Electrochemical corrosion behavior of carbon steel pipes coated with a protective ceramic layer using plasma and HVOF thermal spray techniques for oil and gas

Zavareh, Mitra Akhtari; Sarhan, Ahmed A.D.; Zavareh, Parisa Akhtari; Basirun, Wan Jeffrey

doi:10.1016/j.ceramint.2015.10.134

Cited by 36 publications

(5 citation statements)

References 26 publications

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“…The splat and globular morphology offers high density of the Cr 3 C 2 -NiCr coating in addition to formation of Cr 2 O 3 and spinel of Ni and Cr, which can enhance the degradation resistance, and calculated parabolic constant value during oxidation is found to be one-third of the substrate, which shows the superior oxidation resistance. Furthermore, both polarization and EIS results confirmed that the corrosion protection properties of the HVOF coating were superior to the substrate as well as the plasma coating due to the formation of less pores on the top surface during the test [103][104][105]. Though the erosion mechanism of Cr 3 C 2 -NiCr coating was ductile and brittle, the ductile mode of erosion characteristic dominates.…”

mentioning

confidence: 68%

“…Erosion and corrosion behavior of the reported coatings is summarized in Table 2. The HVOF spraying process is the preferred process of depositing Cr3C2-NiCr cermet coatings as it exhibits high density, low porosity, as well as excellent adhesive strength, and numerous carbide particles remain in the matrix compared to the plasma spraying process [17,73,[103][104][105][106]. Porosity or voids and surface roughness are the important parameters contributing to higher erosion or corrosion resistance of the Potentiodynamic polarisation studies showed that Cr 3 C 2 -NiCr and hard chromium coatings showed decrease in corrosion current and increase in E corr [102].…”

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confidence: 99%

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Nanocrystalline Cermet Coatings for Erosion–Corrosion Protection

et al. 2019

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The processing techniques, microstructural characteristics, and erosion corrosion behaviour of Cr3C2–NiCr and tungsten carbide (WC)-based cermet coatings are reviewed in this work. Conventional and nanocrystalline Cr3C2–NiCr and WC-based cermet coatings are generally synthesized using thermal spray technique. The wear, erosion, and corrosion protection ability of conventional and nanocermet coatings are compared based on available literature. In Cr3C2–NiCr coatings, the corrosion resistance is offered by NiCr metal matrix while the wear resistance is provided by the carbide ceramic phase, making it suitable for erosion–corrosion protection. The nanocrystalline cermet coatings exhibits better erosion–corrosion resistance as compared to the conventional coatings. The nanocrystalline coatings reduces the erosion–corrosion rate significantly compared to conventional coatings. It is attributed to the presence of the protective NiCr metallic binder that allows easier and faster re-passivation when the coating is subjected to wear and the fine-grain structure with homogeneous distribution of the skeleton network of hard carbide phases. In addition, corrosion-accelerated erosion dominates the reaction mechanism of erosion–corrosion and, therefore, higher hardness, strength, and better wear resistance of nanocermet coating along with its faster repassivation kinetics accounts for improved corrosion resistance as compared to conventional coatings.

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confidence: 68%

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confidence: 99%

Nanocrystalline Cermet Coatings for Erosion–Corrosion Protection

et al. 2019

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“…Many materials were used to coat metallic pipelines and fabricate non-dielectric pipes, one of which was an alumina (ε r = 9.4) torus. Ceramic materials have been widely used in pipeline manufacturing, such as the coating for metallic pipelines [42][43][44], ceramic pipes for irrigation [45], heat transmission [46,47], sewer pipes application [48,49], and ceramic-lined pipes [50,51], which have advantages with respect to corrosive resistance, high strength, heat resistance, and thermal stability. Dimensions of ceramic pipes are various.…”

Section: Simulation Resultsmentioning

confidence: 99%

Non-destructive evaluation of pipes by microwave techniques and artificial neural networks

Xie¹,

Yang²,

Yuan³

et al. 2020

Meas. Sci. Technol.

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Near-field imaging based on an electromagnetic sensor has been widely used for nondestructive detection. An approach to detect the near-surface defects in pipeline coatings and dielectric pipelines is proposed. Based on the characteristics of resonant frequency shifts, a novel method using artificial neural network (ANN) is established to quantitatively evaluate circular-section shape defects in pipes, such as air bubbles in pipeline coating layers or qualitative characterize non-circular section-shape defects. The proposed method has three important modules: a new resonator for data acquisition, a signal-processing algorithm for data preprocessing, and an ANN for quantitative imaging. In the designed sensor, we extend the tip of the sensing ring and introduce an appending in the ring gap for high sensitivity. Simulations show that the sensor can detect a defect with a radius as small as 0.7 mm. The raw resonant frequency shifts obtained by the sensor scanning at an angle interval around the specimen first are preprocessed by curve fitting, sampling, and adaptive data interpolation or truncation. Then, using an ANN, the relationships among resonant frequency shifts, external radius of the specimen, and defect size are modeled for imaging of circular-section shape defects. Preliminary simulations and measurements illustrate the efficacy of the method. Consequently, a contactless, high-resolution, near-field imaging measurement based on sensor scanning for inspecting pipe structures is obtained.

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“…The substrate was protected from the chemical attack by the Cr 3 C 2 − 25 percent NiCr composite coatings, preventing the corrosive electrolyte from reaching the substrate. A strong passive layer growth on the coated worn surface limited the tendency for corrosion [31][32][33].…”

Section: Introductionmentioning

confidence: 99%

Surface morphology studies and corrosion behaviour of plasma sprayed Cr₃C₂/8YSZ composite coating on SS316

Maharajan¹,

F²,

Ravindran³

et al. 2023

Surf. Topogr.: Metrol. Prop.

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Austenitic Stainless Steel (SS316) is a commonly used material in marine and offshore locations. The components' surface in such environments degrades due to chloride and moisture exposure. Hence, adding a ceramic coating to the surface enhances its functionality. In the present work, Cr3C2 and 8YSZ powders are mixed in an equal ratio to deposit unique composite coated layers on the SS316 substrate by plasma spray coating method. The performance of the composite coating is also compared to that of uncoated, Cr3C2-coated, and 8YSZ-coated substrates. The surface morphology and cross-sectional microstructures of the coated SS316 substrate are examined using scanning electron microscope (SEM) images and The presence of chemical elements in the coatings is determined using Energy Dispersive X-ray Analysis (EDAX) with elemental mapping. Further, the corrosion resistance of the substrate is evaluated using potentiodynamic polarisation and Electrochemical Impedance Spectroscopy (EIS) methods. The results shows that the composite coating has a decreased porosity of 1.33 % area and a higher microhardness of 880.02HV compared to bare and other coated surfaces. The corrosion analysis reveals that the composite coating has a decreased corrosion current density (Icorr) of 3.233×10-6 mA/cm2 and an enhanced charge transfer resistance of 2396.23 ohms.cm2 due to strong passivation and restricted electrolyte penetration into the coating. Further, the electrochemical corrosion study reveals that the composite coating exhibits the lowest corrosion rate of 0.00004306 mm/year.

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Electrochemical corrosion behavior of carbon steel pipes coated with a protective ceramic layer using plasma and HVOF thermal spray techniques for oil and gas

Cited by 36 publications

References 26 publications

Nanocrystalline Cermet Coatings for Erosion–Corrosion Protection

Nanocrystalline Cermet Coatings for Erosion–Corrosion Protection

Non-destructive evaluation of pipes by microwave techniques and artificial neural networks

Surface morphology studies and corrosion behaviour of plasma sprayed Cr₃C₂/8YSZ composite coating on SS316

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Electrochemical corrosion behavior of carbon steel pipes coated with a protective ceramic layer using plasma and HVOF thermal spray techniques for oil and gas

Cited by 36 publications

References 26 publications

Nanocrystalline Cermet Coatings for Erosion–Corrosion Protection

Nanocrystalline Cermet Coatings for Erosion–Corrosion Protection

Non-destructive evaluation of pipes by microwave techniques and artificial neural networks

Surface morphology studies and corrosion behaviour of plasma sprayed Cr3C2/8YSZ composite coating on SS316

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Product

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Surface morphology studies and corrosion behaviour of plasma sprayed Cr₃C₂/8YSZ composite coating on SS316