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J. Mater. Sci. Technol.  2020, Vol. 49 Issue (0): 186-201    DOI: 10.1016/j.jmst.2019.10.023
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Development mechanism of internal local corrosion of X80 pipeline steel
Zhuowei Tana, Liuyang Yangb, Dalei Zhangb,*(), Zhenbo Wanga,*(), Frank Chengc, Mingyang Zhangd, Youhai Jina
a China University of Petroleum (East China), 266580, Shandong, China
b School of Materials Science and Engineering, China University of Petroleum (East China), 266580, Shandong, China
c University of Calgary, Calgary, AB CAN, T2N 1N4, Canada
d School of Thermal Engineering, Shandong Jianzhu University, 250101, Shandong, China
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Abstract  

The occurrence and development mechanism of internal local corrosion has always been a controversial topic, and especially under flow conditions. In this paper, an improved high shear force loop was experimentally used, and local flow field is induced by simulating corrosion defects on the surface of X80 pipeline steel specimens. The characteristics of corrosion products deposited on the surface of specimens in CO2-saturated NACE solution were investigated by means of electrochemical impedance spectroscopy (EIS), scanning electron microscopy (SEM), X-ray diffraction (XRD), and energy dispersive spectrometry (EDS). The 3D micromorphology of the corrosion test surface after remove the corrosion scale used to measure the size of localized corrosion pit. Under the influence of local defects, the wall shear stress (WSS) and turbulent kinetic energy of local flow fields enhanced significantly, and pressure fluctuations in local flow field were induced. The results showed that the characteristics of surface corrosion products varied with flow velocity. The corrosion scales formed in various regions of specimens with defects exhibited different surface micro-morphologies and chemical compositions. Overall, these data offer new perspectives for better understanding the mechanisms behind local corrosion.

Key words:  X80 pipeline steel      CO2corrosion      Flow conditions      Surface defects      Wall shear stress      Cavitation     
Received:  14 May 2019     
Corresponding Authors:  Dalei Zhang,Zhenbo Wang     E-mail:  zhangdal2008@126.com;wangzhb@upc.edu.cn

Cite this article: 

Zhuowei Tan, Liuyang Yang, Dalei Zhang, Zhenbo Wang, Frank Cheng, Mingyang Zhang, Youhai Jin. Development mechanism of internal local corrosion of X80 pipeline steel. J. Mater. Sci. Technol., 2020, 49(0): 186-201.

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https://www.jmst.org/EN/10.1016/j.jmst.2019.10.023     OR     https://www.jmst.org/EN/Y2020/V49/I0/186

X80 pipeline steel (balance Fe)
Mn Si C Cr S P Ni Ti Nb Mo V
1.83 0.28 0.063 0.03 0.0006 0.011 0.03 0.016 0.061 0.22 0.059
Table 1  Chemical composition of X80 pipeline steel (wt.%).
Fig. 1.  Specification and flow orientation of SAD: left: side view, right: top view, unit: mm.
Fig. 2.  Schematic diagram of the experimental system: 1) gas-pressure meter, 2) gas master valve, 3) gas storage tank, 4) gas flowmeter, 5) gas flow regulating valve, 6) cooling pipe outlet, 7) cooling pipe inlet, 8) solution tank, 9) corrosion resisting centrifugal pump,10) flow master valve, 11) electrochemical workstation, 12) data acquisition computer, 13) fluid buffer box, 14) test channel, 15) testing electrode, 16) fluid distribution box, 17) vertical rotor flow meter, 18) flow control valve, and 19) return valve.
Fig. 3.  Details of test channel.
Fig. 4.  Configuration of the electrodes: 1) epoxy resin, 2) counter electrode, 3) reference electrode, and 4) working electrode (units are in mm).
Fig. 5.  Distinct geometrical regions of the corrosion surface used for SEM analysis (units are in mm, side view).
Fig. 6.  EIS spectra: (a) PS at v = 3 m/s, (b) SAD at v = 3 m/s, (c) SAD at v = 5 m/s, (d) SAD at v = 7 m/s. Left: Nyquist plots; Right: Bode and |Z| plots.
Fig. 7.  Electrochemical equivalent circuit obtained by fitting the experimental impedance data.
Time (h) Rs
(Ω cm2)
Qdl
-1 cm-2 s-n)
ndl Rct
(Ω cm2)
Qpf
-1 cm-2 s-n)
npf Rpf
(Ω cm2)
Ave err (%)
1 11.06 2.6E-4 0.8223 284.1 4.82
3 11.04 2.9E-4 0.8003 275.5 5.16
6 11.24 4.1E-4 0.7684 269.3 4.04
7 11.36 6.9E-5 1 39.89 4.8E-4 0.8614 214.2 8.31
10 11.31 6.9E-5 1 38.95 5.3E-4 0.8570 208.7 8.92
13 11.05 7.4E-5 1 36.29 6.5E-4 0.8529 188.7 9.14
16 11.37 7.6E-5 1 35.87 7.3E-4 0.8515 183.9 9.01
Table 2  Equivalent circuit fitting of EIS data of the PS, v = 3 m/s.
Fig. 8.  SEM views of surface morphologies of the PS after corrosion at v = 3 m/s.
Fig. 9.  XRD patterns of the corrosion scales: (a) PS after corrosion at v = 3 m/s, (b) SAD after corrosion at v = 5 m/s.
Time(h) Rs
(Ω cm2)
Qdl
-1 cm-2 s-n)
ndl Rct
(Ω cm2)
L
(H cm-2)
RL
(Ω cm2)
Ave err (%)
1 11.57 3.7E-4 0.9292 59.97 119.0 214.3 6.32
4 11.73 5.4E-4 0.9775 31.25 87.51 80.83 7.98
7 11.74 8.3E-4 1 21.98 63.51 67.07 4.67
10 11.59 1.1E-3 1 19.53 71.10 66.66 7.17
13 11.07 2.4E-3 1 16.29 91.98 97.67 6.52
16 11.42 4.5E-3 1 11.92 22.26 44.17 6.04
Table 3  Equivalent circuit fitting of EIS data of the SAD at v = 3 m/s.
Fig. 10.  SEM surface morphologies of the SAD after corrosion at v = 3 m/s.
Time(h) Rs
(Ω cm2)
Qdl
-1 cm-2 s-n)
ndl Rct
(Ω cm2)
L
(H cm-2)
RL
(Ω cm2)
Ave err
(%)
1 11.53 9.7E-4 1 14.87 19.63 34.87 5.26
5 11.36 2.1E-3 1 18.97 496.6 91.76 6.31
9 11.58 2.4E-3 1 21.39 1655 168.3 4.44
Table 4  Equivalent circuit fitting of EIS data of SAD at v = 5 m/s from 1-9 h of corrosion.
Time
(h)
Rs
(Ω cm2)
Qdl
-1 cm-2 s-n)
ndl Rct
(Ω cm2)
Qdf
-1 cm-2 s-n)
ndf Rdf
(Ω cm2)
Ave err (%)
10 11.24 2.1E-3 1 15.81 9.4E-3 0.2711 24.23 8.74
13 11.31 2.0E-3 1 19.24 8.2E-3 0.4292 26.22 10.53
16 11.27 1.9E-3 1 21.74 9.9E-3 0.4664 25.45 7.32
Table 5  Equivalent circuit fitting of EIS data of SAD at v = 5 m/s from 10-16 h of corrosion.
Fig. 11.  SEM surface morphologies of the SAD after corrosion at v = 5 m/s.
Time
(h)
Rs
(Ω cm2)
Qdl
-1 cm-2 s-n)
ndl Rct
(Ω cm2)
L
(H cm-2)
RL
(Ω cm2)
Ave err (%)
1 11.80 3.1E-3 1 15.12 49.85 64.03 8.53
4 11.73 2.9E-3 1 16.02 80.79 76.3 5.24
7 11.74 2.6E-3 1 17.38 108.6 101.73 4.69
10 11.51 2.5E-3 1 18.72 129.5 107.3 6.41
13 11.04 2.2E-3 1 19.33 167.8 133 7.04
16 11.81 2.0E-3 1 20.68 215.4 151.6 5.92
Table 6  Equivalent circuit fitting of EIS data of the SAD at v = 7 m/s.
Fig. 12.  SEM surface morphologies of the SAD after corrosion at v = 7 m/s.
Fig. 13.  Absolute pressure (Pa) of defect local magnification under different flow velocities with flow direction from left to right.
Fig. 14.  SEM of the SAD removed corrosion scale.
Fig. 15.  3D surface morphology and profile of area (c) of the SAD removed corrosion scale.
Fig. 16.  Localized corrosion rate and the depth of localized corrosion pits at downstream of defect (the error bar represents the standard deviation of five deepest localized corrosion pits).
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