All-aluminum microchannel heat exchangers are designed to significantly reduce refrigerant charge requirements, weight, reduced brazed joints, and decreased potential for leakage by increasing reliability. Al 3003 alloy is corrosion resistant and can be formed, welded, and brazed but the issue with all-aluminum heat exchangers is localized corrosion (pitting) in corrosive environments. Currently, there is no universally accepted corrosion test that all coil manufacturers use to characterize their products. Electrochemical testing method of cyclic polarization was employed in this investigation and relevant parameters including electrolyte corrosive agent and its concentration, electrolyte pH, and applied potential scan rate was varied to find an optimal set of parameters. Results of cyclic polarization of Al 3003 in electrolytes containing various concentrations of NaCl were compared with those of the tests in Sea Water Acidified Accelerated Test (SWAAT) electrolyte and it is shown the SWAAT electrolyte (4.2% sea salt acidified to pH of 2.9) is by far stronger (in terms of corrosivity) than typical 3.5% NaCl solution used in most corrosion testing. Corrosion rates (g/m2yr) of Al 3003 measured in this investigation were comparable to those provided by ISO 9223 standard corresponding to C1 through CX categories. Duration of cyclic polarization test is much shorter than that of SWAAT and results obtained in this test is more reproducible compared to those of SWAAT. Scanning electron microscopy micrographs show typical pit depths of about 50 μm.

Corrosion of all aluminum microchannel heat exchangers present a challenge in automotive and heating, ventilation, and air conditioning (HVAC) industries. Reproducibility of Salt Water Acetic Acid Test (SWAAT) has been questioned and a need to new corrosion tests with better reproducibility has risen. Cyclic polarization, that is an electrochemical test, was explored for its suitability for the assessment of AA 3102 tube material that is currently a popular aluminum alloy used in manufacturing of heat exchanger. Corrosive electrolytes containing 3.5 % sodium chloride with 0.5 % ammonium sulfate (high chloride) or 0.5 % sodium chloride with 3.5 % ammonium sulfate (high sulfate) at their pH or acidic (pH=4) were used to measure corrosion potential (Ecorr), protection potential (Epp), pitting potential (Epit), Tafel constants (βa and βc), corrosion rate (mpy). Corrosive electrolyte used in SWAAT test (4.2% Sea Salt at pH 2.9) was also used to compare corrosion resistance of AA 3102 in SWAAT electrolyte compared to the other electrolytes used in this research. Scanning electron microscopy (SEM) was used to observe and document sample surface corrosion damage after each electrochemical test on all samples. Results of the cyclic polarization tests indicated that SWAAT electrolytes was the most aggressive electrolyte resulting in highest corrosion rates compared to all other electrolytes used in this investigation. SEM results indicated AA 3102 alloy exhibited higher pitting tendency in electrolytes with high sodium chloride whereas high sulfate electrolytes cause appearance of uniform corrosion surface damage on this alloy. Both high sulfate and SWAAT electrolytes showed intergranular corrosion but high chloride electrolyte showed severe pitting of AA 3102. Mohammad Navid Dorreyatim- Cyclic Polarization of AA 3102 in Corrosive Electrolytes Containing Sodium Chloride and Ammonium Sulfate. Master of Science (Mechanical and Energy Engineering), December 2016, 98 pp., references, 31 titles.

CoordenaÃÃo de AperfeiÃoamento de NÃvel Superior / As torres de destilaÃÃo de petrÃleo sofrem corriqueiramente com problemas relacionados à corrosÃo devido ao elevado Ãndice de acidez presente no petrÃleo exigindo uma elevada resistÃncia à corrosÃo por parte dos equipamentos utilizados. Dentre os materiais empregados na fabricaÃÃo e revestimento dos equipamentos, destacam-se os aÃos inoxidÃveis austenÃticos da sÃrie 300. Os aÃos inoxidÃveis austenÃticos sÃo largamente utilizados em componentes que operam em faixas de temperaturas elevadas, tais como caldeiras, super aquecedores, reatores quÃmicos e etc. Os aÃos inoxidÃveis super austenÃticos, devido ao aumento no teor de cromo e molibdÃnio se comparado aos aÃos austenÃticos da sÃrie 300, apresentam uma excelente resistÃncia à corrosÃo localizada, principalmente à corrosÃo por pites que à uma das mais danosas formas de corrosÃo aos equipamentos fabricados por esses aÃos. Os aÃos inoxidÃveis super austenÃticos tÃm sido apontados como possÃveis substitutos para a sÃrie austenÃtica 300 para aplicaÃÃes em equipamentos que requerem temperaturas elevadas e em meios agressivos como os encontrados na indÃstria do petrÃleo. Objetivando avaliar e comparar a resistÃncia à corrosÃo por pites do aÃo comercial inoxidÃvel super austenÃtico AL 6XN PLUSâ com os aÃos inoxidÃveis austenÃticos 304L, 316L e 317L para elevadas temperaturas, amostras desses aÃos foram submetidas a tratamentos tÃrmicos para as temperaturas de 500, 700 e 900 C por um perÃodo de 72 horas. Foram tambÃm analisadas as amostras na condiÃÃo como recebidas. Foram realizados ensaios de polarizaÃÃo cÃclica para avaliar e comparar a resistÃncia à corrosÃo por pites entre os materiais citados utilizando uma soluÃÃo aquosa de Ãcido sulfÃrico e cloreto de sÃdio nas concentraÃÃes 0,5 M H2SO4 + 0,5 M NaCl e 1 M H2SO4 + 2 M NaCl. Os resultados mostraram uma maior suscetibilidade à corrosÃo por pites no aÃo 304L. Os aÃos 316L e 317L apresentaram desempenho intermediÃrio (pites menores à medida que o material tornava-se mais nobre) e tambÃm corrosÃo em frestas. O aÃo super austenÃtico AL 6XN PLUSâ mostrou o melhor desempenho em ambos os eletrÃlitos utilizados. Somente uma amostra do aÃo super austenÃtico e em uma condiÃÃo extrema de temperatura e meio corrosivo mostrou suscetibilidade à corrosÃo por pites. Esse comportamento à bem desejÃvel na indÃstria do petrÃleo. / The oil distillation towers routinely suffer problems related to corrosion due to the high level of acidity present in the oil requiring a high resistance to corrosion of the equipment in use. Among the materials used in the manufacturing and coating of equipment, we highlight the Austenitic Stainless Steel of the 300 Series. Austenitic stainless steels are widely used in components for high temperatures, such as boilers, super heaters, chemical reactors, etc. Super austenitic stainless steels, due to their high Cr and Mo content, as compared to regular austenitic types, show a higher resistance to pitting corrosion, which is one of the most harmful forms of localized corrosion. These steels have been pointed as a possible replacement for common austenitic steels for applications at high temperatures and aggressive media, as in the oil industry. In order to evaluate and compare the resistance to pitting corrosion of AL 6XN PLUS â super austenitic stainless steel commercial with the 304L, 316L and 317L austenitic stainless steels for high temperatures, samples of these steels were subjected to heat treatments at temperatures of 500, 700 and 900  C for a period of 72 hours. Samples in the as-received condition were also analyzed. Cyclic polarization tests were performed to evaluate and compare the resistance to pitting corrosion of the materials mentioned using an aqueous solution of sulfuric acid and sodium chloride concentrations in 0.5 M H2SO4 + 0.5 M NaCl and 1 M H2SO4 + 2 M NaCl. The results showed a higher susceptibility to pitting corrosion in the 304L steel. 316L and 317L steels showed intermediate performance (smaller pits as the material became more noble) and crevice corrosion as well. The AL 6XN PLUS â super austenitic steel showed the best performance in both electrolytes used. Only a sample of the super austenitic steel and in an extreme condition of temperature and corrosive environment showed susceptibility to pitting corrosion. This behavior is very desirable in the oil industry.