Weir Advanced Research Centre

The main objective of this study was to assess the influence of salt concentration on the corrosion behaviour, including the role of hydrodynamic conditions, of two broad classes of ferrous engineering materials. These are comprised of alloys, typified by a low-alloy steel (UNS G43400) that corrodes actively in aqueous conditions and a range of passive-film-forming stainless steels (UNS S31600, UNS S15500 and UNS S32760). Corrosion monitoring employed electrochemical (potentiodynamic polarisation) techniques. Three concentrations of aerated sodium chloride were utilised: 0.05 wt% NaCl, 3.5 wt% NaCl and 10 wt% NaCl. In quiescent, liquid impingement and solid/liquid impingement conditions, the corrosion rate of the low-alloy steel was observed to peak at 3.5 wt% NaCl, followed by a reduction in 10 wt% NaCl solution. These findings expand the range of previously reported trends, focused on static conditions. Such corrosion rate/salinity trends were observed to be dictated by the progress of the anodic reaction rather than influence on the cathodic reaction. Detailed studies were undertaken using segmented specimens to facilitate comparisons of the influence of hydrodynamic variations on corrosion behavior; these revealed that such variations influence the corrosion rates of low-alloy steel to a much lesser extent than the effect of changes in salinity. For the stainless steels, in quiescent and flowing conditions, when surface passive films are stable, there was a constant increase in corrosion rate with salinity. In solid-liquid conditions, however, the periodic film-destruction/repassivation events resulted in a similar corrosion rate/salinity trend to that displayed by the low-alloy steel, but with a much larger effect of hydrodynamic conditions. Additonally, the study revealed an underlying influence of stainless steel composition that mirrored, to an extent, the corrosion behaviour in pitting/re-passivation situations

Cathodic protection prolongs the service life of fluid transport and offshore engineering components by suppressing corrosion. This study assesses the effect of two cathodic protection methods, such as impressed current cathodic protection (ICCP) and sacrificial anode cathodic protection (SACP), on three ferrous-based materials under laboratory-controlled corrosive wear conditions. The SACP was as effective as ICCP on the protection of the low alloy steel and white chromium cast iron under both solid and solid-free corrosive wear conditions. Under solid–liquid impingement, significant reductions in the material loss were also observed in both the direct impingement zone and the outer area (oblique angle of attack). This demonstrates the substantial impact of cathodic protection systems that are exposed to erosion–corrosion dominated environments.

The introduction of dynamic bonds capable of mediating self-healing in a fully cross-linked polychloroprene network can only occur if the reversible moieties are carried by the cross-linker itself or within the main polymer backbone. Conventional cross-linking is not suitable for such a purpose. In the present work, a method to develop a self-healable and recyclable polychloroprene rubber is presented. Dynamic disulfide bonds are introduced as part of the structure of a crosslinker (liquid polysulfide polymer, Thiokol LP3) coupled to the polymer backbone via thermally initiated thiol-ene reaction. The curing and kinetic parameters were determined by isothermal differential scanning calorimetry and by moving die rheometer analysis; tensile testing was carried to compare the tensile strength of cured compound, healed compounds and recycled compounds, while chemical analysis was conducted by surface X-ray Photoelectron Spectroscopy. Three formulations with increasing concentrations of Thiokol LP-3 were studied (2, 4, 6 phr), reaching a maximum ultimate tensile strength of 22.4 MPa and ultimate tensile strain of 16.2 with 2 phr of Thiokol LP-3, 11.7 MPa and 10.7 strain with 4 phr and 5.6 MPa and 7.3 strain with 6 phr. The best healing efficiencies were obtained after 24 h of healing at 80 °C, increasing with the concentration of Thiokol LP-3, reaching maximum values of 4.5% 4.4% 13.4% with 2 phr, 4 phr and 6 phr, respectively, while the highest recycling efficiency was obtained with 4 phr of Thiokol LP-3, reaching 11.2%.

Abstract This study utilises a recently developed, enhanced approach to assess detailed aspects of the corrosive wear behaviour of different steel grades in aqueous slurries containing three NaCl concentrations (0.05%NaCl, 3.5%NaCl and 10%NaCl). Erosion-corrosion testing was conducted using a slurry impingement test rig and damage was quantified using volume loss, potentiodynamic polarisation scans and surface topography. Single- and segmented specimens were adopted to yield the contribution of the degradation mechanisms in the two hydrodynamic zones (directly impinged and surrounding area). The overall material losses from the two zones of the stainless steels were observed to increase with increasing salinity. However, the overall material loss for the low-alloy steel was found to increase from 0.05%NaCl to 3.5%NaCl, before reducing when the salinity was further increased to 10%NaCl. Changes in salinity were observed to have the most effect on the corrosion-enhanced mechanical damage mechanism. The in-house developed technique demonstrated good linkage between single samples and the outer area damage region. However, it also showed that the use of single samples can be less successful when assessing highly turbulent (directly impinged) damage regions.

configurations are found. Additionally, it is observed that by increasing the level of functionalisation, the glass transition temperature of the resulting modified elastomer also increases. Overall, this study provides valuable insights into the effects of thiol-ene chemistry on the structure and properties of elastomers and could have important implications for the development of new materials with enhanced functionality.

Abstract In some industrial situations, components are subject to repetitive impact in the presence of a slurry. A novel repetitive impact-with-slurry test rig was developed to evaluate the behaviour of a wide range of engineering materials in such conditions. The test materials could be categorised into five main groups – heat treated steels, stainless steels, chromium cast irons, hardfacing coatings and superalloys. Three-dimensional surface topography was used to quantify the depths and volumes of the produced wear scars. Post-test metallurgical examination was also conducted to further evaluate the wear processes. The wear mechanisms could be split into two main groups of materials; ductile materials were observed to plastically deform and hard/brittle materials demonstrated cracking/spalling mechanisms. Hardened martensitic-type materials exhibited the greatest resistance to repetitive impact wear.

Swellable packers have been widely employed in various oil & gas applications. Downhole conditions are difficult to reproduce using physical testing environments, but can be simulated in a virtual environment using CAE software. A better understanding of packers’ mechanical behaviour in downhole conditions would provide a higher confidence and improvement in existing engineering design practices for the manufacturing of packers. The numerical simulation can be incorporated into optimisation procedures searching for an optimal shape of packers aiming to minimise the time to seal the borehole and maximise the contact pressure between the seal and borehole. Such an optimisation would facilitate the development of a packer with various designs optimised for different downhole conditions. The objective of this work is to develop a design tool integrated into Abaqus/CAE to implement parametric numerical studies using implicit and explicit FE-simulations. However, development of such a CAE plugin is associated with a number of technical challenges specific to this class of multiphysics problems, which are addressed in this research and discussed in the paper.

With ever advancing simulation techniques and algorithms being introduced to commercial software, the importance of validation remains a priority. An experimental rig was designed to study the effects of rubber extrusion consisting of a compression testing system and a transparent extrusion barrel, of similar geometry to that used in a forming process. Through visual and numerical comparison, the experimental results would be compared to those obtained through Finite Element Analysis (FEA). To remedy the convergence difficulties of the complexity of the simulation, due to large deformations, a recent Nonlinear Adaptive Remeshing boundary condition was applied to the model.

Swellable elastomeric seal is a type of specifically engineered packer that swell upon contact with wellbore fluids. Assessment of leakage tightness is a fundamental aspect in the design of swellable packers, since they should guarantee a reliable sealing under extreme pressures of the downhole fluids. Numerical capability of the leakage pressure prediction would facilitate improvement in the packer design methodology. Previous work was focused on investigation of the non-parametric optimisation capability seeking for an optimal external shape with a goal to maximise the grip of a packer with a borehole. The verification of an optimised design was done with a dynamic FE-simulation of packer’s failure by extrusion under an excessive pressure. The downside of that verification analysis was that Abaqus/Explicit solver couldn’t implement a realistic adaptive pressure application due to changing packer disposition and contact conditions. This simulation challenge is addressed in this paper by application of the Coupled Eulerian-Lagrangian (CEL) approach in Abaqus/Explicit, which provides the ability to simulate a class of problems where the fluid-structure interaction is important.