• Corrosion Science and Technology
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• v.19 no.3
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• pp.131-137
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• 2020

A number of piping components in the secondary system of nuclear power plants (NPPs) are exposed to aging mechanisms, such as flow-accelerated corrosion (FAC), cavitation, flashing, solid particle erosion, and liquid droplet impingement erosion. Those mechanisms may lead to thinning, leaking, or rupture of the components. Due to the pipe ruptures caused by wall thinning in Surry unit 2 in the USA in 1986 and Mihama unit 3 in Japan in 1994, pipe wall thinning management has emerged as one of the most important issues in the nuclear industry. To manage pipe wall thinning, a foreign program has been utilized for NPPs in Korea since 1996. As our experience and knowledge of pipe wall thinning management have accumulated, our program needs to reflect our experience, requests from users, and the result of recent experiments using Flow Accelerated Corrosion Testing System (FACTS). FACTS is the empirical experimental facility developed by Korea Atomic Energy Research Institute (KAERI) for tests. Accordingly, KEPCO-E&C developed a 3D-based pipe wall thinning management program called ToSPACE in 2016. This paper describes a comparison between the FAC analysis results using ToSPACE and the experimental results using FACTS to verify their applicability to pipe wall thinning management in NPPs.

• Corrosion Science and Technology
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• v.18 no.2
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• pp.61-71
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• 2019

Flow-Accelerated Corrosion (FAC) is a phenomenon in which a protective coating on a metal surface is dissolved by a flow of fluid in a metal pipe, leading to continuous wall-thinning. Recently, many countries have developed computer codes to manage FAC in power plants, and the FAC prediction model in these computer codes plays an important role in predictive performance. Herein, the FAC prediction model was developed by applying a machine learning method and the conventional nonlinear regression method. The random forest, a widely used machine learning technique in predictive modeling led to easy calculation of FAC tendency for five input variables: flow rate, temperature, pH, Cr content, and dissolved oxygen concentration. However, the model showed significant errors in some input conditions, and it was difficult to obtain proper regression results without using additional data points. In contrast, nonlinear regression analysis predicted robust estimation even with relatively insufficient data by assuming an empirical equation and the model showed better predictive power when the interaction between DO and pH was considered. The comparative analysis of this study is believed to provide important insights for developing a more sophisticated FAC prediction model.

• Corrosion Science and Technology
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• v.18 no.2
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• pp.55-60
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• 2019

Corrosion failure in the convection part of peak load boiler (PLB) of the district heating system led to water leakage. Herein, Internal Rotary Inspection System (IRIS) inspection was employed to examine wall thinning and the cause of leakage in the flue tube. The corrosive products of the turbulator and tube were investigated using scanning electron microscope combined with energy dispersive spectroscopy, X-ray diffraction, and inductively coupled plasma (ICP). Majority of the serious corrosion damage was observed near the turbulator located in the upper flue tube. ICP analysis of the boiler water revealed oxide formation of sodium chloride in the lower end part of the flue tube. A cross-sectional view of the turbulator revealed the presence of double-layers of the oxide film, indicating environmental change during operation associated with water leakage. The outer surface of the turbulator consisted of the acid oxides such as $NO_x$ and $SO_x$ along with sodium and chloride ions. Dew-point corrosion is hypothesized as the main cause for the formation of acid oxides in the region of contact of the flue tube and the turbulator.

• Corrosion Science and Technology
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• v.19 no.6
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• pp.296-301
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• 2020

Failure analysis on the welded type 304 pipe used for cooling water piping in the district heating primary side was conducted. Inorganic elements and bacteria in the cooling water and in corrosion products were analyzed, and the weldment was inspected by microscopy and a sensitization test. Corrosion damages were observed in the heat-affected zone, on weld defects such as incomplete fusion or excessive penetration caused by improper welding, or/and at the 6 o'clock position along the pipe axial direction. However, the level of concentration of chloride in the cooling water as low as 80 ppm has been reported to be not enough for even a sensitized type 304 steel, meaning that the additional corrosive factor was required for these corrosion damages. The factor leading to these corrosion damages was drawn to be the metabolisms of the types of bacteria, which is proved by the detection of proton, sulfur containing species, biofilms, and both bacteria and corrosion product analyses.

• Corrosion Science and Technology
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• v.22 no.3
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• pp.201-213
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• 2023

Corrosion management of an aircraft and its engine relies on rinsing and cleaning using tap water. Few studies have reported effects of tap water species on corrosion behaviors of structural materials. In this study, a series of experiments were conducted based on the design of experiment. Solutions with different levels of chloride and sulfate ions were prepared using a full factorial design. Two structural materials (aluminum alloy and steel) were used for an alternate immersion test. Weight loss was then measured. In addition, a silver specimen was utilized as a sensor for chloride deposition measurement. The silver specimen was examined using the electrochemical reduction method, XPS, and SEM-EDS. Surface analysis revealed that levels of chloride and sulfate ions were sufficient for the formation of silver chloride and silver surface. Statistical analysis of weight loss and chloride deposition rate showed significant differences in measured values. Concentration of chloride ions greatly affected corrosion behaviors of structural materials. Sulfate ion hindered the adsorption reaction. These results emphasize the importance of controlling ion concentration of tap water used for cleaning and rinsing an aircraft.

• Corrosion Science and Technology
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• v.23 no.4
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• pp.315-323
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• 2024

This work examined pitting corrosion failure of a copper heat-return pipe used in a district heating system. The copper pipe was corroded with a 48% reduction in thickness due to localized corrosion on the inner surface exposed to heating water of 20 ~ 40 ℃. Fe and Si elements as corrosion products were found around pits. Cl element was also observed, which accelerated oxidation of copper inside pits. Cu₂O deposits on the pit's bottom surface decreased the pH inside the pit. X-ray diffraction analysis revealed hematite, cuprite, malachite and brochantite as corrosion products. Chemical analysis demonstrated that Fe and Si elements did not exist in the copper, supply water, or heating water, indicating that Fe and Si species might have entered into the pipe from the exterior. These results indicated that pits were initiated due to ion concentration gradient near Fe and Si species. Moreover, the interior of pits had lower pH due to Cl^- concentration and Cu₂O reactions, which accelerated the pit's growth and led to formation of pinholes. Additionally, we confirmed that the type of pitting corrosion was a complex combination of types I and II based on the HCO₃^-/SO₄^2- ratio, pH, temperature, and corrosion products.

• Corrosion Science and Technology
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• v.14 no.2
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• pp.47-53
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• 2015

Recently, the bending process is greatly applied to fabricate the pipe line. Bending process can reduce welding joints and then decrease the number of inspection. Thus, the maintenance cost will be reduced. Induction heat bending process is composed of bending deformation by repeated local heat and cooling. By this thermal process, corrosion properties and microstructure can be affected. This work focused on the effect of induction heating bending process on the properties of ASME SA106 Gr. C low carbon steel pipes. Microstructure analysis, hardness measurements, and immersion corrosion test were performed for base metal and bended area including extrados, intrados, crown up, and down parts. Microstructure was analyzed using an optical microscope and SEM. Hardness was measured using a Rockwell B scale. Induction heat bending process has influenced upon the size and distribution of ferrite and pearlite phases which were transformed into finer structure than those of base metal. Even though the fine microstructure, every bent area showed a little lower hardness than that of base metal. It is considered that softening by the bending process may be arisen. Except of I2, intrados area, the others showed a similar corrosion rate to that of base metal. But even relatively high rate of intrados area was very low and acceptable. Therefore, it is judged that induction heat bending process didn't affect boric acid corrosion behaviour of carbon steel.

• Corrosion Science and Technology
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• v.15 no.3
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• pp.120-124
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• 2016

The effect of alloying element Ca (0, 1, and 2 wt%) on corrosion resistance and bioactivity of the as-received and anodized surface of rolled plate AM60 alloys was investigated. A plasma electrolytic oxidation (PEO) was carried out to form anodic oxide film in $0.5mol\;dm^{-3}\;Na_3PO_4$ solution. The corrosion behavior was studied by polarization measurements while the in vitro bioactivity was tested by soaking the specimens in Simulated Body Fluid (1.5xSBF). Optical micrograph and elemental analysis of the substrate surfaces indicated that the number of intermetallic particles increased with Ca content in the alloys owing to the formation of a new phase $Al_2Ca$. The corrosion resistance of AM60 specimens improved only slightly by alloying with 2 wt% Ca which was attributed to the reticular distribution of $Al_2Ca$ phase existed in the alloy that might became barrier for corrosion propagation across grain boundaries. Corrosion resistance of the three alloys was significantly improved by coating the substrates with anodic oxide film formed by PEO. The film mainly composed of magnesium phosphate with thickness in the range $30-40{\mu}m$. The heat resistant phase of $Al_2Ca$ was believed to retard the plasma discharge during anodization and, hence, decreased the film thickness of Ca-containing alloys. The highest apatite forming ability in 1.5xSBF was observed for AM60-1Ca specimens (both substrate and anodized) that exhibited more degradation than the other two alloys as indicated by surface observation. The increase of surface roughness and the degree of supersaturation of 1.5xSBF due to dissolution of Mg ions from the substrate surface or the release of film compounds from the anodized surface are important factors to enhance deposition of Ca-P compound on the specimen surfaces.

• Corrosion Science and Technology
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• v.15 no.3
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• pp.141-146
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• 2016

By using Ni-Cr and Co-Cr alloys, porcelain fused to metal (PFM) samples were prepared to examine the interface and the surface corrosion behavior. The potentiodynamic polarization analysis showed that the corrosion current density of Co-Cr alloy ($1.61{\times}10^{-6}A/cm^2$) was three times lower than that of Ni-Cr alloy ($4.83{\times}10^{-6}A/cm^2$) at room temperature. A dental prosthesis consisting of the porcelain fused to Ni-Cr alloy extracted from a patient after approximately four years of usage was examined to assess its resistance to corrosion. OM and SEM images of the metal part revealed a typical pitting corrosion. As compared to porcelain fused to Ni-Cr alloy having a thick layer (${\sim}10{\mu}m$) of oxide at the interface, a relatively thin oxide layer (less than $5{\mu}m$) was formed on Co-Cr alloy, indicating that the interface between Co-Cr alloy and porcelain may have a better adhesion strength than the interface between Ni-Cr alloy and porcelain.

• Corrosion Science and Technology
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• v.18 no.6
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• pp.300-311
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• 2019

The corrosion behaviors of twinning-induced plasticity (TWIP) steels with different alloying elements (Cu, Al, Si) in a neutral aqueous environment were investigated in terms of the characteristics of the corrosion products formed on the steel surface. The corrosion behavior was evaluated by measuring potentiodynamic polarization test and electrochemical impedance spectroscopy. For compositional analysis of the corrosion products formed on the steel surface, an electron probe x-ray micro analyzer was also utilized. This study showed that the addition of Cu to the steel contributed to the increase in corrosion resistance to a certain extent by the presence of metallic Cu in discontinuous form at the oxide/steel interface. Compared to the case of steel with Cu, the Al-bearing specimen exhibited much higher polarization resistance and lower corrosion current by the formation of a thin Al-enriched oxide layer. On the other hand, Si addition (3.0 wt%) to the steel led to an increase in grain size, which was twice as large as that of the other specimens, resulting in a deterioration of the corrosion resistance. This was closely associated with the localized corrosion attacks along the grain boundaries by the formation of a galvanic couple with a large cathode-small anode.