Particle velocity effects on erosion-corrosion of AISI 1020 carbon steel in CO₂-saturated drilling mud
Original scientific paper
DOI:
https://doi.org/10.5599/jese.2957Keywords:
Slurry flow, mass loss, surface morphology, plastic deformation, particle impingementAbstract
A systematic approach was adopted to independently assess erosion, corrosion, and their combined effects under controlled flow conditions that closely mimic real drilling environments. This study offers in-depth insight into how increasing flow velocities alter the prevailing degradation mechanism, transitioning from corrosion-dominated behaviour at lower speeds to erosion-driven processes at higher speeds. The effect of particle velocity on the erosion-corrosion behaviour of AISI 1020 carbon steel was investigated in a CO₂-saturated, water-based drilling mud containing 3.5 wt.% NaCl and 500 mg L-1 of sand particles (400 to 500 μm in size). Experiments were conducted using a custom jet impingement flow loop at velocities ranging from 5 to 20 m s-1. Degradation rates and surface deterioration were evaluated through total weight loss measurements and detailed analysis using scanning electron microscopy. The results demonstrate a substantial increase in material loss as flow velocity rises, with degradation rates exceeding 20 mm year-1 at 20 m s-1. The synergistic interaction between erosion and corrosion was most evident at lower velocities, whereas erosion alone became predominant at higher velocities. Independent erosion and corrosion tests confirmed that the material loss was caused by the combined influence of mechanical impact and electrochemical reactions. These findings emphasize that synergy decreases with increasing velocity, highlighting the transition from corrosion-assisted erosion to erosion-dominated degradation. The results provide critical insight into the velocity-dependent mechanisms of erosion–corrosion and reinforce the need for velocity management strategies to extend the service life of steel components in drilling operations.
Downloads
References
[1] B. Tian, Y. Cheng, Electrochemical corrosion behavior of X-65 steel in the simulated oil sand slurry. I: Effects of hydrodynamic condition, Corrosion Science 50 (2008) 773-779. https://doi.org/10.1016/j.corsci.2007.11.008 DOI: https://doi.org/10.1016/j.corsci.2007.11.008
[2] B.W. Madsen, Measurement of erosion-corrosion synergism with a slurry wear test apparatus, Wear 123 (1988) 127-142. https://doi.org/10.1016/0043-1648(88)90095-6 DOI: https://doi.org/10.1016/0043-1648(88)90095-6
[3] E. Hussain, M. Robinson, Erosion–corrosion of 2205 duplex stainless steel in flowing seawater containing sand particles, Corrosion Science 49 (2007) 1737-1754. https://doi.org/10.1016/j.corsci.2006.08.023 DOI: https://doi.org/10.1016/j.corsci.2006.08.023
[4] V. Souza, A. Neville, Aspects of microstructure on the synergy and overall material loss of thermal spray coatings in erosion–corrosion environments, Wear 263 (2007) 339-346. https://doi.org/10.1016/j.wear.2007.01.071 DOI: https://doi.org/10.1016/j.wear.2007.01.071
[5] J.R. Shadley, E. Dayalan, E.F. Rybicki, S.A. Shirazi, Prediction of erosion-corrosion penetration rate in a CO2 environment with sand, NACE Proceedings of the CORROSION, (1998) C1998-98059. https://doi.org/10.5006/C1998-98059 DOI: https://doi.org/10.5006/C1998-98059
[6] E. Heitz, Chemo-mechanical effects of flow on corrosion, Corrosion 47 (1991) 135-145. https://doi.org/10.5006/C1990-90001 DOI: https://doi.org/10.5006/1.3585229
[7] W. Li, B. Pots, B. Brown, K.E. Kee, S. Nesic, A direct measurement of wall shear stress in multiphase flow—Is it an important parameter in CO2 corrosion of carbon steel pipelines?, Corrosion Science 110 (2016) 35-45. https://doi.org/10.1016/j.corsci.2016.04.008 DOI: https://doi.org/10.1016/j.corsci.2016.04.008
[8] T.-Y. Chen, A. Moccari, D.D. Macdonald, Development of controlled hydrodynamic techniques for corrosion testing, Corrosion 48 (1992) 239-255. https://doi.org/10.5006/1.3315930 DOI: https://doi.org/10.5006/1.3315930
[9] G. Zhang, Y. Cheng, Electrochemical corrosion of X65 pipe steel in oil/water emulsion, Corrosion Science 51 (2009) 901-907. https://doi.org/10.1016/j.corsci.2009.01.020 DOI: https://doi.org/10.1016/j.corsci.2009.01.020
[10] M. Stack, G. Abdulrahman, Mapping erosion–corrosion of carbon steel in oil–water solutions: effects of velocity and applied potential, Wear 274 (2012) 401-413. https://doi.org/10.1016/j.wear.2011.10.008. DOI: https://doi.org/10.1016/j.wear.2011.10.008
[11] J. Malik, I. Toor, W. Ahmed, Z. Gasem, M. Habib, R. Ben-Mansour, H. Badr, Evaluating the effect of hardness on erosion characteristics of aluminum and steels, Journal of Materials Engineering and Performance 23 (2014) 2274-2282. https://doi.org/10.1007/s11665-014-1004-x DOI: https://doi.org/10.1007/s11665-014-1004-x
[12] I.U. Toor, Z. Alashwan, H.M. Badr, R. Ben-Mansour, S.A. Shirazi, Effect of jet impingement velocity and angle on CO2 erosion–corrosion with and without sand for API 5L-X65 carbon steel, Materials 13 (2020) 2198. https://doi.org/10.3390/ma13092198 DOI: https://doi.org/10.3390/ma13092198
[13] H.M. Irshad, I.U. Toor, H.M. Badr, M.A. Samad, Evaluating the Flow Accelerated Corrosion and Erosion–Corrosion Behavior of a Pipeline Grade Carbon Steel (AISI 1030) for Sustainable Operations, Sustainability 14 (2022) 4819. https://doi.org/10.3390/su14084819 DOI: https://doi.org/10.3390/su14084819
[14] I.U. Toor, H.M. Irshad, H.M. Badr, M.A. Samad, The effect of impingement velocity and angle variation on the erosion corrosion performance of API 5L-X65 carbon steel in a flow loop, Metals 8 (2018) 402. https://doi.org/10.3390/met8060402 DOI: https://doi.org/10.3390/met8060402
[15] J. Malik, I. Toor, W. Ahmed, Z. Gasem, M. Habib, R. Ben-Mansour, H. Badr, Investigations on the corrosion-enhanced erosion behavior of carbon steel AISI 1020, International Journal of Electrochemical Science 9 (2014) 6765-6780. https://doi.org/10.1016/S1452-3981(23)10928-X DOI: https://doi.org/10.1016/S1452-3981(23)10928-X
[16] R. Ben-Mansour, H.M. Badr, A.A. Araoye, I.U.H. Toor, Computational analysis of water-submerged jet erosion, Energies 14 (2021) 3074. https://doi.org/10.3390/en14113074 DOI: https://doi.org/10.3390/en14113074
[17] K.A. Mohammed, A.K. Okab, H.S. Hamad, M. Hashim, R.K. Abdulhussain, Drilling and casing pipes corrosion investigation in water-based drilling mud of Iraqi oil fields environment, Journal of Mechanical Engineering Research and Developments 44 (2021) 232-240. https://www.researchgate.net/publication/353084339_Drilling_and_Casing_Pipes_Corrosion_Investigation_in_Water_Based_Drilling_Mud_of_Iraqi_Oil_Fields_Environment
[18] M.S. Parancheerivilakkathil, S. Parapurath, S. Ainane, Y.F. Yap, P. Rostron, Flow velocity and sand loading effect on erosion–corrosion during liquid-solid impingement on mild steel, Applied Sciences 12 (2022) 2530. https://doi.org/10.3390/app12052530 DOI: https://doi.org/10.3390/app12052530
[19] K.A. Mohammed, Experimental and theoretical investigation of top of the line corrosion in CO2 gas and oil environments, University of Leeds, 2018. oai:etheses.whiterose.ac.uk:20479
[20] H. Zhou, Q. Ji, W. Liu, H. Ma, Y. Lei, K. Zhu, Experimental study on erosion-corrosion behavior of liquid–solid swirling flow in pipeline, Materials & Design 214 (2022) 110376. https://doi.org/10.1016/j.matdes.2021.110376 DOI: https://doi.org/10.1016/j.matdes.2021.110376
[21] T. Jing, H.-l. Huang, Z.-q. Pan, Z. Hong, Effect of flow velocity on corrosion behavior of AZ91D magnesium alloy at elbow of loop system, Transactions of Nonferrous Metals Society of China 26 (2016) 2857-2867. https://doi.org/10.1016/S1003-6326(16)64414-X DOI: https://doi.org/10.1016/S1003-6326(16)64414-X
[22] C. Telfer, M. Stack, B. Jana, Particle concentration and size effects on the erosion-corrosion of pure metals in aqueous slurries, Tribology International 53 (2012) 35-44. https://doi.org/10.1016/j.triboint.2012.04.010 DOI: https://doi.org/10.1016/j.triboint.2012.04.010
[23] H. Hu, Y. Zheng, The effect of sand particle concentrations on the vibratory cavitation erosion, Wear 384 (2017) 95-105. https://doi.org/10.1016/j.wear.2017.05.003 DOI: https://doi.org/10.1016/j.wear.2017.05.003
[24] J. Liu, W. BaKeDaShi, Z. Li, Y. Xu, W. Ji, C. Zhang, G. Cui, R. Zhang, Effect of flow velocity on erosion–corrosion of 90-degree horizontal elbow, Wear 376 (2017) 516-525. https://doi.org/10.1016/j.wear.2016.11.015 DOI: https://doi.org/10.1016/j.wear.2016.11.015
[25] A. Neville, C. Wang, Erosion–corrosion of engineering steels—Can it be managed by use of chemicals?, Wear 267 (2009) 2018-2026. https://doi.org/10.1016/j.wear.2009.06.041 DOI: https://doi.org/10.1016/j.wear.2009.06.041
[26] R. Elemuren, R. Evitts, I. Oguocha, G. Kennell, R. Gerspacher, A. Odeshi, Slurry erosion-corrosion of 90 AISI 1018 steel elbow in saturated potash brine containing abrasive silica particles, Wear 410 (2018) 149-155. https://doi.org/10.1016/j.wear.2018.06.010 DOI: https://doi.org/10.1016/j.wear.2018.06.010
[27] T. Harvey, J. Wharton, R. Wood, Development of synergy model for erosion–corrosion of carbon steel in a slurry pot, Tribology-Materials, Surfaces & Interfaces 1 (2007) 33-47. DOI: https://doi.org/10.1179/175158407X181471
[28] A. Neville, C. Wang, Erosion–corrosion mitigation by corrosion inhibitors—an assessment of mechanisms, Wear 267 (2009) 195-203. https://doi.org/10.1179/175158407X181471 DOI: https://doi.org/10.1016/j.wear.2009.01.038
[29] X. Hu, A. Neville, The electrochemical response of stainless steels in liquid–solid impingement, Wear 258 (2005) 641-648. https://doi.org/10.1016/j.wear.2004.09.043 DOI: https://doi.org/10.1016/j.wear.2004.09.043
[30] R. Wood, S. Hutton, The synergistic effect of erosion and corrosion: trends in published results, Wear 140 (1990) 387-394. https://doi.org/10.1016/0043-1648(90)90098-U DOI: https://doi.org/10.1016/0043-1648(90)90098-U
Downloads
Published
Issue
Section
License
Copyright (c) 2025 Khalid A. Mohammed
This work is licensed under a Creative Commons Attribution 4.0 International License.
