Erosioncorrosion PDF

Corrosion for Engineers
Dr. Derek H. Uster

Chapter 10: EROSION CORROSION
page 10 - 1
EROSION CORROSION ("Flow-Assisted" Corrosion)
An increase in corrosion brought about by a high relative velocity between
the corrosive environment and the surface.
Removal of the metal may be:
as corrosion product which "spalls off" the surface because of the high
fluid shear and bares the metal beneath;
as metal ions, which are swept away by the fluid flow before they can
deposit as corrosion product.
N.B., Remember the distinction between erosion-corrosion and erosion:
erosion is the straightforward wearing away by the mechanical abrasion
caused by suspended particles . .. e.g., sand-blasting, erosion of turbine
blades by droplets . ..
erosion-corrosion also involves a corrosive environment . .. the metal
undergoes a chemical reaction.
University of New Brunswick, Canada Chutatongkom University, Thaitand
Dr. Derek H. Lister
page 10 - 2
Erosion-corrosion produces a distinctive surface finish: .
grooves, waves, gullies, holes, etc., all oriented with respect to the
fluid flow pattern . ..
.. Water flow
Erosion corrosion of condenser tube wall.
Erosion of stainless alloy pump impeller.
Impeller lasted - 2 years in
oxidizing conditions;
after switch to reducing
conditions, it lasted - 3 weeks!
Universify of New Brunswick, Canada Chula/ongkorn Universify, Thailand
Dr. Derek H. Lister
page 10 - 3
Most metals/alloys are susceptible to erosion-corrosion.
Metals that rely on protective surface film for corrosion protection are
particularly vulnerable, e.g.:
AI
Pb
55.
Attack occurs when film cannot form because of erosion caused by
suspended particles (for example), or when rate of film formation is less
than rate of dissolution
and transfer to filA,;' flow' bulk fluid.
- - - ~
Dr. Derek H. Lister
page 10 - 4
Erosion-Corrosion found in: - aqueous solutions;
- gases;
- organic liquids;
- liquid metal;
If fluid contains suspended solids, erosion-corrosion may be aggravated.
Vulnerable equipment is that subjected to high-velocity fluid, to rapid
change in direction of fluid, to excessive turbulence ...
viz. equipment in which the contacting fluid has a very thin boundary layer
- high mass transfer rates.
Vulnerable equipment includes:
- pipes (Bends, elbows, tees);
- valves;
- pumps;
- blowers;
- propellers, impellers;
- stirrers;
- sti rred vessels;
- HX tUbing (heaters, condensers);
Universify of New Brunswick, Canada
- flow-measuring orifices, venturies;
- turbine blades;
- nozzles;
- baffles;
- metal-working equipment (scrapers,
cutters, grinders, mills);
- spray impingement components;
- etc.
Chulalongkorn Universify, Thai/an(/!,
Dr. Derek H. Lister
page 10 - 5
Surface film effects
Protective corrosion-product films important for resistance to erosion-
corrosion.
Erosion corrosion of hard lead by 10%
sulphuric acid (velocity 39 ft/sec).
x =Static test
e= E-C
....
/
/
V
,,/
/'
80
>-
a. 60
E
c
o
.+=
o
'-
t 40
c
QJ
a.
-
o
2! 20
o
a::
Hard, dense, adherent, continuous films give good resistance, provided
that they are not brittle and easily removed under stress.
Lead sulphate film protects lead against DILUTE H
2
S04 under stagnant
conditions, but not under rapidly
moving conditions.
0
40 60
C
80 100
University of New Brunswick, Canada Chula/ongkom University, Thai/andi
Dr. Derek H. Lister
page 10-6
pH affects films in erosion-corrosion of low-alloy steel.
400
~
E.
300
c:
.2
III
o
~
...
8200
~
lU
-
o
0.: 100
I I I I I
Erosion-corrosion disk
-
o Specimens immersed
in tonk
\II / :"\
\
I
\
\
~
.-0-
~
3- :c
~ - i
~ ~ ... -
Effect of pH of distilled water on
erosion of carbon steel at 50C
(velocity 39 ft/sec) .
4 5 6 7 8 9
pH of solution
10 11
Scale generally granular Fe304 (non-protective). But at pH 6 & pH 10, scale
Fe(OHh/Fe(OHh ... hinders mass transport of oxygen and ionic species.
University of New Brunswick, Canada Chulalongkorn University, Thailan<fi
Dr. Derek H. Lister
page 10-7
N.B. Dissolved O
2
often increases erosion-corrosion ...
e.g. copper alloys in seawater... BUT ... on steels, dissolved O
2
will
inhibit erosion-corrosion ... utilized in boiler feedwater systems.

1.0
',2
E
E

.s
0.6' 'lij
'm
::!
20
350C
10
OJ
Dissolved oll.ygen concentra1ion, mg/kg H20
'"
E

iii
.9
-
s::. 40
.21
Effects of temperature and dissolved O

2
on the weight-loss of AISI 304
stainless steel exposed for 800 hours in flowing water at 3.7 m/s.
University of New Brunswick, Canada Chulalongkorn University, Thailanff
Dr, Derek H. Lister
page 10 - 8
Effect of oxygen dosing on erosion-
corrosion and potential of carbon steel
in water at 150C, pH25 =7.8.
>
E
<3
Ol
~
Ol
-200
..
>
-400
0;
';::
c
CD
~
0
-600 a..
-BOO
-1000
-1200
-1400
180
10
1 2 3 4 5
~
~ ~ ~
~
8
If
~
6
d
i
4
.0\
.. .".#
-L-,
I'
I ,..
\
.-
::i
2
0
,
2 ~ 34 44 5 ~
24
20
i 16
!
Palenlial
~
12
..
'-
::i Loss Rate
1.12mmly
University of New Brunswick, Canada Chulalongkorn University, Thailand3
Dr, Derek H, Lister
page 10 - 9
Good resistance of Ti to erosion-corrosion in: - seawater;
- cr solutions;
- HN0
3
;
and many other environments.
Resistance depends on formation and stability of Ti0
2
films.
Chromium imparts resistance to erosion-corrosion to: - steels;
- Cu alloys.
25
15-18"4 NI
25 ,.
28-32%N1
!!1
!!1
'E
20
'E 20-
:>i
:>i
0
0
'"
15
::::
~
-
-
c:
c: Q)
Q)
E 10
-
E 10 Q)
Q)
C>
Cl c:
c:
'5.
'5.
5 E
5 ~
E
-
0
0
1,5
0
to t5
0 0,5 to
Percent Chromium
Effect of chromium additions on
seawater impingement-corrosion
resistance of copper-nickel alloys.
36 day test with 7.5 m/s jet velocity;
seawater temperature: 27C.
Such tests have led to the marketing of a new alloy for condenser tubes ..
"CA-722" ... previously "IN-838" ... with constituents ... Cu-16Ni-O.4Cr.
University of New Brunswick, Canada Chula/ongkom University, T h a i l a n ~
Dr. Derek H. Lister
Velocity Effects
page 10 - 10
~
c:
o
'e
...
8
I
c:
o
'e
w
... r - - l ...
Laminar I Turbulent
flow , flow
regime \ regime
I
I
I
I
I
I
I
I
I
I
I
1
I
I
I
I
I
I
1
Schematic showing
the effect of flow
velocity on erosion-
corrosion rate.
V
c
Flow Velocity
N.B. Turbulent flow regime for V < V
c
is sometimes called "Flow-Assisted
Corrosion" regime.
University of New Brunswick, Canada Chulalongkorn University, Thailat1<fJ
Dr. Derek H. Lister
page 10-11
Relationship between flow velocity, v, and erosion-corrosion rate, w, may
be written as ...
where k and a are constants that depend on the system.
DISCUSS: What happens when v =0 ?
How do we express no dependence on velocity?
The exponent "a" varies between ...
0.3 (laminar flow) and
0.5 (turbulent flow) ...
occasionally reaching> 1.0 for mass transfer effects.
For mechanical removal of oxide films (spalling), the fluid shear stress at
the surface is important, and a > 1.0 ... (may reach 2 - 4).
University of New Brunswick, Canada Chulalongkom University, Thailatlc1,
Dr. Derek H. Uster
page 10 - 12
Erosion-Corrosion in Carbon Steel and low-alloy steels
N.B. these materials are used extensively in boilers, turbines, feed-water
heaters in fossil &nuclear plants.
High velocities occur in single-phase flow (water) and two-phase flow
(wet steam).
Single-phase E-C seen in H.P. feedwater heaters, SG inlets in AGRs,
feedwater pumps.
Two-phase E-C more widespread . .. steam extraction piping, cross-over
piping (HP turbine to moisture separator), steam side of feedwater heaters.
University of New Brunswick, Canada Chulalongkom University, Thailarlcl
Dr. Derek H. Lister
page 10 - 13
Material effects - low alloy steel ...
30---------------,
25
5
10 .
Cr additions
reduce E-C.
500
400
Mild Steel Flow 279 kg/h
.Loss Rate: 0.36 mm/year
200 300
Time, hours
100
1 Cr 0.5 Mo Steel Flow 388 kgfh
Loss Rate: 0.03 mm/year
-------
~ - - - - - - - - - _ - .
~ - -----------
_::;...-e-
o
o
t!!
:::l
,g
20
Q)
E
t=
E 15
::s.
I/)
I/)
o
...J
'"iU
Q)
~
Erosion-corrosion loss as a function of time for mild steel and 1 Cr 0.5 Mo
steel in water (pH
2
5 =9.05) flowing through an orifice at 130C.
University of New Brunswick, Canada Chulalongkorn University, Thailat1r13
Dr. Derek H. Uster
Flow dependence (single phase) ...
Erosion-corrosion rate of carbon
steel as a function of flow rate
deoxygenated water orifice
at pH 9.05 and at 149C.
0.'
0.2
~ . 6
page 10 - 14
Average Rales
x Active Specimen Rate
~ . 8
2.'
2.5
2.6
2.7
2.8
2.9
3.0
University of New Brunswick, Canada
Log" Flow Rate. kg/hour
Chula/ongkom University, Thailarle4
Dr. Derek H. Lister
page 10 - 15
Accepted mechanism ... for E-C of C.S. in high temperature de-oxygenated
. water ...
- magnetite film dissolves reductively
Fe304 + (3n-4) H
2
0 + 2e
!
3Fe{OH)n(2-n) + {3n-4)H+
- high mass transfer rates remove soluble Fe II species;
- metal dissolves to try and maintain film.
Mass transfer characteristics correlated by expressions such as...
Sh - kRe
a
Sc
b
Sh = Sherwood Number
= kd
D
Re = dvp
f.l
Sc - ---!L
pD
Re = Reynolds Number
Sc = Schmidt Number
Chutatongkom University, Thailand
Or. Derek H. Lister
page 10 - 16
Temperature and pH dependence for single-phase E-C of CS ...
pH9.05
A pH9.3
3.0 ." pH 9.5
pH9.65
-
c:
Ql
c:
o
Do
2.0
-
c:
Ql
'0
o
..
Q)
'iii
c:
Ol
F 1.0
::l
Ol
:::!
O

120 140
80 100
Temperature C
Effect of temperature on the
exponent of the mass transfer
coefficient for the erosion-
corrosion of carbon steel in
flowing water at various pHs.
Chula/ongkom University, Thailand
Dr. Derek H. Lister
page 10 - 17
Prevention of Erosion-Corrosic
design (avoid impingemt. 'eOI .. ..::LI ",3, high velocity, etc.);
chemistry (e.g., in steam supply systems ... for CS or low-alloy steel
add O
2
, maintain pH > 9.2, use morpholine rather than NH
3
);
materials (use Cr-containing steels);
use hard, corrosion-resistant coatings.
NOTE:
Cavitation damaMsimilar effect
to E-C: mechanical removal of
oxide film caused by collapsing
vapour bubbles.
- r, ....
,. - "
(l)
\
. .. \
,'.
2
3
1
-.
(11'

,
5
6
4
Schematic repre::tcntalion of steps in cavitation.
High-speed pressure oscillations (pumps, etc.) can create shock waves
> 60,000 psi. Surface attack often resembles closely-spaced pitting.
Universify of New Brunswick, Canada Chulalongkorn Universify, Thal1and
Dr. Derek H. Uster
page 10 - 18
FRETTING CORROSION
Similar to E-C but surface mechanical action provided by wear of another
surface . .. generally intermittent, low-amplitude rubbing.
Two theories . .. with same overall result . ..
8efore

weld
After
-c- :J

point .
Oxidized
porticles
Schematic illustration of the wear-oxidation theory of fretting corrosion.
Olide
10yerS
8efore
ElPOSed
metol
Schematic illustration of the oxidation-wear theory offrelling corrosion.
Chula/ongkorn University, Thailand
Dr. Derek H. Lister
page 10 -19
Effects in terms of materials COMBINATIONS
Fretting resistance of various materials
Poor Average Good \
Aluminum on cast iron Cast iron on cast iron Laminated plastic on gold plate
Aluminum on stainless steel Copper on cast iron Hard tool steel on tool steel
Magnesium on cast Iron Brass on cast iron Cold-rolled steel on cOld- rolled
Cast Iron on chrome plate Zinc on cast iron steel
Laminated plastic on cast Iron Cast iron on silver plate Cast iron on cast Iron with
Bakelite on cast iron Cast iron on silver plate phosphate coating
Hard tool steel on stainless Cast iron on amalgamated Cast iron on cast iron with
Chrome plate on chrome plate copper plate coating of rubber cement
Cast Iron on tin plate Cast iron on cast iron with Cast iron on cast iron with
Cast iron on cast iron with rough surface coating of tungsten sulfide
coating of shellac Magnesium on copper plate Cast iron on cast iron with rubber
Zirconium on zirconium gasket
Cast iron on cast iron with
Molykote lubricant
Cast iron on stainless with
Molykote lubricant
Source: J.R. McDowell, ASTM Special Tech. Pub. No. 144, p. 24, Philadelphia, 1952.
Prevent fretting corrosion...
- lubricate;
- avoid relative motion (add packing, etc.);
- increase relative motion to reduce attack severity;
- select materials (e.g., choose harder component).
University of New Brunswick, Canada Chulalongkorn University, Thailand

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Corrosion for Engineers

Dr. Derek H. Uster

Effects of temperature and dissolved O

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