NaCl solution using the EIS, gravimetric measurements, and surface morphology characterization. A computational fluid dynamics simulation is used to simulate the impact velocity and trajectory of the sand particles in the test cell. The simulation results reveal that at a relatively lower flow velocity of 2 m/s, the average impact velocity of the sand particles on the electrode surface is presented as a decreasing trend along with increasing size (100-850 μm). However, increment in the particle size could still lead to rise in the impact energy due to mass increase. The EIS and gravimetric measurement results show that at low flow rate conditions, corrosion is the main contributor to the steel degradation in the sand-containing electrolyte. Meanwhile, corrosion is the prerequisite for severe erosion in this case. The steel loss induced by erosion would rise with an increase in the particle size. The surface characterization results show that the erosion-corrosion pattern changed from the typical “flow mark” to pitting damage with increasing particle size. It suggests that the increase in the impact energy could lead to a pitting initiation, thereby accelerating localized corrosion. It was determined that the particle size increase would promote the synergy of erosion and corrosion compared to pure corrosion, pure erosion, and erosion-corrosion performances. The initiation and propagation of localized erosion-corrosion are determined by the coupled effect of local sand impacts, anodic dissolution, and flow-enhanced analyte transportation. When the diameter of the sand particle is 100 μm, the erosion-corrosion process is controlled by the analyte transportation, leading to the formation of a typical “flow mark”. When the diameter of the sand particle ranges from 430 μm to 850 μm, the synergy of the sand impact and local anodic dissolution would effectively retard the analyte transportation, resulting in the formation of stable pitting damage.
Fund: National Key Research and Development Program of China(2022YFC2806204);High-Tech Ship Pr-oject of MIIT(MC-202030-H04);National Natural Science Foundation of China(52001055)
Corresponding Authors:
XU Yunze, associate professor, Tel: (0411)84706061, E-mail: xuyunze123@163.com
Fig.1 Schematic of the erosion-corrosion test system (a) and microstructure of EH36 steel (working electrode) (b) (RE—reference electrode, WE—working electrode, CE—counter electrode, SCE—saturated calomel electrode)
Fig.2 SEM images of the three kinds of sand particles with different average diameters (a) 100 μm (b) 430 μm (c) 850 μm
Fig.3 Models of the stirring electrochemical cell used for CFD simulation (CFD—computational fluid dynamics) (a) geometrical model (b) mesh model
Fig.4 Trajectory and velocity distributions of the sand particles with different sizes in the stirring electrochemical cell (a) 100 μm (b) 430 μm (c) 850 μm
Fig.5 Nyquist plots (left) and Bode diagrams (right) in the electrolytes containing different kinds of sand particles (Inset in Fig.5a shows the equivalent circuit used to fit the EIS results; Rsol—solution resistance, Rt—charge transfer resistance, CPE—constant phase element)
Fig.6 Time dependence of the corrosion rates of EH36 steel in the electrolyte containing sand particles with different sizes
Fig.7 Photos (with rust layer and after rust removal), 3D profiles, and SEM images of the coupon electrodes in different flowing conditions (a) without sand (b) 100 μm (c) 430 μm (d) 850 μm
Fig.8 Photos, 3D profiles, and SEM images of the coupon electrodes after pure erosion of different size sand particles (Ra—roughness) (a) 100 μm (b) 430 μm (c) 850 μm
Fig.9 Average steel losses induced by corrosion, erosion, erosion enhanced corrosion, and corrosion enhanced erosion under sand particle impacts of different sizes (—corrosion component, —erosion component, —erosion enhanced corrosion component, —corrosion enhanced erosion component)
Fig.10 Schematics of local erosion-corrosion development mechanism under sand particle impacts with different sizes and the typical erosion-corrosion morphologies (insets) (a) 100 μm (b) 430 μm (c) 850 μm
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