Advanced Coatings for Wear and Corrosion Protection: Session I
Program Organizers: Evelina Vogli, Flame Spray Inc.; Virendra Singh, Schlumberger
Monday 8:00 AM
October 18, 2021
Room: A220
Location: Greater Columbus Convention Center
Session Chair: Virendra Singh, Schlumberger
8:00 AM
New Multidisciplinary Approach for Investigating Hot Corrosion Behavior in Thermal Barrier Coatings: Guanlin Lyu1; JunSeong Kim1; SeungCheol Yang1; Yeon-Gil Jung1; 1Changwon National University
A new multidisciplinary approach for investigating the corrosion behavior of thermal barrier coatings has been proposed, combining the thermo-gradient mechanical fatigue (TGMF) method with hot corrosion tests. Corrosive salts (Na2SO4; V2O5) of varying concentrations (10–20 mg/cm2) were deposited on the surface of YSZ coating to evaluate the microstructural change during the reaction, via TGMF tests. The tests were conducted at a surface temperature of 1150 °C in 10 min cycles with uniaxial tensile loads of 60 and 100 MPa. It was verified that the corrosion byproduct, ZrV2O7, plays an important role as an intermediate in the collapse of lamellar structures during the reaction, which resulted from the repetitive precipitation of V2O5 and m-ZrO2 from ZrV2O7. The microstructure of corroded YSZ coating exhibited a different degradation mechanism under a thermomechanical environment, compared with the testing under an isothermal atmospheric condition.
8:20 AM
Aerosol Cold Spray Technology for Ceramic and Metal Coating Deposition: Volf Leshchynsky1; Gregorz Kubicki2; Joanna Chojnacka2; Ahmed Elseddawy1; Roman Maev1; 1IDIR; 2Lukasiewicz- INOP
Aerosol deposition (AD) is modification of low-pressure cold spray technology which allows to deposit ceramic and metal based coatings. AD technology in vacuum possesses the formation of films from sub-micro and nanoparticles directly at room temperature. The AD technology is still under development to cover more application and discover solutions of spraying different kind of powders on different types of material substrate and optimizing spraying conditions to obtain the best results. The main objective of the present work is to develop a new AD cold spray technology of Hydroxyapatite (HA) and Copper powder deposition onto both the implants and ceramic substrates. The new AD spraying system with radial injection of particles being deposited is constructed and tried. An influence of technology parameters on the coating structure and properties will be presented. In addition, the combined cold spray- sintering technology technique is further investigated for additive manufacturing applications.
8:40 AM
Now On-Demand Only - Combinatorial PVD Coatings on SiC-SiC for Boiling Water Reactor Conditions: Ryan Schoell1; Joey Kabel2; Sebastian Lam3; Amit Sharma4; Petho Laszlo4; Peter Hosemann3; Djamel Kaoumi1; 1North Carolina State University; 2University of California Berkeley ; 3University of California Berkeley; 4Empa
A combinatorial physical vapor deposition system was used to create 1 µm coatings on SiC samples with various compositions of chromium, zirconium, and titanium. Four samples within the ternary diagram were made to test the corrosion resistance of the coatings in simulated boiling water reactor conditions (288 °C and 1100 psi with 2 ppm of dissolved oxygen). Weight changes were tracked with a high precision balance while microstructure characterization was conducted on Focused Ion Beam (FIB) samples under Transmission Electron Microscopy (TEM). Initial TEM showed the coating to be initially amorphous in its as-received state. Sample weight was monitored through several 7-day corrosion cycles. Whether weight gain or loss was observed depended on the composition. Post experiment TEM revealed changes in the coating microstructure with oxide build up. The relative corrosion resistance is discussed in terms of composition, phases formed and microstructure of the coating.
9:00 AM
Now On-Demand Only - Amorphous Based PTA Weldings for Icy Surfaces: Evelina Vogli1; Liang Hong2; Yan Chen2; John Kang1; Rick Salas1; 1LM Group Holdings Inc.; 2Texas A&M University
Prior developed and actually used drill bits have limited application under icy and severe conditions. LM Group Holdings, Inc. has developed and applied with Plasma Transferred Arc (PTA) proprietary innovative amorphous metallic alloy coatings that are able to withstand the severe corrosive environment. Amorphous alloys and amorphous-based alloys, on the other hand, have the potential to bring a paradigm shift in materials science and enable components to reach their peak design performance. Amorphous-based alloys combine a weight saving design with high wear and low friction properties to get a new concept for drilling bits for extreme environments. Amorphous metals are a novel class of materials that have a disordered, non-crystalline, glassy structure. Due to their unique microstructure, amorphous metals combine ultrahigh strength, high hardness and ductility in one single material. Amorphous Metals are more corrosion resistant compared to conventional metals due to the lack of long-range periodicity, related grain boundaries and crystal defects such as dislocations.This presentation will highlight amorphous-based alloys applied by PTA, which have been tested at Texas A&M University regarding wear resistance and friction under cryogenic conditions.
9:20 AM
The Environmental Performance of Nitrided Corrosion Resistance Alloys in a Water – Glycol Hydraulic Fluid: Virendra Singh1; Manuel Marya1; 1Schlumberger
Water - glycol fluids are used for the hydraulic power control of subsea, downhole valves, and for the preservation of oilfield mechanical parts. These fluids have been designed to provide good compatibility with low-alloy steels and common corrosion-resistant alloys, but their effects on corrosion is unclear after surface diffusion treatments, especially on stainless steel and nickel-based alloys. In this investigation, surface modification by nitrocarburizing is applied on martensitic grade of stainless steels (13Cr, S13Cr and 17-4PH) and Ni-based alloys (935, 925, 718, 625+), with goals to establish the environmental performance of these alloys in clean and seawater-contaminated hydraulic fluids. Crevice corrosion immersion tests and electrochemical polarization technique are complementarily used to measure the environmental performance of these alloys, the effects of the surface treatments, and establish widely accepted yet incompletely documented industry practices.
9:40 AM
Properties of Ni-P-ZrC Nanocomposite Coatings for Corrosion Protection in the Oil and Gas Industry: Abdul Shakoor1; Osama Fayyaz1; Ahmed Radwan1; Anwarul Hasan1; Mostafa Sleim1; Aboubakr Abdullah1; 1Qatar University
Corrosion is the main cause for material deterioration and failure in oil and gas industry. Nickel phosphorus-based coatings are proven to be corrosion resistant but lack the mechanical strength. Incorporating second phase elements in the Ni-P matrix to improve its properties are extensively researched around the globe. In this study, hard and inert zirconium carbide nanoparticles (ZCNPs) are deposited in Ni-P matrix through electrodeposition process from Watts bath to obtain nanocomposite coatings. XRD proves the amorphous structure of nanocomposite coating. XPS and EDS confirms the presence of ZCNPs in the Ni-P matrix. Addition of ZCNPs has major impact on mechanical and corrosion resistant of Ni-P matrix which can be attributed to dispersion hardening and reduction in the active region for corrosion initiation. Ni-P-ZrC nanocomposite coatings offer a very promising alternative for the use of different kinds of application in aerospace, automotive, oil & gas industries.
10:00 AM Break
10:20 AM
Effects of Laser Remediation Treatments on Environmentally-assisted Cracking of 5xxx Aluminum Alloys and Ship Plates: Yang Liu1; Benjamin Palmer1; John Lewandowski1; 1Case Western Reserve University
5xxx series Al-Mg alloys are solid solution strengthened by Mg and used in a variety of applications due to their good strength, weldability and corrosion resistance. However, thermal exposures at sufficient time/temperature combinations may sensitize the material to corrosion and/or environmentally-assisted cracking (EAC) via the precipitation of Mg-rich phases at grain boundaries. In this work, the effects of sensitization treatments and changes in laser surface remediation treatments (e.g. power, speed) on EAC have been determined for laboratory-sensitized and service-sensitized 5xxx ship plates. Fracture experiments were conducted in 0.6M NaCl on both sensitized and laser remediated materials. The changes in crack growth response due to sensitization/laser remediation will be presented along with SEM fractography.
10:40 AM
Investigations on the Effect of Open Atmosphere Laser-nitriding on Surface Mechanical and Elevated Temperature Fretting Wear Properties of A356-Alloy: Achyuth Kulkarni1; Palani I.A.1; Jayaprakash Murugesan1; 1IIT Indore
Fretting wear was found to be one of the major problems encountered in automobile engine components. Therefore, to improve the surface characteristics of the Al alloys, laser nitriding was discovered as one of the efficient techniques. But this process requires a nitriding chamber, which restrains the viability in industrial applications, which includes large and intricate shapes. To mitigate this, in this research, laser nitriding was performed in an open atmosphere using a third harmonic (355nm) Nd+3: YAG laser accompanying liquid N2 gas purging. The AlN layer formed was confirmed using GI-XRD and EDS analysis. The effect of process parameters, for instance, gas flow rate (L/min) on the average roughness (Ra), hardness, and elevated temperature (250 ̊C) fretting wear performance were investigated in detail.