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A. R. Hemmati
Centre of Excellence for High Strength Alloys Technology, School of Metallurgy and
Materials Engineering, Iran University of Science and Technology, Narmak, Tehran
16844, Iran
Alireza_Hemmati.1990@yahoo.com
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M. Soltanieh1
Centre of Excellence for High Strength Alloys Technology, School of Metallurgy and
Materials Engineering, Iran University of Science and Technology, Narmak, Tehran
16844, Iran
Email Address: Mansour_Soltanieh@iust.ac.ir
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S.M. Masoudpanah
Centre of Excellence for High Strength Alloys Technology, School of Metallurgy and
Materials Engineering, Iran University of Science and Technology, Narmak, Tehran
16844, Iran
Masoodpanah@iust.ac.ir
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ABSTRACT
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In this study, the effect of flow velocity (4-7.5 m s-1) and impact angle (30-90o) on erosion-corrosion
behavior of chromium carbide coating was investigated under impingement by silica containing NaCl
solution. Chromium carbide coating was deposited on low carbon steel by thermal reactive
deposition/diffusion method at 1050oC for 12 hours in a molten salt bath. Mass loss measurement and
potentiodynamic polarization tests were employed in order to determine coating performance under
impingement. Polarization curves showed that the coated samples had less corrosion current density and
high chemical stability. High mass loss at low impact angle indicated ductile behavior for the uncoated
sample, while the mass loss for the coated sample changes less than 30% with impact angle up to 60o.
Furthermore, the erosion-corrosion behavior of the coated sample was slightly dependent on flow velocity.
Scanning electron micrographs showed that at lower impact angle, the Cr 7C3 coating eroded with flake
fragmentation mechanism, while at high impact angle, fatigue fracture is the main degradation
mechanism.
Keywords: Erosion-corrosion, chromium carbide, flow velocity, impact angle.
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1- INTRODUCTION
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particles and liquid droplet [1]. Since there is an interaction between erosion and
corrosion, the total material loss due to erosion-corrosion is much greater than the sum
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of the pure erosion and the pure corrosion, individually [2]. There are three different
parameters affecting the erosion-corrosion behavior, namely, sample material
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temperature), and eroding particle features (such as mass, hardness, density, size,
shape) [3]. The erosion-corrosion damage is strongly influenced by the impact angle and
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flow velocity. The impact angle controls stress distribution originating from impacting
particles on metals surface, which affects the damage mechanisms. Moreover, particles
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impact transfer kinetic energy on the surface. This energy directly related to flow
velocity and particle size. There is a threshold impact kinetic energy that breaks the
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metal/alloy surface [4, 5, 11-14]. Hard coatings can withstand the mechanical damage
during impacts of eroding particles. The hard coating are usually carbides, nitrides,
carbo-nitrides, and borides which exhibit high chemical stability in corrosion
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found in oil production systems, hydroelectric power plants, paper and mining
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industries and desalinization plants [16]. This is because they offer high hardness, good
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by high velocity oxy-fuel [19], air plasma spraying [20], and thermo-reactive
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deposition/diffusion (TRD) process [21]. Espallargas et al. [16] compared the erosioncorrosion behavior of Cr3C2 and WC deposited by high velocity oxy-fuel. The chromium
carbide coatings have better performance against erosive conditions. This is because
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[20, 22]. Although there are many literature on the erosion and corrosion performance
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of chromium carbide coating, the erosion-corrosion behavior of this coating was not
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investigated. However, Cr-C coating as well as chromium carbide based cermet were
studied previously [6, 16, 18].
Wear by abrasion is a form of wear caused by contact between a particle and solid material. Abrasive
wear is the loss of material by the passage of hard particles over a surface.
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The aim of this work was to study the effect of environment conditions including
impact angle and flow velocity on the performance of chromium carbide coating under
erosion-corrosion condition. To this end, a layer of chromium carbide coating was
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deposited on carbon steel by TRD method. Mass loss measurement was conducted in
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order to determine the effects of impact angle and flow velocity. SEM studies were
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under impingement. Polarization curves have shown the better corrosion behavior of
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2. Experimental Procedure
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A low carbon steel with 0.30 wt. %C, 0.12 wt. % Si, 0.50 wt. % Mn, and 0.14 wt. %
Cr was used as the substrate. Disc type samples with a 25 mm in diameter and a
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thickness of 10 mm were ground with grid abrasive paper. A molten salt bath method
for TRD treatment used in this research. To this end, 85 wt. % borax and 15 wt. % low
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carbon Ferro chromium were used as molten salt bath. Then, the samples were
immersed in molten salt at 1050oC for 12 hours followed by air cooling.
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(HUVITZ). X-ray diffraction (XRD) analysis of chromium carbide coating was carried out
by using an X-ray diffractometer (Philips-PW1800) with copper K radiation. The microhardness of the coating was measured on the cross-section of chromium carbide coating
using a micro-hardness tester (SCTMC-MHV-1000z). The micro-hardness number were
average of three measurements in similar area to have reliable results.
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The erosion-corrosion tests were carried out using an impingement jet apparatus
as shown in Fig. 1. A jet of 3.5 wt. % NaCl solution containing 3 wt. % SiO2 sand particles
from a nozzle with 5 mm in diameter was impacted to the sample surfaces. The SiO 2
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particle size was between 100 and 200 standard mesh. In order to ensure that all
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corrosion measurement are related to the erosion-corrosion process only, all the sample
surfaces were covered by sticky tapes except a circle with 0.2 cm2 surface area. So, in all
of the calculation, the sample surface was considered as 0.2 cm2. The distance between
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jet nozzle impact and surface was kept at 5 mm. Before the test, the samples were
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degreased by alcohol, washed in distilled water and dried in air. The test was carried out
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in 3 hours and after that, the samples were degreased, rinsed, dried and weighted using
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A , where Q, is the flow rate (m3 s-1) and A, is the nozzle
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an analytical balance (Shimadzu-ATX 224) with an accuracy of 0.1 mg. The flow velocity
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surface area (m2). At normal impact angle, the fluid velocity was chosen as 4, 5, 6 and
7.5 m s-1. Furthermore, the impact angles of 30o, 45o and 60o were also used at constant
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polarization data were measured through sweeping the potential in a positive direction
from -900 to 600 mV at a sweep rate of 1 mV s-1 during the test in room temperature.
3. Results and discussion
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The optical microscopy and the cross sectional micro hardness profile of the
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coated sample are presented in Fig. 2. It is observed that two separate layer formed on
steel surface after TRD treatment. The micro hardness decreases gradually from 1380 to
300 HV0.01. In TRD process, when a chromium carbide layer is formed on the steel
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sample by the salt bath method, three stages must occur: First, chromium must be
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transferred from the chromium-containing bath to the steel sample surface. Second,
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carbon must be provided from the surface layer or interior one. In this Situation, the
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needed carbon must diffuse from the bulk of sample to its surface (once carbide layer is
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produced on the sample surface, carbon must, also, diffuse through it). Finally, the
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diffused carbon must react with the coming chromium from bath to from a stable
chromium carbide layer on the surface of the sample. The Cr concentration decreases
gradually from the surface to the sample depth. This leads to the formation of a layer
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with the higher micro hardness value in a range between 650-1000 HV0.01 which is
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higher than that of substrate. This is in agreement with other work [23, 24]. According
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to the micro hardness profile, the coating thickness is about 10-13 m. Moreover, X-ray
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diffraction pattern of the coated sample (Fig. 3) shows the formation of Cr7C3 carbide
[Joint Committee on Powder Diffraction Standards (JCPDS) card number: 00-011-0550].
Same results has been obtained in other investigation [25, 26] in which the common top
layer phases after TRD treatment are Cr7C3, Cr23C6, and Fe-Cr ferrite phases.
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the material [27]. Furthermore, the mass loss of the coated and the uncoated samples
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increases from 3.06 to 6.28 mg cm-2 hr-1 and from 4.58 to 9.85 mg cm-2 hr-1 with
increasing the flow velocity from 4 to 7.5 m s-1, respectively. The coated sample shows
less mass loss than that of the uncoated sample in the whole range of flow velocity. This
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indicates that although the dependence of mass loss on flow velocity for the coated and
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uncoated sample is similar, the latter shows higher resistance in comparison to the
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to higher hardness as well as better corrosion resistance of chromium carbide (Cr 7C3)
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coating [23].
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With increasing the flow velocity, SiO2 particles eroded the surface at an
increased rate, thus removing the passive oxide layer at a higher rate. From the
electrochemical data, it was concluded that highest improvement in pure corrosion rate
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after coating was about 41% at a flow velocity of 4 m s-1. At this flow velocity, the value
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of pure corrosion rate for uncoated sample was 3.56 mg cm-2 hr-1, while the coated
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sample suffers 2.03 mg cm-2 hr-1. On the other hand, at flow velocity of 7.5 m s-1, the
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pure corrosion rate for the coated and uncoated samples were almost equal.
Fig. 5 shows the potentiodynamic polarization curves of the uncoated and
coated samples at flow velocity of 5 m s-1. Looking at the both curve, for decreasing
potential, material starting with an anodic current on a thoroughly activated surface and
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then the samples pass through a potential where the cathodic and anodic reaction rates
are equal and the log curve shows a V at zero crossing. Then the samples experience
cathodic current on an activated surface. The absence of passive region for the samples
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indicate an active dissolution dominating the anodic behavior. These results are similar
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to the results of Stack et al [28]. The slow increase in current density with potential at
the potential range of 0-600 mV is rather similar to traditional passivation region. The
higher corrosion resistance of the coated sample can be attributed to the higher
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addition, increasing the flow velocity increases the oxygen transfer with fluid, hence it
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accelerate the formation of chromium oxide layer. This lead to a reduction in anodic
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current density, thus shifting the entire polarization curve to the left.
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Fig. 6 shows the mass loss of the coated and uncoated samples against impact
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angle. For all impact angles, the mass loss for the coated sample was lower than that of
the uncoated one. The mass loss of the uncoated sample increases with impact angle up
to 45o and then decreases, while the mass loss varies slightly for the coated sample. The
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maximum mass loss at impact angle of 45o can be attributed to the erosion-corrosion
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behavior of ductile material which experiencing maximum mass loss at shallow impact
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angle [13, 29]. The ductile materials are mostly subjected to abrasive wear by impact of
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hard eroding particles on the soft surface and failure with cutting action [30-32]. The
dependency of the erosion rate to impact angle varies by impact velocity. At impact
velocity lower than threshold impact velocity, the deformation erosion is negligible.
When particle velocity increases up to normal impact angle, the deformation
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mechanism become more dominated and changes the dependence of the erosion rate.
Arabnejad et al [32] believed that at all impact velocity, target material have not similar
performance at different impact angle. They proposed a model that it captured angle
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function variation with impact velocity and proved that this phenomena are only
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important at impact velocities which is higher than threshold impact velocity. However,
at higher impact angle, the flake formation resulting from impact of eroding particles it
is believed as the possible mechanism. In this situation, the repeated impact of eroding
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particles induce normal stress on surface. Once the stress exceed the elastic limit and
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The mass loss of the coated sample is not strongly dependent on impact angle.
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However, the mass loss increases slightly from 3.39 to 4.92 mg cm-2 hr-1 with impact
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impact angle.
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the Cr7C3 coating through the elimination of micro cracks propagation path at high
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impact angle of 45o are shown in Fig. 7. The higher corrosion potential (Ecorr) of Cr7C3
coating compared to the uncoated sample shows more nobility of the Cr7C3 coating in
erosion-corrosion condition. In addition, the erosion-corrosion performance of the
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coated sample after TRD treatment is better in comparison with the uncoated sample in
which the corrosion current density of the uncoated sample (7.37 10-4 A) is higher
than that of the coated sample (3.36 10-4 A).
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The SEM micrographs of the eroded surface of the coated sample at flow
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velocities of 6 and 7.5 m s-1 and at impact angle of 90o are depicted in Fig. 8. As can be
seen in Fig. 8, because of the erosion conditions, lots of erosion pits and subsurface
cracks formed in the sample surface. Inside some of the erosion pits, SiO2 particles are
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embedded, as shown in Fig. 8. Increasing the flow velocity, increased the number of pits
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and cracks. It is well known that the mass loss is due to the initiation and propagation of
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fatigue cracks. The hard and brittle Cr7C3 coating with high hardness (Fig. 3) resists
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against micro cutting and plastic deformation. Impact kinetic energy which transferred
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by eroding particles to surface results in aggregation of elastic strain energy and cracks
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nucleation in the brittle carbide grain of the coating. The cracks propagate by
continuously action of repeated impingement until the grain had been fragmented. This
is in agreement with other studies [34]. It is also observed that higher flow velocity
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causes deeper grooves in the surface leading to moderate increase in corrosion rate
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[35]. Eroding particles which have low flow velocity and subsequently low kinetic energy
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cannot directly fractured Cr7C3 coating. Elastic strain energy which transmitted to the
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toughness of the coating- can improve tribological performance of the coating [36].
Cr7C3 coating with high hardness (1400 HV) and elastic modulus (370 GPa) [37] shows
good resistance under erosive conditions. The higher impact energy resulting from
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eroding particles at high flow velocity, the more intensive cracking at both impact region
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Fig. 9 shows the SEM micrographs of the eroded surface of the coated sample at
impact angle of 60o and 90o at 5m s-1 flow velocity. As shown in Fig 9 (a), the erosion test
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done at impact angle of 90o causes some micro cracks in the erosion pits. Most
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probably, these micro cracks cause brittle fracture in coating layer. For chromium
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carbide coating, it can be suggested that subsurface lateral cracking is the main
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The repeated impacts of the erodent at impact angle of 60o (Fig 9 (b)), applies
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shear stress on the surface leading to the propagation of the micro cracks along the
impact direction. Moreover, the micro cracks increase material surface area subjected
to corrosion which enhances corrosion, which was stated by Stack et al [18]. High shear
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cracks which formed during particle impact. These cracks, then linked together leading
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to material removal by flake fragmentation. Levy et al [38] believed that during erosion-
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corrosion, a combined mechanism of ductile and brittle erosion failure occur, but
primarily the brittle behavior. He showed that cracking and chipping off a small pieces of
scales are the main erosion-corrosion failure mechanism of brittle coating. Since
chromium carbide coating is the corrosion-resistance coating, it has been suggested that
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4. Conclusions
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Chromium carbide coating was successfully deposited on low carbon steel using
thermal reactive deposition method. The effect of flow velocity and impact angle on
erosion-corrosion performance of the coated sample was investigated. The mass loss of
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the coated samples was slightly changed with the impact angle, on account of high
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hardness and corrosion resistance of the chromium carbide coating. As a results the
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chromium carbide coating was not sensitive to impact angle. On the other hand, the
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uncoated samples show the ductile behavior under erosion-corrosion condition. The
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ductile erosion behavior experience maximum mass loss at oblique angle. In addition,
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increasing the flow velocity lead to increase in mass loss change with gentle slope and
reach to a maximum at a flow velocity of 7.5 m s-1. This is because of high hardness of
coated samples, which resist against eroding particles kinetic energy. Microstructural
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observation showed that the higher impact energy at high flow velocity introduce may
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be deeper pits on surface. Inside the pits, embedded particles as well as subsurface
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cracks observed. This confirm a brittle fracture. Furthermore, shear stress at lower
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impact angle propagates cracks and forms flakes. During the erosion-corrosion test,
repeated impact of the eroding particles results in flake fragmentation.
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NOMENCLATURE
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(3) flow-controlled valve, (4) slurry container, (5) counter electrode, (6)
nozzle, (7) reference electrode, (8) holder, (9) sample, (10) potentiostat
Fig. 2
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Fig. 3
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Fig. 4
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Fig. 5
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Mass loss of uncoated and Cr7C3 coated samples at various impact angle
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Fig. 6
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of 90
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Fig. 8
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impact and at impact velocity (a) 6 m.s-1 and (b) 7.5 m.s-1.
Fig. 9
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impact velocity and at impact angle of (a) 90o and (b) 60o.
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Fig 1.
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Carbide layer
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Diffusion layer
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Substrate
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Fig. 2
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50 m
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Fig. 3
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Fig. 5
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