Cavitation erosion remains the primary cause of material degradation in fluid machinery components operating at high speed. Micro-jets/shock waves caused by implosion of bubbles on material surface results in significant material loss and premature failure of the components. The presence of corrosive medium further exuberates this effect, causing rapid degradation. Here, we demonstrate a novel pathway to control cavitation erosion-corrosion by tailoring the surface properties using submerged friction stir processing (FSP), a severe plastic deformation process. FSP parameters were varied over wide range of strain-rates to generate tailored microstructures. High strain-rate processing resulted in nearly single phase fine grained structure while low strain-rate processing resulted in phase transformation in addition to grain refinement. As-received and processed samples were subjected to ultrasonic cavitation in distilled water as well as in corrosive environment of 3.5\% NaCl solution. Individual roles of cavitation erosion, corrosion and their synergistic effects were analyzed. Depending on the microstructure, processed samples showed nearly 4–6 times higher cavitation erosion resistance compared to as-received alloy. Superior cavitation erosion-corrosion resistance of processed samples was attributed to surface strengthening, higher strain-hardening ability and quick passivation kinetics. The results of current study could be potentially transformative in designing robust materials for hydro-dynamic applications. © 2018 Elsevier B.V.

Harpreet Singh Grewal

Mechanical Engineering

(SoE) School of Engineering

Harpreet Singh

Selvam K.

Mandal P.

Fulltext

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Shiv Nadar University

Ultrasonics Sonochemistry

Here, an excellent cavitation erosion-corrosion resistance of stainless steel using a novel severe surface deformation technique, reciprocating friction processing (RFP) was demonstrated. The RFP treated stainless steel showed nano-grained, nano-twinned microstructure along with high dislocation density. The RFP treated steel significantly surpassed the performance of advanced structural materials including high entropy alloy (Al0.1CoCrFeNi) and complex concentrated alloy (SiC reinforced Al0.1CoCrFeNi), demonstrating the lowest cavitation erosion and cavitation erosion-corrosion rates for this class of materials. The RFP treated steel demonstrated outstanding corrosion behavior in 3.5\% NaCl solution as well. The unusual performance of RFP treated steel is attributed to its excellent mechanical strength and strong passivating behavior. © 2020 Elsevier B.V.

Wear

Cavitation erosion-corrosion resilient surfaces through reciprocating friction processing

Thermal spray coatings (TSCs) are widely utilized for limiting degradation of structural components. However, the performance of TSCs is significantly impaired by its inherent non-homogeneous microstructure, comprising of splat boundaries, porosities, secondary phase-formation, and elemental segregation. Herein, we report a simplistic approach for significantly enhancing the corrosion resistance of TSCs. Ni-Cr-5Al2O3 coatings were deposited on stainless steel using high-velocity oxy-fuel technique. The microstructure of as-sprayed coating showed significant inhomogeneities in the form of isolated splats and elemental segregation. The microstructure of developed coatings was modified using a novel processing technique, known as stationary friction processing (SFP). The SFP treatment resulted in complete refinement of coating microstructure with elimination of splat boundaries and pores along with elemental homogenization. The corrosion behavior of as-sprayed and SFP treated coating was evaluated in 3.5\% NaCl solution using potentiodynamic polarization and electrochemical impedance spectroscopy. The SFP treatment reduced the corrosion rate of as-sprayed coating by an order of magnitude. Long-time immersion studies showed continuously decreasing impedance of the as-sprayed coating due to the penetration of the electrolyte along the splat boundaries. In contrast, impedance for the SFP treated coating increased with the immersion time due to the removal of all microstructural defects. Copyright © 2020 American Chemical Society.

ACS Omega

Facile and Green Engineering Approach for Enhanced Corrosion Resistance of Ni-Cr-Al2O3Thermal Spray Coatings

Cavitation erosion is a huge problem in engineering structures working under hydrodynamic conditions. The synergistic effect of erosion and corrosion can aggravate the material removal by several orders of magnitude. Surface coatings are widely used to address material degradation by erosion–corrosion. However, non-homogenous microstructure and presence of defects leads to premature coating failure under erosion–corrosion conditions. Thus, it is imperative to identify plausible solutions to address cavitation-related material degradation. In this study, Ni-Cr-5Al2O3 coatings were deposited on stainless steel substrate using high-velocity-oxy-fuel technique. The as-sprayed coating showed highly non-homogeneous microstructure comprising splats, pores, intermetallic compounds and elemental segregation. A new thermo-mechanical processing technique, stationary friction processing (SFP), was utilized for achieving through-thickness microstructural refinement in as-sprayed coating. As-sprayed and SFP-treated coatings were tested in pure cavitation erosion, corrosion in 3.5\% NaCl solution and erosion–corrosion. SFP treatment resulted in 5-times enhancement in the erosion and corrosion resistance compared to as-sprayed coating. The remarkable performance of Ni-Cr-5Al2O3 coatings after SFP treatment is attributed to significant enhancement in the mechanical properties including hardness and fracture toughness which is the consequence of complete removal of splat boundaries, pores, intermetallic compounds and uniform element distribution up to the coating–substrate interface. © 2020, ASM International.

Journal of Thermal Spray Technology

Enhanced Cavitation Erosion–Corrosion Resistance of High-Velocity Oxy-Fuel-Sprayed Ni-Cr-Al2O3 Coatings Through Stationary Friction Processing

Friction stir processing of an Al0.1CoCrFeNi high entropy alloy (HEA) was performed at controlled cooling conditions (ambient and liquid submerged). Microstructural and mechanical characterization of the processed and as-cast HEAs was evaluated using electron backscat-ter diffraction, micro-hardness testing and nanoindentation. HEA under the submerged cooling condition showed elongated grains (10 µm) with fine equiaxed grains (2 µm) along the boundary compared to the coarser grain (∼2 mm) of as-cast HEA. The hardness showed remarkable improvements with four (submerged cooling condition) and three (ambient cooling condition) times that of as-cast HEA (HV ∼150). The enhanced hardness is attributed to the significant grain refinement in the processed HEAs. Cavitation erosion behavior was observed for samples using an ultrasonication method. All of the HEAs showed better cavitation erosion resistance than the stainless steel 316L. The sample processed under a submerged liquid condition showed approximately 20 and 2 times greater erosion resistance than stainless steel 316L and as-cast HEA, respectively. The enhanced erosion resistances of the processed HEAs correlate to their increased hardness, resistance to plasticity, and better yield strength than the as-cast HEA. The surface of the tested samples showed nucleation and pit growth, and plastic deformation of the material followed by fatigue-controlled disintegration as the primary material removal mechanism. © 2020, University of Science and Technology Beijing and Springer-Verlag GmbH Germany, part of Springer Nature.

International Journal of Minerals, Metallurgy and Materials

Enhanced cavitation erosion resistance of a friction stir processed high entropy alloy

In the current work we developed Ni-SiC based composite claddings on SS316L through microwave irradiation using different reinforcement weight fractions and particle sizes (micron to nano scale). A bimodal derivative using equal proportions of both micro and nano scale particles was also developed. Microstructural characterization showed claddings were composed of columnar structure with precipitated intermetallic phases segregated at the grain boundaries. The Ni-SiC bimodal particle reinforced claddings showed highest hardness and fracture toughness. All the developed claddings showed significantly high cavitation erosion resistance compared to SS316L steel. The Ni-10 wt\% SiC bimodal particle reinforcement cladding showed highest erosion resistance with around 5 times lower erosion rates than SS316L steel along with highest incubation period. The investigated bimodal particle reinforced cladding also outperformed the thermal sprayed WC10Co4Cr and Stellite 6 coatings and CA6NM hydroturbine steel used for comparison. Detailed structure-property correlation analysis showed that the exquisite performance of the investigated bimodal particle reinforcement cladding can be ascertained to high hardness and H/E ratio (inversely related with plasticity index). Compared to brittle failure mode exhibited by thermal spray coatings due to splat delamination, the Ni-SiC claddings showed mixed signatures of both ductile and brittle failure modes. Examination of the eroded surfaces of the claddings showed presence of significant number of micro pits surrounded by extruded lips and dislodged intracellular phase. Detailed SEM analysis of the samples near incubation period showed damage accumulation initiated around these intermetallic phases in the form of cracks and pits. It was shown that Ni-SiC based microwave-derived bimodal particle reinforced claddings are an effective and efficient solution for countering the cavitation induced erosion in fluid machinery. © 2019 Elsevier B.V.

Microwave synthesized composite claddings with enhanced cavitation erosion resistance

Cavitation erosion and corrosion of structural materials are serious concerns for marine and offshore industries. Durability and performance of marine components are severely impaired due to degradation from erosion and corrosion. Utilization of advanced structural materials can play a vital role in limiting such degradation. High entropy alloys (HEAs) are a relatively new class of advanced structural materials with exceptional properties. In the present work, we report on the cavitation erosion behavior of Al0.1CoCrFeNi HEA in two different media: distilled water with and without 3.5 wt\% NaCl. For comparison, conventionally used stainless steel SS316L was also evaluated in identical test conditions. Despite lower hardness and yield strength, the HEA showed significantly longer incubation period and lower erosion-corrosion rate (nearly 1/4th) compared to SS316L steel. Enhanced erosion resistance of HEA was attributed to its high work-hardening behavior and stable passivation film on the surface. The Al0.1CoCrFeNi HEA showed lower corrosion current density, high pitting resistance and protection potential compared to SS316L steel. Further, HEA showed no evidence of intergranular corrosion likely due to the absence of secondary precipitates. Although, the degradation mechanisms (formation of pits and fatigue cracks) were similar for both the materials, the damage severity was found to be much higher for SS316L steel compared to HEA. © 2017 Elsevier B.V.

Exceptionally high cavitation erosion and corrosion resistance of a high entropy alloy

Erosion-corrosion is a critical problem in marine components and has huge economic impact. In the current study, friction stir processing was utilized for enhancing the erosion-corrosion resistance of SS316L steel, most widely used material for marine applications. Compared to the unprocessed alloy, the friction-stir processed specimen showed nearly 3.5 times and 5 times higher erosion and erosion-corrosion resistance respectively at oblique impingement. In contrast, erosion and erosion-corrosion resistance for processed alloy was 2 times higher at normal impingement. The unusual enhancement in erosion-corrosion resistance was attributed to surface strengthening through grain-size refinement and martensite phase formation. In addition, higher corrosion resistance due to stronger passivation also contributed towards superior performance of the processed alloy. © 2017 Elsevier B.V.

Enhancing the erosion-corrosion resistance of steel through friction stir processing

Marine and off-shore components including propellers, pumps, valves, pipelines and other submerged surfaces are subjected to severe degradation by erosion. Impingement of solid particles mixed in a liquid, referred as slurry, leads to significant material loss and shortens the life span of components. Tailoring the surface properties of materials is an economical way for addressing their degradation. Surface modification through high strain-rate deformation is widely used to enhance functional properties of materials. However, surface modification, particularly at low temperature, is extremely challenging for high strength materials such as stainless steel and has not been investigated comprehensively so far. In the present work, high strain-rate deformation of austenitic steel, SS316L, was performed by innovative submerged friction stir processing technique. For comparative studies, friction stir processing was also performed under ambient cooling conditions. Electron back scatter diffraction studies showed significant grain refinement for the sample processed under submerged conditions. The erosion behavior of as-received and processed steel was investigated using slurry erosion tests. Erosion tests were performed at constant impact velocity of 20 m/s and particle size, while varying the impingement angles. The sample processed under submerged conditions showed nearly two times higher erosion resistance compared to as-received steel. The enhancement in erosion resistance is explained using structural rejuvenation achieved at high strain-rate deformation. All the samples showed similar erosion mechanisms with micro-cutting and ploughing being evident at acute angles and platelet mechanism at normal impingement angle. Erosion phenomena showed a strong correlation with material's hardness at oblique impingement angle while, erosion behavior at normal impingement is explained by the flow work given as hardness to elastic modulus ratio. The study provides fundamental insights into material design for advanced structural applications. © 2017 Elsevier B.V.