Corrosion and Cavitation Erosion Behaviours of Cast Nickel Aluminium Bronze in 3.5% NaCl Solution with Different Sulphide Concentrations

doi:10.1007/s40195-019-00963-7

Abstract

Abstract:

The effect of sulphide (Na₂S) concentration (SC) on the corrosion and cavitation erosion behaviours of a cast nickel aluminium bronze (NAB) in 3.5% NaCl solution is investigated in this study. The results show that when the SC exceeds 50 ppm, the hydrogen evolution reaction dominates the cathodic process, and a limiting current region appears in the anodic branch of the polarisation curve due to the formation of a copper sulphide film, which is a diffusion-controlled process. After long-term immersion, the increased mass loss rate of NAB with the sulphide additions of 20 and 50 ppm is attributed to the less protective films, which contains a mixture of copper oxides and sulphides. Moreover, NAB undergoes severe localised corrosion (selective phase corrosion, SPC) at the β′ phases and eutectoid microstructure α + κ_III. By comparison, NAB undergoes general corrosion and a copper sulphide film is formed in 100 and 200 ppm sulphide solutions. Cavitation erosion greatly increases the corrosion rate of NAB in all solutions and causes a negative potential shift in 3.5% NaCl solution due to the film destruction. However, a positive potential shift occurs in the solutions with SC higher than 50 ppm due to the accelerated mass transfer of the cathodic process. The cavitation erosion mass loss rate of NAB increases with the increase of SC. The occurrence of severe SPC decreases the phase boundary cohesion and causes brittle fracture under the cavitation impact. The corrosion-enhanced erosion is the most predominant factor for the cavitation erosion damage when the SC exceeds 50 ppm.

Key words: Nickel aluminium bronze, Sulphide, Corrosion, Cavitation erosion, Synergy

Qi-Ning Song, Nan Xu, Yao Tong, Chen-Ming Huang, Shou-Yu Sun, Chen-Bo Xu, Ye-Feng Bao, Yong-Feng Jiang, Yan-Xin Qiao, Zhi-Yuan Zhu, Zheng-Bin Wang. Corrosion and Cavitation Erosion Behaviours of Cast Nickel Aluminium Bronze in 3.5% NaCl Solution with Different Sulphide Concentrations[J]. Acta Metallurgica Sinica (English Letters), 2019, 32(12): 1470-1482.

Figures/Tables 16

Fig. 1 Schematic diagram of the ultrasonically vibrating equipment for cavitation erosion test. 1: water inlet; 2: cooling system; 3: Pt electrode; 4: reference electrode; 5: amplitude transformer; 6: transducer; 7: horn; 8: sample; 9: water outlet; 10: ultrasonic generator

Fig. 2 Optical microstructure of the cast NAB

Fig. 3 Polarisation curves of NAB in 3.5% NaCl solutions with different SCs

Fig. 4 a Mass loss, b film weight results of NAB after immersion for different periods in 3.5% NaCl solutions with different SCs

Fig. 5 Surface morphologies of NAB after immersion for 7 days in 3.5% NaCl solutions with SCs of a, b 0 ppm, c, d 20 ppm, e, f 50 ppm

Fig. 6 Surface morphologies of NAB after immersion for 7 days in 3.5% NaCl solutions with SCs of a, b 100 ppm, c, d 200 ppm

Table 1 Chemical compositions of the corrosion products located on different areas in Figs. 5 and 6 (wt%)

Solutions (SC)	Areas	O	Al	Ni	Fe	Mn	Cu	Cl	S
0 ppm	1	1.84	8.44	13.53	10.28	0.57	64.56	0.48	-
	2	3.60	9.48	9.10	8.61	1.44	66.51	1.27	-
	3	12.40	14.01	4.42	3.04	0.30	63.40	2.43	-
20 ppm	4	5.03	2.31	7.56	3.38	0.10	72.42	4.82	4.37
20 ppm	5	2.36	2.27	4.64	4.49	0.77	81.39	0.81	3.26
50 ppm	6	11.89	1.42	1.86	1.42	0.57	67.84	-	15.00
	7	7.59	-	1.68	3.35	0.77	71.85	-	13.94
	8	8.47	2.47	3.80	4.53	1.86	69.59	-	9.28
100 ppm	9	-	-	-	1.08	0.58	78.12	-	20.22
100 ppm	10	-	-	-	1.10	0.89	76.66	-	21.35
200 ppm	11	-	-	0.59	1.25	1.27	77.65	-	19.24
200 ppm	12	-	-	-	0.87	-	80.30	-	18.83

Fig. 7 XRD patterns of NAB after immersion for 7 days in 3.5% NaCl solutions with different SCs

Fig. 8 Cross-sectional morphologies of NAB after immersion for 7 days in 3.5% NaCl solutions with SCs of a, b 0 ppm, c 20 ppm, d 50 ppm, e 100 ppm, f 200 ppm

Fig. 9 Cumulative mass loss results of NAB after cavitation erosion in 3.5% NaCl solutions with different SCs for 5 h

Fig. 10 OCP results of NAB under alternate quiescence and cavitation erosion conditions in 3.5% NaCl solutions with different SCs

Fig. 11 Schematic diagrams for OCP and current density evolution under alternate conditions of quiescence and cavitation erosion: a with, b without a protective film on the material surface under quiescence condition

Fig. 12 Polarisation curves of NAB under quiescence and cavitation erosion conditions in 3.5% NaCl solutions with different SCs

Table 2 Electrochemical parameters obtained from the polarisation curves in Fig. 12 for NAB in 3.5% NaCl solutions with different SCs

Conditions	3.5% NaCl solution + x ppm Na₂S
Conditions	0	20	50	100	200
Quiescence
I (A cm^-2)	6.8175?×?10^-6	3.1426?×?10^-6	2.7630?×?10^-6	2.5147?×?10^-6	7.0212?×?10^-6
E_corr (mV)	-?277	-?341	-?950	-?963	-?962
Cavitation
I (A cm^-2)	3.0678?×?10^-5	2.6561?×?10^-4	5.5525?×?10^-4	8.1464?×?10^-4	8.6688?×?10^-4
E_corr (mV)	-?290	-?364	-?746	-?790	-?837

Table 3 Cavitation erosion-corrosion synergy results for NAB in 3.5% NaCl solutions with different SCs

Solutions (SC)	Mass loss rate (mg cm^-2 h^-1)						Percentages (%)
Solutions (SC)	T	E	C	?E	?C	S	E/T	C/T	S/T	?E/T	?C/T
0 ppm	1.4722	0.9111	0.0163	0.4879	0.0570	0.5448	61.89	1.11	37.01	33.14	3.87
20 ppm	1.9611	0.9111	0.0075	0.4154	0.6266	1.0420	46.46	0.38	53.16	21.21	31.95
50 ppm	3.9611	0.9111	0.0066	1.7226	1.3189	3.0415	23.00	0.17	76.83	43.54	33.30
100 ppm	5.2278	0.9111	0.0060	2.3713	1.9387	4.3100	17.43	0.11	82.46	45.37	37.08
200 ppm	8.0778	0.9111	0.0168	5.0994	2.0527	7.1521	11.28	0.21	88.51	63.10	25.41

Fig. 13 Surface morphologies of NAB after cavitation erosion for 5 h in a distilled water and 3.5% NaCl solutions with SCs of b 0 ppm, c 20 ppm, d 50 ppm, e 100 ppm, f 200 ppm

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