Yue Zhangab,
Xiangyu Yinab,
Yunfeng Yana,
Jianzhang Wanga and
Fengyuan Yan*a
aState Key Laboratory of Solid Lubrication, Lanzhou Institute of Chemical Physics, Chinese Academy of Sciences, Lanzhou 730000, PR China. E-mail: fyyan@licp.cas.cn; Tel: +86-0931-4968185
bUniversity of Chinese Academy of Sciences, Beijing 100049, PR China
First published on 26th January 2015
The tribocorrosion behavior of 304SS in chloride-containing solutions with different pH (pH 7.2–9.2) was investigated under rubbing conditions of 50 N and 100 R min−1 using a pin-on-disc tribometer with an Al2O3 pin mounted on a vertical rotating axis. When combined with rubbing, the corrosion of 304SS was accelerated due to the formation of galvanic couples between the mechanical depassivated areas and the surrounding passivated areas. In addition, the continuous sliding-over processes also make the pitting corrosion to occur more easily due to the affinity of Cl− to metal cations near the active surface. However, OH− has better affinity than Cl−; therefore, a high pH solution mitigates the local corrosion with a wear track. It was found that high pH solution exhibits good lubricity, and both the friction coefficient and total material loss reduce evidently with increasing pH. From the calculation results and wear morphologies, we can confirm that pure mechanical and corrosion-accelerated wear, including abrasion and delamination, are among the chief reasons for material loss.
Malik et al. reported that with increasing pH, the corrosion rate of 316L steel decreases in a 1000 ppm Cl− aqueous solution, being highest at pH 4 and lowest at pH 9.15 Recently, Liu and Wu found that in a 3.5% NaCl solution, the acidity of the electrolyte (pH 0.8–5) influences the passivation performance of highly alloyed austenitic 254SMO stainless steel, in terms of the film's composition, structure, growth-rate and cations dissolution behavior, but has no effect on the pitting resistance of the passive film.21 Similarly, earlier studies have also shown that the critical potential is not greatly affected in acid 0.1 mol L−1 NaCl with pH ranging from 1 to 7; in alkaline solutions, pH 7–10, however, the critical potential was reported to shift in the noble direction upon the addition of NaOH to 0.1 M NaCl, which directly corresponds to an increased resistance to pitting; above pH 10, the potential also moves in the active direction as the pH increases, which is due to the formation of CrO4− instead of reflecting the pitting resistance.12,22
Recently, special attention has been paid to investigations of the role of pH on the corrosion susceptibility of metals and alloys during various friction and wear processes, including abrasion, fretting and erosion etc. in chloride containing corrosive solutions, because during these processes, the mass loss of materials is often not a simple sum of the losses caused by mechanical wear and corrosion but exceed this sum somewhat.23–28 Therefore, the influence of pH on corrosion or wear resistance is bound to be reflected by the tribocorrosion behavior of the materials. Licausi et al. found that during sliding friction and wear, icorr is three times higher in an acidic solution (pH 3) than in a neutral (pH 6) or basic (pH 9) one for both cast and sintered alloys. However, at the OCP, the total degradation of the cast alloy is independent of the pH, while for the sintered material, it increases slightly with pH.29 Despite this, Mathew did not accept these results and proposed the total degradation peaks at pH 6 because at this pH value, the reformed passive film layer is not cohesive and the tribocorrosion products are easily sheared off in the presence of motion.30 Unfortunately, little work has been carried out to investigate the influence of pH on the corrosion, wear, and following tribocorrosion behavior of austenite stainless steels in chloride-containing solutions.
It is well known that austenite stainless steels (e.g. 304 and 316 steels) perform excellently as marine engineering materials because of their general and even pitting corrosion resistances. However, tribocorrosion is an important and widespread phenomenon encountered in many practical engineering situations. When they undergo various contact motions, such as impacting, rubbing and rolling, the good anti-corrosion properties will degrade due to destruction of the protective passive film on metal surface.25,31–34 In addition, the performance of a passive film is also restricted by its formation conditions, such as the chloride concentration, temperature, and pH. Indeed, the pH is changing in different seawater environments and always ranges from 7.5 to 8.6. Therefore, in this study, a wider range of pH values (7.2–9.2) was used to investigate its effect on the tribocorrosion behavior of 304SS in chloride-containing electrolytes.
Elements | Cr | Si | Mo | Ni | Mn | C | P | S | Fe |
---|---|---|---|---|---|---|---|---|---|
Content/wt% | 18.50 | 0.59 | 0.30 | 8.12 | 0.88 | 0.05 | 0.015 | 0.028 | Bal. |
The electrochemical characteristics of 304SS with and without rubbing in artificial seawater were studied using a conventional three-electrode cell, and the assembly of electrodes was also described in ref. 35. Potentiodynamic polarization tests were performed at a scanning rate of 2 mV s−1 from −250 mV to +1000 mV with respect to Ecorr of the steel. Upon the electrochemical results, several electrochemical parameters, such as the free corrosion potential (Ecorr), pitting potential (Epit), and corrosion current density (icorr), were calculated and are listed in Table 1. The corrosion rate with (C, mm per year) and without (C0, mm per year) wear was also calculated according to ASTM G 102-89. All tests were carried out at least three times at room temperature open to the air, and the average values are reported.
Based on C, and total mass loss (T), the wear rate with corrosion (W, mm per year) can be calculated using the following equation:
W = T − C | (1) |
By combining with the pure wear rate (W0, mm per year) and the pure corrosion rate (C0, mm per year) obtained from the static Tafel curve, the wear increment (ΔWC, mm per year) and the corrosion increment (ΔCW, mm per year) can be deduced as follows:
ΔWC = W − W0 | (2) |
ΔCW = C − C0 | (3) |
Therefore, the synergistic effect between mechanical and electrochemical material loss can be described by eqn. (4) and (5):
S = T − W0 − C0 | (4) |
S = ΔWC + ΔCW | (5) |
In addition, three dimensionless factors, i.e., the total synergism factor, corrosion augmentation factor, and wear augmentation factor, are used to depict the synergism degree of corrosion and wear.
The total synergism factor is:
![]() | (6) |
The wear augmentation factor is:
![]() | (7) |
The corrosion augmentation factor is:
![]() | (8) |
pH | Corrosion | Tribocorrosion | ||||||||
---|---|---|---|---|---|---|---|---|---|---|
7.2 | 7.7 | 8.2 | 8.7 | 9.2 | 7.2 | 7.7 | 8.2 | 8.7 | 9.2 | |
Ecorr/VAg/AgCl | −0.234 | −0.137 | −0.070 | −0.001 | 0.034 | −0.730 | −0.691 | −0.604 | −0.598 | −0.567 |
Epit/VAg/AgCl | — | 0.136 | 0.199 | 0.233 | 0.265 | 0.009 | 0.058 | 0.096 | 0.111 | 0.208 |
Epit–corr/VAg/AgCl | — | 0.273 | 0.269 | 0.234 | 0.231 | 0.739 | 0.749 | 0.700 | 0.709 | 0.775 |
icorr/μA cm−2 | 2.30 | 0.99 | 0.83 | 0.76 | 0.18 | 347.0 | 337.31 | 300.07 | 227.50 | 209.35 |
βc/mV dec−1 | −51.69 | −54.15 | −54.13 | −54.06 | −56.75 | −63.32 | −59.40 | −61.26 | −56.62 | −60.64 |
βa/mV dec−1 | 26.99 | 48.37 | 50.78 | 49.35 | 48.55 | 65.04 | 66.16 | 63.73 | 57.99 | 63.31 |
Fig. 1a shows the typical potentiodynamic polarization curves for 304SS in alkaline, chloride solutions with different pH values. Consistent with the conclusions reported previously,12 both the free corrosion potential (Ecorr) and the pitting potential (Epit) shift towards the noble direction with increasing pH, indicating that high OH− concentration inhibits the occurrence of corrosion for 304SS.
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Fig. 1 Potentiodynamic polarization curves of 304SS obtained in different solutions (a) without and (b) with mechanical rubbing. |
Although it is difficult to distinguish the pitting potential for 304SS when polarized in a pH 7.2 solution, pitting did occur, as proven by the thickly dotted pits found on the surface. In addition, between pH 7.7–9.2, Epit was found to be a function of pH. By linear regression, the following relation was established:
Epit = 0.084 pH − 0.503 | (9) |
This equation can be derived on the view that competitive adsorption occurs between OH− and Cl− for the sites on the passive surface. As discussed in detail by Kolotyrkin,4,36 the initiation of pitting is a process, where Cl− ions constantly adsorb and accumulate on the passive surface of alloys by displacing adsorbed oxygen until a sufficient concentration corresponding to the critical potential is reached. The Cl− ions succeed at the favored sites in destroying the passivity. However, when OH− ions are present, they also tend to adsorb on the passive surface and displace Cl− ions, due to the better affinity of OH− ions for passive surface of 304SS than Cl− ions.15,36,37 Hence, in the presence of OH− ions, the initiation of pitting requires a shift in the potential towards a more positive value to enable Cl− ions to reach a concentration adequate enough to break the protective passive film locally. The higher the OH− concentration, the more notable the shift in the pitting potential for 304SS in the positive direction.
In addition, the icorr also increases apparently with decreasing pH. When the 304SS sample is immersed in a pH 7.2 electrolyte, icorr increases over one order of magnitude compared to that in a pH 9.2 solution. In neutral or alkaline solutions, the cathodic reaction of electrochemistry corrosion is dominated by the reduction of dissolved oxygen occurring on the passive surface, as shown in reaction (10).
O2 + 2H2O + 4e− ⇄ 4OH− | (10) |
A high OH− concentration is adverse to shifting the reaction equilibrium to the positive direction. In other words, a high OH− concentration may restrain this oxygen reduction reaction, which provides the driving force for the anodic dissolution of 304SS. Therefore, a smaller icorr for 304SS is displayed as the solution pH increases from 7.2 to 9.2.
In the case of tribocorrosion for 304SS, as shown in Fig. 1b, Ecorr, Epit and icorr present the same variation trend with increasing solution pH, i.e., Ecorr and Epit become more positive, and icorr decreases gradually with increasing pH. However, there is an essential difference between the course of the polarization of 304SS during static corrosion and tribocorrosion. The combination of corrosion and rubbing significantly shifts Ecorr and Epit towards a more negative direction with respect to those in the absence of rubbing. Under these conditions, the change in the pitting potential of 304SS with increasing pH follows the law below:
Epit = 0.090 pH − 0.643 | (11) |
In addition, a larger difference between Ecorr and Epit (represented symbolically by Epit–corr and the values are listed in Table 2) was observed than that obtained from static corrosion experiment at the same pH, which was attributed to the constant removal-recovery of the passive film on 304SS during the periodic sliding-over processes.
Sliding contact between 304SS and Al2O3 must destroy the completeness of the passive film and produce an electrochemically active surface with a lower equilibrium potential exposed to a corrosive solution. First, this partial destruction of protective film initiates the occurrence of galvanic corrosion, as previously described by Lucas,34 and shifts the Ecorr to the negative direction. In addition, the results showing that icorr increases by even four orders of magnitude compared to that obtained under static corrosion should also be attributed to the establishment of the galvanic couples between the mechanical depassivated areas (anode) and the surrounding passivated areas (cathode). Most importantly, the continuous sliding-over processes also make pitting corrosion take place more easily. As discussed above, the dissolution of active surface is actuated by the rubbing processes in seawater, as described by reactions (12–14).
Fe − 2e− → Fe2+ | (12) |
Cr − 3e− → Cr3+ | (13) |
Ni − 2e− → Ni2+ | (14) |
As a result of these reactions, the electrolyte very near the active surface gains a positive electrical charge relative to the surrounding electrolyte. The anions (Cl−, OH−, SO4−, etc.) are attached and migrate to the active surface to achieve a charge balance, and some even react with metal cations to form Fe2+, Cr3+ and Ni2+ chlorides at the anode areas or pits, destroying the passivity and preventing its recurrence by dissolved oxygen as follows:38–41
Fe2+ + Cl− + OH− → FeOCl− + H+ | (15) |
Cr3+ + Cl− + OH− → CrOCl + H+ | (16) |
Ni2+ + Cl− + OH− → NiOCl− + H+ | (17) |
The pH of the electrolyte very near the active surface decreases due to the formation of H+, which causes the further acceleration of corrosion of 304SS and even stimulates the pitting corrosion of 304SS by the nucleation of more metastable pits, as demonstrated by Burstein and Sasaki.42 However, the survival of these metastable pit below the pitting potential is determined by the perforated cover over the pit mouth by providing an additional diffusion barrier that enables the concentrated pit solution to be maintained.43 However, the continuous rubbing processes must rupture or even remove the perforated cover, and make the process of pit growth display a wide range of amplitudes in a certain scale of potentials under tribocorrosion, evidenced by the larger Epit–corr values.
On the basis of the experimental data reported above, it is clear that rubbing may significantly increase the susceptibilities of general corrosion and pitting corrosion, as well as corrosion rate. We can therefore draw the conclusion that the electrochemical signals are governed by the continuous depassivation caused by rubbing. In addition, the pH of the chloride-containing electrolytes also have distinguished influence on the electrochemical signals.
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Fig. 3 pH dependence of the worn surface morphologies of 304SS after tribocorrosion in different solutions. |
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Fig. 4 Synergetic contributions of mechanical wear and corrosion to each other and to the total mass loss of 304SS in different solutions. |
Fig. 4a displays the synergistic effects between corrosion and wear, which were calculated using eqn (6)–(8). It is evident that corrosion and wear were claimed to interact and accelerate each other, as evidenced by all three dimensionless factors greater than 1, and the augmentation extent of wear to corrosion is much greater. With increasing pH, the acceleration of corrosion due to wear increases; rather, the acceleration of wear by corrosion decreases gradually, as shown in Fig. 4a. The opposite acceleration tendencies can be explained in the following two ways. On one hand, corrosion can accelerate wear in that its occurrence may deteriorate the characteristics of the contact surface between the 304SS sample and Al2O3 pin. In this situation, with increasing pH, the absolute corrosion rate decreases apparently in the presence of rubbing in chloride solutions (Fig. 4b), so the corresponding surface deterioration mitigates, and shows a reduced acceleration of wear. On the other hand, the absolute wear rate decreases gradually with increasing pH (Fig. 4c), as a higher alkaline solution has better lubricity and makes the rubbing process run more smoothly as was pointed out above. Consequently, under the same mechanical condition, after each rubbing-over process, the fresh wear track areas that correspond to the damage areas of the regenerated passive film within the wear track are small in a high pH solution. In other words, during the periodic removal-regeneration processes, the completeness of the passive film is in a state of dynamic balance, and the area ratio of the passive surface to a mechanically depassivated surface, corresponding to cathode-to-anode area ratio (Ac/Aa), is a quasi-constant when 304SS experiences tribocorrosion in the same pH solution.
In a galvanic cell, the apparent external current is nil at the OCP.29 Considering the cathodic ic and anodic ia current densities, one equation can be written for the case of the tribocorrosion experiments:
iaAa = −icAc ⇔ −ia/ic = Ac/Aa | (18) |
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