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Research Papers: Friction and Wear

Effect of Prehot Corrosion on Erosion Behavior of High Chromium Ferritic Steel for Heat Exchangers

[+] Author and Article Information
Ankitendran Mishra

Department of Metallurgical Engineering,
Indian Institute of Technology (B.H.U.),
Varanasi 221005, India
e-mail: ankitendranm.rs.met15@iitbhu.ac.in

Dhananjay Pradhan, C. K. Behera, S. Mohan

Department of Metallurgical Engineering
Indian Institute of Technology (B.H.U.),
Varanasi 221005, India

A. Mohan

Department of Physics,
Indian Institute of Technology (B.H.U.),
Varanasi 221005, India

1Corresponding author.

Contributed by the Tribology Division of ASME for publication in the JOURNAL OF TRIBOLOGY. Manuscript received October 3, 2018; final manuscript received December 15, 2018; published online January 25, 2019. Assoc. Editor: Yi Zhu.

J. Tribol 141(4), 041607 (Jan 25, 2019) (9 pages) Paper No: TRIB-18-1411; doi: 10.1115/1.4042391 History: Received October 03, 2018; Revised December 15, 2018

This study presents the prehot corrosion effect on erosion behavior of AISI 446 SS in simulated heat exchanger environment at elevated temperature. Samples were spray deposited using two salt mixture (Na2SO4/NaCl). Subsequently, low-temperature hot corrosion tests were carried out at 550, 650, and 750 °C for 20 h. Chlorination followed by sulfidation was mainly responsible for the passive layer formation during the process of hot corrosion. The prehot corroded samples were subjected to air-jet erosion test using alumina as the erodent, at impact velocity of 100 m/s and flux rate of 4.2 g/min, with variable impingement angles of 30 deg, 60 deg, and 90 deg. The passive layer formed during corrosion underwent detachment of metallic flakes through cracking during the impact of erodent, and was responsible for a significant change in erosion rate. Cutting, plowing, lip formation, and particle embedment were identified as the operative mechanisms during erosion.

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Figures

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Fig. 1

Microstructure of as received AISI 446 (a) optical micrograph and (b) SEM micrograph

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Fig. 2

Macrograph of hot corroded samples for 20 h at (a) 550 °C, (b) 650 °C, and (c) 750 °C

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Fig. 3

Weight gain per unit area versus temperature showing the effect of hot corrosion at 550,650 and 750 °C for 20 h in air

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Fig. 4

SEM micrograph of cross section of hot corroded samples showing the effect of diffusion of corrosive species at (a) 750 °C, (b) 650 °C, and (c) 550 °C

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Fig. 5

XRD pattern of the oxides formed during hot corrosion of salt mixture coated sample in air for 20 h under variable temperature

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Fig. 6

SEM/EDX showing morphology and concentration of different elements of salt mixture deposited sample exposed at 550 °C for 20 h

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Fig. 7

SEM/EDX showing morphology and concentration of different elements of salt mixture deposited sample exposed at 650 °C for 20 h

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Fig. 8

SEM/EDX showing morphology and concentration of different elements of salt mixture deposited sample exposed at 750 °C for 20 h

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Fig. 9

Secondary electron X-ray mapping of cross section of the two salt mixture deposited sample exposed at 750 °C for 20 h, focusing the elemental distribution (a) cross section, (b) iron, (c) chromium, and (d) oxygen

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Fig. 10

Secondary electron X-ray mapping of cross section of the two salt mixture deposited sample exposed at 650 °C for 20 h, focusing the elemental distribution (a) cross section, (b) iron, (c) chromium, and (d) oxygen

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Fig. 11

Plot of erosion rate versus impact angles for corroded-eroded samples at (a) 550 °C, (b) 650 °C, and (c) 750 °C

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Fig. 12

Erosion rate versus time graph of the sample at 30 deg impact angle

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Fig. 13

Annotated view of corroded–eroded surface at 90 deg impact angle at 750 °C

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Fig. 14

Annotated cross-sectional view of corroded–eroded surface at 90 deg impact angle at 750 °C

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Fig. 15

SEM micrograph showing the scar at 30 deg for (a) 650 °C and (b) 750 °C

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Fig. 16

SEM micrograph showing the scar at 60 deg for (a) 650 °C and (b) 750 °C

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Fig. 17

SEM micrograph showing the scar at 90 deg for (a) 650 °C and (b) 750 °C

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