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Tribo-electrochemical behavior of a high chromium white cast iron (high-Cr WCI) used in, e.g., slurry pumps in mining and mineral processing applications, was investigated using a combination of electrochemical techniques, including zero resistance amperometry as well as potentiostatic and potentiodynamic polarisation. The effects of third body particles angularity on the localised tribocorrosion response of the cast alloy was studied during and post abrasion-corrosion by round ceramic beads and semi-angular silica sand particles. Advanced characterization methods such as electron backscatter diffraction and focused-ion beam cross-sectioning of affected areas were also employed to understand the wear and corrosion interactive actions. It was found that in chloride-free solutions, the behavior of high-Cr WCI resembled that of the austenitic 316 SS studied before. In contrast, in chloride-containing electrolytes, the semi-angular silica sand particles increased interfacial (carbide/matrix) localised corrosion susceptibility during and post-abrasion as indicated by the stark increase in anodic current and the morphology of the attack. Semi-angular silica sand abrasives had a greater adverse impact on post-abrasion interfacial corrosion vulnerability, compared to round ceramic beads. The complex behavior observed indicates that any material developed for tribocorrosive conditions must account for the particles angularity and their subsequent effects on localised corrosion.

The formation of interconnected grain boundary (GB) phases in precipitation hardening (PH) nickel Alloy 725 (UNS N07725) compromises its mechanical properties and has been linked to hydrogen embrittlement failures. However, normative industry standards such as API 6ACRA are inadequate for differentiating between Alloy 725 batches with a critical extent of GB precipitation, creating the need for a complementary qualification method. In Alloy 725, intergranular phases produce a Cr and Mo depletion adjacent to GBs (i.e., sensitization). In Part I of this work, this impoverishment in Cr and Mo was used as the basis to develop a double-loop electrochemical potentiokinetic reactivation (DL-EPR) test, optimized to quantify the extent of GB precipitation in Alloy 725. Part II explores the reproducibility and sensitivity of the new approach using three new independent commercial batches containing different extents of precipitation. Results were highly reproducible and confirmed the method’s sensitivity to detect small amounts of GB phases. Additionally, the DL-EPR procedure revealed clear microstructural inhomogeneities across the bars’ thickness, which increased with increasing bar diameter. This investigation strongly supports the validity of the new DL-EPR technique as a reliable and straightforward industry-friendly qualification method to quantify the extent of intergranular phases in Alloy 725.

Precipitation hardened nickel-based Alloy 725 (UNS N07725) has been proven susceptible to hydrogen embrittlement in oil and gas production. Moreover, current standards cannot differentiate unequivocally between acceptable and affected microstructures, making the development of an appropriate quality control test a priority for the oil and gas industry. Recently, Alloy 725 failures were associated with the precipitation of nanoscale Cr- and Mo-rich phases at grain boundaries (GBs). Since these intergranular precipitates could lead to Cr- and Mo-depletion along the decorated GBs (i.e., sensitization), the double-loop electrochemical potentiokinetic reactivation (DL-EPR) test was explored as an alternative approach to detect affected microstructures. Herein, the DL-EPR technique was optimized for Alloy 725 by testing three types of samples with different degrees of sensitization, including a full GB-decorated microstructure that was shown prone to hydrogen embrittlement in oil and gas service. The optimized DL-EPR test conditions were 2 M HCl + 1 M H2SO4 + 10−4 M KSCN aqueous solution at 30 °C with a 1.667 mV s−1 scan rate and a vertex potential of Ecorr + 700 mV. Results were reproducible and consistent with the degree of GB decoration determined using metallographic methods. The test procedure developed herein could lead to the standardization of the DL-EPR method for Alloy 725.