Corrosion, Erosion and Wear Behavior of Complex Concentrated Alloys: A Review
Abstract
:1. Introduction
2. Evaluation of Surface Degradation Mechanisms
2.1. Corrosion Characterization
2.2. Wear Testing
2.3. Erosion and Erosion Corrosion Characterization
3. Corrosion Behavior of Complex Concentrated Alloys
4. Erosion and Erosion Corrosion of CCAs
5. Wear Behavior of CCAs
6. Conclusions
- Several CCA compositions showed high corrosion resistance in terms of corrosion current density, corrosion potential and pitting resistance. This was primarily attributed to the high wt% of passivating elements, such as Co, Cr, and Ni (cumulatively as high as 40%) in several of the alloys studied.
- Precipitation of secondary phases by either addition of elements or heat treatment deteriorated the corrosion behavior of multi-phase complex concentrated alloys compared to single-phase ones. On the other hand, heat treatment and secondary phase precipitation resulted in surface hardening and improved the wear resistance and erosion characteristics of the alloys.
- Alloying elements that contributed to the precipitation of secondary phases such as B, Cu, Ti, Mo, and Al deteriorated corrosion resistance. The secondary phase precipitates resulted in galvanic corrosion and promoted materials’ degradation.
- Erosion and erosion-corrosion resistance of CCAs was superior when compared to stainless steel grades, owing to their strong passivation and relatively higher hardness.
- When compared to conventional alloys, CCAs/HEAs in many cases showed better overall corrosion and erosion resistance in different media. However, there are significant knowledge gaps with respect to surface passivation mechanisms and synergy between the different degradation routes.
- The wear resistance of some CCA compositions was significantly higher than state of the art steels, such as the SJ grades. The wear resistance varied between 0.8–2.0 m/mm3 as a function of Vanadium, Boron and Aluminum content.
- Two-phase BCC + FCC alloys and single-phase BCC alloys showed orders of magnitude higher wear resistance (~5500 m/mm3 wear resistance) when compared to single-phase FCC alloys (~1.0 m/mm3 wear resistance).
- In addition to as-cast and heat treated alloys, thermally sprayed and annealed CCA coatings showed better wear resistance with minimal weight loss when compared to structural steels.
- Certain CCA compositions demonstrated excellent marine corrosion resistance. The wear volume loss was an order of magnitude lower than mild steels.
7. Future Opportunities and Outlook
Author Contributions
Funding
Conflicts of Interest
References
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Flow Related Parameters | Erodent Related Parameters | Materials Related Parameters |
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|
|
|
Complex Concentrated Alloy | Microstructure | Corrosion Environment | Test Procedure/Analysis | Major Finding |
---|---|---|---|---|
AlCoCrCu0.5FeNiSi [18] | Two Phase: Dendritic phase: mixture of amorphous and BCC; Inter-dendritic phases: amorphous and nano-scale precipitates | 3.5 wt% NaCl, H2SO4 at 30–70 °C | Anodic polarization | CCA showed overall better corrosion resistance than SS304, but had poor pitting resistance; Corrosion resistance was lower than SS304 at higher temperatures |
Al0.1CoCrFeNi [31] | Single phase FCC | 3.5 wt% NaCl | Potentiodynamic Polarization | Very high corrosion resistance, passive region as wide as 1 V; Grain boundary corrosion, very low corrosion current density |
Al0.3CrFe1.5MnNi0.5Tix [61] | BCC with increasing intermetallic with increasing Ti | 3.5 wt% NaCl | Potentiodynamic Polarization | Adding Ti lowered corrosion resistance |
Al0.3CrFe1.5MnNi0.5Six [61] | BCC with increasing intermetallic with increasing Si | 3.5 wt% NaCl | Potentiodynamic Polarization | Adding Si lowered corrosion resistance |
Al0.5CoCrCuFeNiBx [39] | FCC + BCC crystal structure | 1 N H2SO4 | Anodic polarization | CCA was nobler than SS304 in terms of corrosion current density, and corrosion potentials; not susceptible to localized corrosion in sulfate solutions |
Al0.5CoCrFeNi [35] | FCC solid solution matrix with secondary phases rich in Al–Ni | 3.5 wt% NaCl | Potentiodynamic Polarization | Secondary phases rich in Al–Ni were more susceptible to corrosion |
Al2CrFeNiCoCuTix [51] | x = 0.0 FCC + BCC1 | 0.5 M HNO3 | Potentiodynamic Polarization | Increasing Ti content increased corrosion resistance in terms of corrosion current density |
x = 0.5 FCC + BCC2 | ||||
x = 1.0 BCC1 + BCC2 | ||||
x = 1.5 BCC1 + BCC2 | ||||
x = 2.0 FCC + BCC2 | ||||
AlCoCrCuFeNi [37] | FCC + BCC two phase mixture | 1 mol/L NaCl | Potentiodynamic Polarization | Good corrosion resistance despite two phase structure |
AlCoCrFeNi [62] | BCC | 3.5 wt% NaCl | Potentiodynamic Polarization | Corrosion resistance after processing was three orders of magnitude better than steel and one order of magnitude better than unprocessed HEA |
AlCoCrFeNiTi [36] | Complex Microstructure: Al, Co, Ni and Ti rich dendritic phase. Fe and Cr rich inter-dendritic phase. Ti and Ni rich third phase. Ordered phase—A2, B2, D03 and A12 | 3.5 wt% NaCl | Polarization | Ti addition improved corrosion resistance of the alloy; Through the re-melting process, the distribution of elements in the alloy improved, improving the corrosion resistance |
AlCrCuFeMnNi [63] | Complex Microstructure: BCC dendritic phase, interdendritic area with two phases—a eutectic type and FCC solid solution phase | 3.5 wt% NaCl | Potentiodynamic Polarization | CCA was easier to passivate; higher corrosion resistance than SS304L; Galvanic coupling reduced by dissolving Cu during re-melting |
AlxCoCrCu0.5FeNi [41] | x = 0.5 is FCC | 0.5 mol/L H2SO4 + 0.5 mol/L NaCl solution | Potentiodynamic Polarization | Single-phase alloys had better corrosion resistance that phase mixtures; BCC alloy was comparable with 321 stainless steel |
x = 1.0 is BCC | ||||
x = 1.5 FCC + BCC | ||||
AlCoCrCuFe [49] | FCC and BCC phase mixture | 1 mol/L NaCl and 0.5 mol/L H2SO4 | Potentiodynamic Polarization | Segregation of Cu was seen in the microstructure; CCA performed better in NaCl solution than in acidic solution |
AlxCoCrFeNi (x = 0, 0.25, 0.50, 1.00) [33] | x = 0 | 0.5 mol/L H2SO4 | Potentiodynamic Polarization | Corrosion current density decreased with Al content at 23 °C; Overall superior corrosion resistance compared to steels |
x = 0.25 | ||||
x = 0.50 | ||||
x = 1.00 | ||||
AlxCoCrFeNi [34] | x = 0.3 | 3.5 wt% NaCl | Potentiodynamic Polarization | Increasing Al content decreased corrosion resistance by formation of intermetallic phases |
x = 0.5 | ||||
x = 0.7 | ||||
AlxCrFe1.5MnNi0.5 [66] | x = 0.0 FCC | 1 mol/L NaCl + 0.5 mol/L H2SO4 | Potentiodynamic Polarization | Alloys showed extended passive region, greater than 1 V; Increasing Al lowered corrosion resistance in terms of pitting behavior |
x = 0.3 BCC + FCC | ||||
x = 0.5 BCC | ||||
BxCoCrFeNi [67] | x = 0.5 FCC | 3.5 wt% NaCl | Potentiodynamic Polarization | Corrosion resistance improved with increasing B content up to 1%., beyond which corrosion resistance decreased; The CCAs showed superior corrosion resistance than SS304 |
x = 0.75 FCC | ||||
x = 1.0 FCC | ||||
x = 1.25 FCC + M2B | ||||
Co1.5CrFeNi1.5Ti0.5Mo0.1 [43] | FCC solid-solution structure | 0.001 to 1 M NaCl and sulfate doped 1 M NaCl | Potentiodynamic Polarization | Sulfate ions increased the pitting potential and critical pitting potential of the alloys |
Co1.5CrFeNi1.5Ti0.5Mox [42] | FCC solid-solution | 0.5 M H2SO4 1 M NaCl and NaOH | Potentiodynamic Polarization | Mo addition lowered the overall corrosion resistance |
CoCrCu0.5FeNi [68] | Dendritic Structure: Copper lean dendritic phase, copper rich interdendritic phase, aged at different temperatures | 3.5 wt% NaCl | Potentiodynamic Polarization | Corrosion current density lowered while corrosion potential decreased with aging temperature; Corrosion properties worsened when heat treated at 1100–1350 °C. Pitting increased with aging temperature |
CoCrCuFeNiNb [55] | FCC and Laves phases | 6 M HCl | Potentiodynamic Polarization | Alloying with Nb lowered corrosion current density |
CoCrFeMnNi [31] | Simple single phase FCC | 3.5 wt% NaCl | Potentiodynamic Polarization | ~500 mV wide passivation region; Corrosion rate as low as one micron per year |
CoCrCuxFeNi [29] | FCC and Cu rich FCC | 3.5 wt% NaCl | Potentiodynamic Polarization | Addition of Cu deteriorated the corrosion resistance |
Immersion Test | Galvanic corrosion between inter-dendritic region and dendrite resulting in localized corrosion | |||
CoCuFeNiSnx [69] | Single phase FCC solid solution when Sn < 0.09, small BCC phase beyond that | 3.5 wt% NaCl and 5% NaOH | Potentiodynamic Polarization | CCAs showed wide passivation range in NaOH and relatively smaller region in NaCl; Better resistance than SS304; FeCoNiCuSn0.04 showed improved corrosion resistance |
CoCuFeNiSnx [69] x = 0–0.09 | FCC when x < 0.09, small BCC for x > 0.09 | 3.5 wt% NaCl and 5% NaOH | Potentiodynamic Polarization | Better corrosion resistance than SS304 alloy when tested in NaCl, while lower corrosion resistance when tested in NaOH |
Cr0.5NbTiZr0.5, Cr0.5NbTiVZr0.5 Cr0.5MoNbTiZr0.5 [70] | Dendritic Structure: BCC Disordered Solid Solution phase and Cr2Zr phase | 3.5 wt% NaCl and 0.5 M H2SO4 | Potentiodynamic Polarization | Superior corrosion resistance, with passive region more than 1400 mV; Mo and V addition decreased corrosion resistance but improved pitting resistance in NaCl and H2SO4 |
CoCrCuxFeNi [29] | FCC crystal structure, Cu rich interdendritic phase | 3.5 wt% NaCl | Potentiodynamic Polarization | Increasing Cu content caused segregation into inter-dendritic phases, and consequent deterioration of corrosion resistance; General corrosion trend was seen as FeCoNiCrCu > FeCoNiCrCu0.5 > FeCoNiCr |
CuCr2Fe2Ni2Mn2 Cu2CrFe2NiMn2 [44] | FCC | 1 M H2SO4 | Potentiodynamic Polarization | Cr2 alloy showed better corrosion resistance while Cu2 alloy promoted segregation and had lower corrosion resistance |
FCC + BCC | ||||
AlCoCuFeNi AlCoCuFeNiCr AlCoCuFeNiTi AlCoCrCuFeNiTi [40] | FCC + A2 + B2 | 0.5 mol/L H2SO4 | Potentiodynamic Polarization | Adding Ti decreased the corrosion resistance of the AlCoCuFeNi alloys, whereas adding Cr improved corrosion resistance |
System | Alloy | Hardness (HV) | Wear Resistance |
---|---|---|---|
Al0.5CoCrCuFeNiVx [90] | Al0.5CoCrCuFeNiV0.2 | 200 | 0.910 |
Al0.5CoCrCuFeNiV0.4 | 225 | 0.875 | |
Al0.5CoCrCuFeNiV0.4 | 325 | 0.850 | |
Al0.5CoCrCuFeNiV0.8 | 450 | 0.900 | |
Al0.5CoCrCuFeNiV1.0 | 650 | 0.925 | |
Al0.5CoCrCuFeNiV1.2 | 575 | 1.050 | |
Al0.5CoCrCuFeNiV1.4 | 578 | 1.100 | |
Al0.5CoCrCuFeNiV1.6 | 600 | 1.050 | |
Al0.5CoCrCuFeNiV1.8 | 600 | 1.100 | |
Al0.5CoCrCuFeNiV2.0 | 598 | 1.110 | |
AlxCo1.5CrFeNi1.5Tiy [91] | Al0Co1.5CrFeNi1.5Ti0.5 | 501 | 250 |
Al0.2Co1.5CrFeNi1.5Ti0.5 | 480 | 255 | |
Al0Co1.5CrFeNi1.5Ti | 650 | 2000 | |
Al0.2Co1.5CrFeNi1.5Ti | 700 | 5500 | |
AlxCoCrCuFeNi [89] | Al0.5CoCrCuFeNi | 252 | 0.925 |
Al1.5CoCrCuFeNi | 350 | 0.825 | |
Al2.0CoCrCuFeNi | 550 | 0.850 | |
Al0.5BxCoCrCuFe [38] | Al0.5B0CoCrCuFe | 300 | 0.8 |
Al0.5B0.2CoCrCuFe | 400 | 0.9 | |
Al0.5B0.6CoCrCuFe | 500 | 1.0 | |
Al0.5B1.0CoCrCuFe | 725 | 1.6 | |
AlCoCrFexMo0.5Ni [100] | AlCoCrFe0.6Mo0.5Ni | 675 | 1600 |
AlCoCrFe1.0Mo0.5Ni | 700 | 1500 | |
AlCoCrFe1.5Mo0.5Ni | 525 | 1200 | |
AlCoCrFe2.0Mo0.5Ni | 425 | 1250 |
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Ayyagari, A.; Hasannaeimi, V.; Grewal, H.S.; Arora, H.; Mukherjee, S. Corrosion, Erosion and Wear Behavior of Complex Concentrated Alloys: A Review. Metals 2018, 8, 603. https://doi.org/10.3390/met8080603
Ayyagari A, Hasannaeimi V, Grewal HS, Arora H, Mukherjee S. Corrosion, Erosion and Wear Behavior of Complex Concentrated Alloys: A Review. Metals. 2018; 8(8):603. https://doi.org/10.3390/met8080603
Chicago/Turabian StyleAyyagari, Aditya, Vahid Hasannaeimi, Harpreet Singh Grewal, Harpreet Arora, and Sundeep Mukherjee. 2018. "Corrosion, Erosion and Wear Behavior of Complex Concentrated Alloys: A Review" Metals 8, no. 8: 603. https://doi.org/10.3390/met8080603