Formation of Corrosion‐Resistant Thermal Diffusion Boride Coatings

Medvedovski, Eugene

doi:10.1002/adem.201500102

Cited by 41 publications

(56 citation statements)

References 72 publications

Supporting

Mentioning

Contrasting

Order By: Relevance

“…Their structures, thicknesses, and compositions are defined by the initial (starting) mix compositions, chemistry, and other features of the substrate materials and the process parameters such as temperature, exposure time, gas pressure, and others. As an example of the thermal diffusion process and coating formation, the boronizing process employed by Endurance Technologies Inc. (ETI) has been described in detail elsewhere [40,41]. This process significantly distinguishes from the thermal reactive carbide-based coatings that utilize a salt bath process.…”

mentioning

confidence: 99%

“…This process significantly distinguishes from the thermal reactive carbide-based coatings that utilize a salt bath process. The later process has been described in detail by Liu et al elsewhere [38].Numerous studies on the corrosion resistance of boronizing thermal diffusion coatings on steels have been conducted with respect to a variety of practical applications, particularly for oil and gas production, refinery, and power generation applications [40][41][42]. It was shown that the boronizing process provides enhanced corrosion resistance of steel components, especially for applications dealt with large-size complex shapes and long tubular components [40].…”

mentioning

confidence: 99%

“…The later process has been described in detail by Liu et al elsewhere [38].Numerous studies on the corrosion resistance of boronizing thermal diffusion coatings on steels have been conducted with respect to a variety of practical applications, particularly for oil and gas production, refinery, and power generation applications [40][41][42]. It was shown that the boronizing process provides enhanced corrosion resistance of steel components, especially for applications dealt with large-size complex shapes and long tubular components [40]. These coatings with thicknesses of 50-400 µm and uniform, dense "saw-tooth" structures (for carbon steels) demonstrated high wear and corrosion resistance in steam with hydrocarbons, carbonaceous gases (CO + CO 2 ), hydrogen sulfide (H 2 S), and chloride salts (NaCl and CaCl 2 ) at elevated pressures (14-28 MPa) and temperatures (200-300 • C) for long time exposure, as well as in the actual oil well corrosive conditions [41].…”

mentioning

confidence: 99%

See 2 more Smart Citations

Corrosion Resistance of Boronized, Aluminized, and Chromized Thermal Diffusion-Coated Steels in Simulated High-Temperature Recovery Boiler Conditions

et al. 2018

Self Cite

View full text Add to dashboard Cite

In this study, the high-temperature molten salt corrosion resistance of bare steels and steels with protective coatings, fabricated by thermal diffusion processes (boronizing, aluminizing and chromizing), were investigated and compared. Surface engineering through thermal diffusion can be used to fabricate protective coatings against corrosion, while alleviating issues around possible cracking and spallation that is typical for conventional thermal-sprayed coatings. In this regard, samples of low carbon steel and 316 stainless steel substrates were boronized, chromized, and aluminized through a proprietary thermal diffusion process, while some of the samples were further coated with additional thin oxide and non-oxide layers to create new surface architectures. In order to simulate the actual corrosion conditions in recovery boilers (e.g., from black liquor combustion), the surfaces of the samples sprayed with a modeling salt solution, were exposed to low-temperature (220 • C) and high-temperature (600 • C) environments. According to microstructural and X-ray diffraction (XRD) studies and results of hardness determination, the coatings with multilayered architectures, with and without additional oxide layers, showed successful resistance to corrosive attack over bare steels. In particular, the samples with boronized and chromized coatings successfully withstood low-temperature corrosive attack, and the samples with aluminized coatings successfully resisted both low-and high-temperature molten salt corrosive attacks. The results of this study conducted for the first time for the thermal diffusion coatings suggest that these coatings with the obtained architectures may be suitable for surface engineering of large-sized steel components and tubing required for recovery boilers and other production units for pulp and paper processing and power generation.2 of 36 materials and process features, low-melting temperature ash or smelt is produced. The produced smelt mainly consists of different salts, e.g., sodium and potassium chlorides, sulfates, and carbonates. At elevated temperatures, mostly greater than 500 • C, the aforementioned salts in certain combination likely become molten. In the presence of oxygen, the molten salts can be highly corrosive [2,3]. Combustion of the black liquor fuel also results in the formation of hot corrosive gases, such as SO 2 , CO 2 , Cl 2 , and some others [5].Generally, high-temperature black liquor corrosion occurs according to two main mechanisms, namely (i) high-temperature active oxidation and (ii) corrosion due to the formation of sulfidic and chlorine gasses and residual deposits of molten salts and their interaction with the steel surface [6]. In the former mechanism, which generally occurs in high temperatures (above 450 • C), the anions of the molten salt, such as chlorides (Cl − ), sulfates (SO 4 2− ) and sulfides (S 2− ), continuously diffuse into the oxide-metal interface and actively sustain the oxidation. On the other hand, in the latter mechanism, the presence of the an...

show abstract

mentioning

confidence: 99%

mentioning

confidence: 99%

mentioning

confidence: 99%

See 1 more Smart Citation

Corrosion Resistance of Boronized, Aluminized, and Chromized Thermal Diffusion-Coated Steels in Simulated High-Temperature Recovery Boiler Conditions

et al. 2018

Self Cite

View full text Add to dashboard Cite

show abstract

“…In this process, at high temperatures, gaseous boron species are formed within specially formulated mixes of certain inorganic powders, which include B-containing ingredients. Further, these B-rich species deposit onto the steel substrates, and finally boron atoms diffuse into the steel structure with consequent formation and growth of iron borides Fe 2 B and FeB on the steel surface [19][20][21][22][23][24][25]. Due to the diffusion nature, the boronizing process and, therefore, the structure and thickness of the formed iron boride coating (protective layer) can be managed by varying temperature and time, substrate surface preparation, by creation of the conditions favorable of the B formation in the gas phase and some other factors [21,22,24,25].…”

Section: Introductionmentioning

confidence: 99%

Influence of Boronizing on Steel Performance under Erosion-Abrasion-Corrosion Conditions Simulating Downhole Oil Production

Medvedovski¹,

Mendoza²,

Vargas³

2021

CMD

Self Cite

View full text Add to dashboard Cite

Downhole heavy oil production and oil sand processing are associated with severe damage and failures of production equipment components, e.g., production tubing and pumping systems, due to erosion-corrosion resulting in processing losses, production downtime, high maintenance and replacement cost. Protective coatings (layers) on the production components mostly fabricated from low-alloy steels can be applied to minimize these problems. In the present work, the performance of hard boronized coating on carbon steel obtained through the thermal diffusion process and consisted of two iron boride layers (FeB and Fe2B) was studied in synergistic erosion-abrasion-corrosion conditions simulating oil production environment in comparison with bare steel. Special wear testing equipment was designed and fabricated. In this testing, the inner surface of tubular sections was subjected to high velocity erosive flows of water-oil slurries containing silica sand and salts combined with rotating and oscillating motions of steel pony rods. Structural examination of the studied materials’ surfaces and their profilometry after wear testing were conducted. The iron boride coating demonstrated significantly higher performance in abrasion and erosion-abrasion-corrosion conditions compared to bare carbon steel due to its high hardness, high chemical inertness, dual-layer architecture and diffusion-induced bonding with the substrate. The boronized steel tubing and casing with inner surface protection can be effectively employed in the most critical operation conditions.

show abstract

“…In the first case, interstitial solid solutions are formed on a metal surface through atomic diffusion, such as the thermal spray coating [ 7 ]. In other case, new compounds are formed on the surface through the reaction of the diffused atoms and base metal, such as boronized coatings [ 8 ]. Compared with the thermal spray coating, the thermal diffusion boronized coating exhibits compact structure and higher coating hardness, along with superior erosion resistance [ 9 , 10 ].…”

Section: Introductionmentioning

confidence: 99%

Investigation of the Erosion Damage Mechanism and Erosion Prediction of Boronized Coatings at Elevated Temperatures

Cai

Wang

et al. 2020

Materials

View full text Add to dashboard Cite

In this study, the high temperature erosion mechanisms and damage characteristics of a boronized coating have been systematically studied by employing an improved high-temperature accelerated erosion test bench and impact contact theory analyses. Within the scope of the experimental parameters, the erosion rate of the boronized coating under the same erosion conditions was observed to be only one half to one-twelfth of the erosion rate of the substrate. Furthermore, the boronized coating was noted to be less sensitive to the speed of the erosion particles than the plastic substrate, thus, indicating superior and more stable erosion resistance than the base material. The boronized coating exhibited typical brittle fracture characteristics under impact by the high-speed particles. When the particle impact normal stress exceeded the critical stress for crack propagation owing to the coating defects, the surface and subsurface layers of the coating initially formed horizontal and vertical micro-cracks, followed by their gradual expansion and intersection. After destabilization, the brittle coating material was peeled layer-by-layer from the surface of the test piece. At the same incident speed, as the particle size was increased from 65 μm to 226 μm and 336 μm, the size (width) of the erosion cracks on the coating surface increased from 1 μm to 30 μm and 100 μm respectively. Correspondingly, the erosion damage thickness of the coating was enhanced from 15 μm to 50 μm and 100 μm. In the case of the quartz sand particle size exceeding 300 μm, the dual-phase boronized coating did not provide effective protection to the substrate. Furthermore, based on the elastoplastic fracture theory, a prediction model for the erosion weight loss of the boronized coatings within the effective thickness range has been proposed in this study.

show abstract

Formation of Corrosion‐Resistant Thermal Diffusion Boride Coatings

Cited by 41 publications

References 72 publications

Corrosion Resistance of Boronized, Aluminized, and Chromized Thermal Diffusion-Coated Steels in Simulated High-Temperature Recovery Boiler Conditions

Corrosion Resistance of Boronized, Aluminized, and Chromized Thermal Diffusion-Coated Steels in Simulated High-Temperature Recovery Boiler Conditions

Influence of Boronizing on Steel Performance under Erosion-Abrasion-Corrosion Conditions Simulating Downhole Oil Production

Investigation of the Erosion Damage Mechanism and Erosion Prediction of Boronized Coatings at Elevated Temperatures

Contact Info

Product

Resources

About