Mitigating Localized Corrosion Using Thermally Sprayed Aluminum (TSA) Coatings on Welded 25% Cr Superduplex Stainless Steel

Paul, Shiladitya; Lu, Quanbin; Harvey, M. D. F.

doi:10.1007/s11666-015-0224-4

Cited by 10 publications

(10 citation statements)

References 1 publication

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“…The synthetic seawater used for the test was replaced once a week. The pH was not monitored as previous work suggested that weekly replenishment would be sufficient to keep the bulk pH to 8.0 ± 0.2 [6,21,35]. After completion of the 30-day exposure, the specimens were removed from the seawater tank.…”

Section: Exposure Testsmentioning

confidence: 99%

“…In addition, these coatings also act as a barrier when intact. If these coatings are damaged in service, the proximity of the anodic coating allows the steel in the damaged region to remain cathodically polarized and hence protected as long as a layer of electrolyte (seawater) is present [20][21][22][23][24][25]. The cathodic polarisation of steel in the damaged region also results in the localised increase in pH.…”

Section: Introductionmentioning

confidence: 99%

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Hydrogen in Aluminium-Coated Steels Exposed to Synthetic Seawater

Paul

2020

Surfaces

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Thermally sprayed aluminium (TSA) coatings provide protection to offshore steel structures without the use of external cathodic protection (CP) systems. These coatings provide sacrificial protection in the same way as a galvanic anode, and thus hydrogen embrittlement (HE) becomes a major concern with the use of high strength steels. The effect of TSA on the HE of steel seems to remain largely unknown. Further, the location of hydrogen in TSA-coated steel has not been explored. To address the above knowledge gap, API 5L X80 and AISI 4137 steel coupons, with and without TSA, were prepared and the amount of hydrogen present in these steels when cathodically polarised to −1.1 V (Ag/AgCl) for 30 days in synthetic seawater was determined. One set of TSA-coated specimens was left at open circuit potential (OCP). The study indicates that the amount of hydrogen present in TSA-coated steel is ~100 times more than the amount found in uncoated steel, and that the hydrogen seems to be largely localised in the TSA layer.

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Section: Exposure Testsmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Hydrogen in Aluminium-Coated Steels Exposed to Synthetic Seawater

Paul

2020

Surfaces

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“…More recently, the use of TSA on stainless steels to prevent galvanic corrosion of nearby carbon steels or to protect stainless steels like 22%Cr duplex or 25%Cr super duplex stainless steels from hydrogen stress cracking (HSC) from CP‐systems or chloride stress corrosion cracking (SCC) have been investigated . TSA has also been used to protect duplex stainless steels from localized corrosion like crevice corrosion or pitting in atmospheric conditions or under insulation. The consensus is that TSA can be used to mitigate localized corrosion and SCC, but will, if anything, increase the probability of HSC.…”

Section: Introductionmentioning

confidence: 99%

Properties of TSA in natural seawater at ambient and elevated temperature

Wilson

Johnsen

Torres

et al. 2018

Materials & Corrosion

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Electrochemical properties of thermal sprayed aluminium (TSA) coating were investigated in natural seawater at elevated temperatures with and without cathodic protection (CP). TSA has a low current density requirement when connected to a CP system, regardless of temperature. The corrosion rates for TSA were found to be low both under CP and at open circuit potential at temperatures in the range 20–90 °C. However, measurements of the TSA coating thickness before and after exposure indicate there might be chemical dissolution of the coating. However, this has not been reported anywhere else in the literature, so more data is necessary to conclude. Post exposure analysis indicated calcareous deposits on the TSA exposed for up to 280 days. In SEM small amounts were found, and the type of deposits were dependent on temperature, with the deposits being more based on Mg at higher temperatures.

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“…However, welded structures will always be high-risk areas for the occurrence of corrosion crack in the sea and source of corrosion failure of marine steel structures [5][6][7][8]. With international investment increasing in marine projects, corrosion protection of welded structures in the marine environment has been a focus of research [9][10][11][12].…”

Section: Introductionmentioning

confidence: 99%

“…In marine environments, embalmment of welded structures is usually done by smearing marine anticorrosive coating [11,[13][14][15]. However, absorption and osmosis of corrosion factor (Cl − ) still enable it to penetrate protective coating, leading to the generation of corrosion couple on metal surface and coating failure [16,17].…”

Section: Introductionmentioning

confidence: 99%

Corrosion Crack Nucleation Mechanism in the Welded Structures of X65 Steel in Natural Seawater

Bai

Gao

Jiang

2018

Advances in Materials Science and Engineering

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The nucleation mechanism of corrosion cracks in welded structures in natural seawater has been revealed through investigation on the corrosion behavior of X65-welded structures in natural seawater. The evolution laws of surface corrosion morphology, residual stress, and areas of welded structures with the most serious corrosion damage were analyzed by microstructure observation, corrosion morphology observation, residual stress detection, and magnetic field detection. The results show that the main factors of determining surface corrosion morphology evolution law of welded structures are microstructures of the weld joint, heat-affected zone (HAZ), and the fusion line. Due to the difference of corrosion rates between the weld joint, HAZ, and the coarse Widmänstatten structure in fusion line, the fusion line of welded structures receives the most serious damage while being corroded. Meanwhile, mutual reinforcement of residual stress and corrosion damage on the surface of welded structures further accelerate the nucleation of corrosion cracks. Under the influences of microstructure, residual stress, and corrosion, corrosion cracks that are parallel to weld joints generate first in the fusion line of welded structures. Therefore, it makes welded structures the source of marine steel structures’ corrosion failure.

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Mitigating Localized Corrosion Using Thermally Sprayed Aluminum (TSA) Coatings on Welded 25% Cr Superduplex Stainless Steel

Cited by 10 publications

References 1 publication

Hydrogen in Aluminium-Coated Steels Exposed to Synthetic Seawater

Hydrogen in Aluminium-Coated Steels Exposed to Synthetic Seawater

Properties of TSA in natural seawater at ambient and elevated temperature

Corrosion Crack Nucleation Mechanism in the Welded Structures of X65 Steel in Natural Seawater

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