• 한국해양공학회지
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• 제24권4호
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• pp.38-46
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• 2010

The wall thinning phenomenon of pipes was simulated as metal loss due to erosion and corrosion. Such wall thinning defects in the pipes of power plants are a very important safety consideration. In this study, we analyzed wall thinning defects that occurred by weld bead of weld zone of boost pump recirculation pipe. From the results of the analysis of pipe failures, numerical analysis was performed by Fluent v6.3.26 using the standard k-$\varepsilon$ model of the weld bead shape, such as an elliptical or a spherical shape, on the inner wall of the pipe. Using the results obtained, we showed the overlap effect by cavitations corrosion and erosion-corrosion at the bottom of the wall-thinning defect.

• Corrosion Science and Technology
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• 제15권4호
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• pp.182-188
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• 2016

Significant piping wall thinning caused by Flow-Accelerated Corrosion (FAC) and Erosion-Corrosion (EC) continues to occur, even after the Mihama Power Station unit 3 secondary pipe rupture in 2004, in which workers were seriously injured or died. Nuclear power plants in many countries have experienced FAC and EC-related cases in steam cycle piping systems. Korea has also experienced piping wall thinning cases including thinning in the downstream straight pipe of a check valve in a feedwater pump line, the downstream elbow of a control valve in a feedwater flow control line, and failure of the straight pipe downstream of an orifice in an auxiliary steam return line. Cause analyses were performed by reviewing thickness data using Ultrasonic Techniques (UT) and, Scanning Electron Microscope (SEM) images for the failed pipe, and numerical simulation results for FAC and EC cases in Korea Nuclear Power Plants. It was concluded that the main cause of wall thinning for the downstream pipe of a check valve is FAC caused by water vortex flow due to the internal flow shape of a check valve, the main cause of wall thinning for the downstream elbow of a control valve is FAC caused by a thickness difference with the upstream pipe, and the main cause of wall thinning for the downstream pipe of an orifice is FAC and EC caused by liquid droplets and vortex flow. In order to investigate more cases, additional analyses were performed with the review of a lot of thickness data for inspected pipes. The results showed that pipe wall thinning was also affected by the operating condition of upstream equipment. Management of FAC and EC based on these cases will focus on the downstream piping of abnormal or unusual operated equipment.

• Corrosion Science and Technology
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• 제14권5호
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• pp.239-246
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• 2015

Stainless steel is generally known to have characteristics of excellent corrosion resistance and durability, but in a marine environment it can suffer from localized corrosion due to the breakdown of passivity film due to chloride ion in seawater. Furthermore, the damage behaviors are sped up under a cavitation environment because of complex damage from electrochemical corrosion and cavitation-erosion. In this study the characteristics of electrochemical corrosion and cavitation erosion behavior were evaluated on 16.7Cr-10Ni-2Mo stainless steel under a cavitation environment in natural seawater. The electrochemical experiments have been conducted at both static conditions and dynamic conditions inducing cavitation with different current density parameters. The surface morphology and damage behaviors were compared after the experiment. After the cavitation test with time variables morphological examinations on damaged specimens were analyzed by using a scanning electron microscope and a 3D microscope. the galvanostatic experiment gave a cleaner surface morphology presented with less damage depth at high current density regions. It is due to the effect of water cavitation peening under the cavitation condition. In the cavitation experiment, with amplitude of $30{\mu}m$ and seawater temperature of $25^{\circ}C$, weight loss and cavitation-erosion damage depth were dramatically increased after 5 hours inducing cavitation.

• Corrosion Science and Technology
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• 제12권3호
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• pp.125-131
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• 2013

The most common pipe wall thinning degradation mechanisms that can occur in the steam and feedwater systems are FAC (Flow Acceleration Corrosion), cavitation, flashing, and LDIE (Liquid Droplet Impingement Erosion). Among those degradation mechanisms, FAC has been investigated by many laboratories and industries. Cavitation and flashing are also protected on the piping design phase. LDIE has mainly investigated in aviation industry and turbine blade manufactures. On the other hand, LDIE has been little studied in NPP (Nuclear Power Plant) industry. This paper presents the development of prediction system for pipe wall thinning caused by LDIE in terms of erosion rate based on air-water ratio and material. Experiment is conducted in 3 cases of air-water ratio 0.79, 1.00, and 1.72 using the three types of the materials of A106B, SS400, and A6061. The main control parameter is the air-water ratio which is defined as the volumetric ratio of water to air (0.79, 1.00, 1.72). The experiments were performed for 15 days, and the surface morphology and hardness of the materials were examined for every 5 days. Since the spraying velocity (v) of liquid droplets and their contact area ($A_c$) on specimens are changed according to the air-water ratio, we analyzed the behavior of LDIE for the materials. Finally, the prediction equations(i.e. erosion rate) for LDIE of the materials were determined in the range of the air-water ratio from 0 to 2%.

• Corrosion Science and Technology
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• 제9권6호
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• pp.317-324
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• 2010

Marine transportation by ships is characterized by remote, large-volume and lower rates than the others carry system. Ships account for over 80% of all international trading, and marine transportation is an internationally competitive, strategic, and great national important industry. The construction of larger and faster ships has brought about many problems such as cavitations and erosion corrosion. Cavitations and erosion corrosion make damages on materials and leads to break down members due to continuous physical contacts with shock waves and fluids from the generation and extinction of air bubbles in sea water vortex. The steel used for ship constructions was spray-coated with Al wire, and additionally sealed with fluorine silicone sealing material. Results of experiment, corrosion resistance of sealed thermal spray coating was improved, however in cavitation resistance, the large effect was not appeared. Accordingly, this study applied for thermal spray coating to provide better electrochemical characteristics and corrosion resistance in marine environment.

• Corrosion Science and Technology
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• 제6권6호
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• pp.291-296
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• 2007

The corrosion of metals and alloys in flowing liquids can be classified into uniform corrosion and localized corrosion which may be categorized as follows. (1) Localized corrosion of the erosion-corrosion type: the protective oxide layer is assumed to be removed from the metal surface by shear stress or turbulence of the fluid flow. A macro-cell may be defined as a situation in which the bare surface is the macro-anode and the other surface covered with the oxide layer is the macro-cathode. (2) Localized corrosion of the differential flow-velocity corrosion type: at a location of lower fluid velocity, a thin and coarse oxide layer with poor protective qualities may be produced because of an insufficient supply of oxygen. A macro-cell may be defined as a situation in which this surface is the macro-anode and the other surface covered with a dense and stable oxide layer is the macro-cathode. (3) Localized corrosion of the active/passive-cell type: on a metal surface a macro-cell may be defined as a situation in which a part of it is in a passivation state and another in an active dissolution state. This situation may arise from differences in temperature as well as in the supply of the dissolved oxygen. Compared to uniform corrosion, localized corrosion tends to involve a higher wall thinning rate (corrosion rate) due to the macro-cell current as well as to the ratio of the surface area of the macro-anode to that of the macro-cathode, which may be rationalized using potential vs. current density diagrams. The three types of localized corrosion described above can be reproduced in a Jet-in-slit test by changing the flow direction of the test liquid and arranging environmental conditions in an appropriate manner.

• 한국표면공학회지
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• 제49권4호
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• pp.344-348
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• 2016

Stainless steel is widely applied in many industrial fields due to its excellent anti-corrosion and durability characteristics. However, stainless steel is very vulnerable to cavitation attack caused by high speed flow of fluid in the chloride environments such as marine environment. These conditions promote intergranular corrosion and cavitation-erosion, leading to degradation of the structural integrity and service life. In order to prevent these problems, the stabilized stainless steel is applied to the offshore and shipbuilding industries. In this study, Ti was added to 19%Cr-9%Ni as the stabilizer element with different concentrations (0.26%, 0.71%), and their durabilities were evaluated with cavitation-erosion experiment by a modified ASTM G32 method. The microstructural change was observed with the stabilizer element contents. The result of the observation indicated that the amount of carbide precipitation was decreased and its size became finer with increasing Ti content. In the cavitation-erosion experiment, both weight loss and surface damage depth represented an inverse proportional relationship with the amount of Ti element. Consequently, the stainless steel containing 0.71% of Ti had excellent durability characteristics.

• 한국결정성장학회지
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• 제27권2호
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• pp.99-104
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• 2017

저급탄을 가스화하는 반응기에 사용되는 내화물은 고온에서 부식성이 강한 $H_2S$ 가스에 노출되며, 경도나 내마모성과 같은 기계적 특성이 가스에 노출되는 시간이 길어짐에 따라서 떨어진다. 그러나 $H_2S$ 가스에 의한 내화물의 기계적 특성 약화 원인이 아직 잘 알려져 있지 않다. 본 실험에서는 내화도가 다른 두 종류의 케스터블 내화물을 $H_2S$ 농도가 높은 $H_2O/N_2/H_2S$ 혼합가스에 100시간 동안 $900^{\circ}C$에서 노출시키고, 미세구조, 결정상과 내마모 특성 변화를 비교하였다. 혼합가스에 노출되면서 내화물 시편의 무게는 감소하였다. 노출 후 기공률은 감소하고, 내마모 특성은 현저하게 떨어졌다. 부식에 의해서 내화물을 구성하는 상에 변화가 일어났는데, $CaAl_2O_4$와 일부의 $SiO_2$는 사라지고 $CaSO_4{\cdot}2H_2OS$와 $Al_2Si_2O_5(OH)_4$ 상이 나타났다. 내화물의 내마모 특성이 $H_2S$ 가스에 노출된 후에 감소하는 주 원인은 캐스터블 내화물에서 결합제 역할을 하는 $CaAl_2O_4$가 사라지고 기계적 특성이 나쁜 $CaSO_4{\cdot}2H_2OS$가 생성되기 때문인 것으로 생각되었다.

• 동력기계공학회지
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• 제18권5호
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• pp.80-87
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• 2014

The pipelines are apt to erosion or corrosion because of the high-speed flow of water and steam with high temperatures or high pressures. This study was carried out a finite element analysis (FEA) and an experimental for the fracture behavior of T-joint pipes with local wall thinning under internal pressure. Local wall thinning was machined on the pipes in order to simulate erosion and corrosion of the metal. The configurations of the eroded area included an eroded ratio of d/t=0.80~0.963 and an eroded length of l=25 mm, 50 mm, and 102 mm. Three-dimensional elastic-plastic analyses were also carried out using FEA, which accurately simulates failure behaviors. In regards to the relationship between pressure and eroded, the criterion that indicates what can be used safely under operating pressure and design pressure were obtained from FEA. The FEA results were in relatively good agreement with that of the experiment.

• Corrosion Science and Technology
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• 제14권2호
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• pp.76-84
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• 2015

The components in ultra super critical (USC) steam turbine, which is under development for high efficient power generation, are encountering harsher solid particle erosion by iron oxide scales than ones in the existing steam turbines. Therefore, the currently used boride coating will not be able to hold effective protection from particle erosion in USC system and should be replaced by new particle erosion resistant coatings. One of the best protective coatings developed for USC steam turbine parts was found to be vanadium-boride (V-boride) coating which has a hardness of about 3000 HV, much higher than that of boride, 1600~2000 HV. In order to evaluate particle erosion resistance of the various coatings such as V-boride, boride and Cr-carbide coatings at high temperature, particle erosion test equipments were designed and manufactured. In addition, erosion particle velocity was simulated using FLUENT software based on semi-implicity method for pressure linked equations revised (SIMPLER). Based on experimental results of this work, the vanadium-boride coating was found to be superior to others and to be a candidate coating to replace the boride coating.