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Corrosion Science 111 (2016) 690702

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Corrosion Science
journal homepage: www.elsevier.com/locate/corsci

The effects of particle angularity on low-stress three-body


abrasion-corrosion of 316L stainless steel
Grazyna B. Stachowiak a , Mobin Salasi a, , William D.A. Rickard b , Gwidon W. Stachowiak a

a
Tribology Laboratory, Department of Mechanical Engineering, School of Civil and Mechanical Engineering, Curtin University, Bentley, WA 6102, Australia
b
John de Laeter Centre, Curtin University, Bentley, WA 6102, Australia

a r t i c l e i n f o a b s t r a c t

Article history: This study investigates the effects of particle angularity on the tribo-electrochemical behaviour of 316L
Received 26 May 2016 stainless steel under low-stress three-body abrasioncorrosion conditions. Different angularity particles
Accepted 8 June 2016 were delivered to the interface between the samples and a rotating rubber counterface, while changes
Available online 9 June 2016
in current with time were potentiostatically monitored. Based on a linear relationship existed between
tribological factors (load and speed) and the average current evolved, an empirical correlation is proposed
Keywords:
and possible underlying mechanisms are discussed. The effects of particle angularity on the surface and
A. Stainless steel
sub-surface damage are also demonstrated. It was found that increasing particle angularity improved
B. Polarization
B. Potentiostatic
their depassivation efciency.
C. Passive lms 2016 Elsevier Ltd. All rights reserved.

1. Introduction Abrasion-corrosion, the second category of tribocorrosion, is


further divided into two contact types: i) two-body; where two
Superior corrosion resistance of stainless steels is due to the solid bodies slide against each other, and ii) three-body; where
presence of a nano-scale passive lm on their surface [13]. The abrasive particles are trapped between two surfaces in relative
passive lm is, however, prone to localised breakdown as a result motion. In both cases the surfaces are loaded and the motion occurs
of chemical [46] and/or mechanical attack [79], leading to accel- in a corrosive environment.
erated corrosion. Tribocorrosion, dened as the conjoint action Fundamentals of the dynamic two-body abrasion-corrosion of
of tribological wear (mechanical damage) and corrosion (electro- passive materials have been studied by several research groups,
chemical dissolution), is a frequently encountered cause of the e.g. Refs [15,3033]. It was shown that in a two-body abrasion-
passive lm breakdown [10,11]. Over the past two decades, various corrosion contact (reciprocating or pin-on-disc) where an inert
tribo-electrochemical methods have been successfully applied to counterface slides on a passive metal, the depassivated area is gen-
elucidate how mechanical abrasion or erosion accelerate corrosion erated at a rate that depends on the sliding velocity, v, and the
of passive stainless steels [1219]. applied normal force, F.
Tribocorrosion is usually divided into two distinct categories: Three-body abrasion-corrosion, involving interactions between
i) erosion-corrosion, and ii) abrasion-corrosion [10]. In erosion- loosely held coarse abrasive particles forced against the passive
corrosion, the particles (entrained in a owing solution) disturb lm, is yet to be well understood. The particles (third bodies)
the integrity of the passive lm by impacting the surface. Pub- trapped between two surfaces under load, abrade the passivating
lished results revealed the following critical mechanical factors that material (which could be one or both of the surfaces) by rolling
determine the severity and rate of erosion-corrosion: impact angle or sliding across the interface. Studies published so far either
[8,2022], kinetic energy of the particles (affected by particle size, quantied the synergy between three-body abrasion and corro-
density and impact velocity) [2327], particle hardness [28], shape sion [34,35], or investigated the interactions between three-body
and the shattering strength [29]. abrasion and electrochemical corrosion [19,36]. Under identical
electrochemical conditions, the damage to the passive lm in three-
body abrasion-corrosion can be affected by several interconnected
variables such as the load exerted on the particles, frequency of
Corresponding author.
particle-surface interactions, load-bearing ability of the passive
E-mail addresses: mobin.salasi@curtin.edu.au, mobin.salasi@gmail.com
(M. Salasi).

http://dx.doi.org/10.1016/j.corsci.2016.06.008
0010-938X/ 2016 Elsevier Ltd. All rights reserved.
G.B. Stachowiak et al. / Corrosion Science 111 (2016) 690702 691

Fig. 1. Tribo-electrochemical test rig used in the three-body abrasion-corrosion experiments.

lm, hardness of the counteracting surfaces, and particles charac- The particles angularity (ASPQ ) was quantied using a spike
teristics such as hardness, size and angularity. parameter-quadratic t (SPQ) method, developed by Hamblin and
A signicant factor in controlling three-body abrasive wear rate Stachowiak [40]. For each particle, the method isolates the bound-
is angularity (or sharpness) of the abrading particles. This study ary features protruding outside the average-radius circle of the
investigates how the particle angularity affects the electrochem- particle. These protrusions, called spikes, are most likely to cause
ical corrosion of 316L stainless steel at different normal loads abrasion. Quadratic segments are then tted to both sides of each
and counterface tangential speeds, under low-stress three-body spike and differentiated; the cosine of half the apex angle, called
abrasion-corrosion. It is believed that understanding the relation- spike value (SV), is used as a measure of the spikes angularity.
ship between the mechanical factors and the current evolved is The SPQ value for a particle is averaged over all individual SVs [41].
instrumental in developing a semi-mechanistic model for three- For each type of abrasive particles used the SPQ values of at least 50
body abrasion-corrosion contacts. particles were calculated and the average value is denoted as ASPQ .
Particle hardness, another parameter considered in abrasion-
corrosion, signicantly affects the wear rate only when the ratio r
2. Experimental
of particle hardness to wear sample hardness is between 0.8 and
1.5 [42,43]. Since in all tests the ratio r was higher than 2 (the hard-
2.1. Test rig and materials
ness of SS316L was 210 HV), the abrasive wear rate is presumed to
be independent of the particle hardness. Therefore, any differences
Schematic of the tribo-electrochemical test rig is illustrated in
in the wear rates, or abrasion efciency, between the three types
Fig. 1 while the details are described in Refs [19,36,37]. As shown
of particles used should be affected predominantly by the differ-
in Fig. 1, the test rig incorporates three electrodes necessary for
ences in their angularity. The low-stress abrasion conditions were
electrochemical testing, i.e. 316L stainless steel (SS316L) work-
selected to avoid fracture of the loaded particles that would alter
ing electrode (WE1), platinum (Pt) counter electrode (CE) and
their original angularity values.
Pt pseudo-reference electrode (P-RE). A rubber ring counterface
The SS316L wear samples, mounted in an epoxy resin, were
(10 mm wide and 40 mm in diameter) rotates against a loaded at
ground using SiC papers to a 1200 grit nish, resulting in an aver-
wear sample (WE 1) while the abrasive slurry is delivered to the
age surface roughness Ra of 0.03 m. Prior to testing, the samples
contact interface. This contact conguration was found to simulate
were rinsed with ethanol and ultrasonically cleaned for 3 min in
low-stress three-body abrasion-corrosion, i.e. the particles remain
deionised water. A nominal surface area of 1.13 cm2 was exposed to
relatively intact [36].
1.5 L of an open-to-air 3.5 wt% NaCl electrolyte. Temperature of the
Three types of abrasive particles were used: glass beads (GB),
solution was 24 (2) C. Unbuffered solution (pH 6.2) was used for
silica sand (SS), and alumina (AO). Particle average size, Vickers
the tests. It was found, however, that the presence of GB increased
microhardness, and angularity (ASPQ ) of each abrasive type are
the pH of the unbuffered solution from 6.2 to 11. To investigate the
given in Table 1. Representative secondary electron SEM images
effect of pH change on the current evolved, verication tests were
in Fig. 2a illustrate shape differences of the particles while the par-
conducted where the solution pH was buffered at 8.35 (0.03) by
ticle size distribution, measured by laser diffraction, is shown in
adding 0.01 M sodium bicarbonate. No signicant differences in the
Fig. 2b.
current evolved were found between the buffered and unbuffered
It is generally accepted that the particle-size effect on abrasive
solutions indicating that the GB effect on the solution pH did not
wear rate becomes pronounced for particles smaller than about
change the tribo-electrochemical results.
100150 m, and for larger particles abrasive wear is rather inde-
pendent of grit size [38,39]. This size effect was conrmed for
wear samples with different hardness and for different applied 2.2. Tribo-electrochemical tests
loads. Therefore, small differences in the average sizes between the
three particle types (Table 1) are deemed not signicant in affect- The tribo-electrochemical tests were conducted potentiostati-
ing three-body abrasion-corrosion. On the other hand, the particle cally while potential of the sample was monitored against a long
shape, characterized in this study in terms of particle angularity, is Pt wire used as a pseudo-reference electrode (P-RE) [44,45]. Prior
very important. For a given load on a particle, particle angularity to selecting Pt wire as the pseudo-reference (P-RE), its potential
affects the groove area and the contact pressure. in 3.5 wt% NaCl was measured against a double junction Ag/AgCl
692 G.B. Stachowiak et al. / Corrosion Science 111 (2016) 690702

Table 1
Characteristics of abrasive particles used in the three-body abrasion-corrosion experiments.

Abrasives Average size (m) a Microhardness (HV0.1 ) SD b ASPQ SD c

Glass beads (GB) 242 490 23 0.03 0.05


Silica sand (SS) 305 1220 54 0.22 0.09
Alumina (AO) 359 2020 130 0.52 0.16
a
Laser diffraction was used to measure the average size of at least 6 g of particles.
b
Vickers microhardness of at least 50 particles was measured.
c
ASPQ is the average SPQ value from at least 50 particles.

Fig. 2. a) Representative secondary electron SEM images of the particles used in the three-body abrasion-corrosion tests: glass beads (GB), silica sand (SS), and alumina (AO);
b) size distribution of the particles measured by laser diffraction.

(sat.) reference electrode for 7000 s and the results are shown in contact interface. Biologic SP300 potentiostat was used for the
Fig. A1 in the Appendix. Since the P-RE potential depends on the test tribo-electrochemical measurements.
conditions (such as chemical composition and temperature of the
solution), before each test its potential was rst measured against 2.3. Surface and sub-surface examination
the double junction Ag/AgCl reference electrode for at least 300 s
(an example is shown in Fig. A2 in the Appendix). Then, during After abrasion-corrosion tests, all worn surfaces were exam-
abrasion-corrosion the wear sample potential was held constant ined using optical prolometry (Altisurf 530), followed by scanning
against the P-RE at the potential approximate to 0.1 V/SSE (0.02). electron microscopy (SEM). The sub-surface deformation due to
After the tests were nished, the potential of P-RE was re-measured abrasion-corrosion was studied using a Tescan Lyra focused ion
and differences of less than 20 mV were found. Constant potential beam (FIB) and SEM dual-beam platform. Prior to FIB milling, a thin
of approximately 0.1 V/SSE was chosen based on two potentio- platinum layer was deposited on the surface. Finally, an orthogonal
dynamic polarization curves of SS316L, shown in Fig. A3 in the time-of-ight secondary ion mass spectroscopy (TOF-SIMS) (Tofw-
Appendix, measured using either Ag/AgCl (sat) or Pt wire as the erk, Germany) system, utilising the FIB, was used to determine if
standard and pseudo-reference electrodes, respectively. Since no there was material transfer between the particles and the abraded
incidents of metastable pitting are seen in the potentiodynamic surface.
curves in Fig. A3 at 0.1 V/SSE, and also previous studies [36] show
that this potential is below the repassivation potential of 316L 3. Results
stainless steel, material repassivation after mechanical/chemical
lm breakdown can be assumed. The results of all these tests con- 3.1. Tribo-electrochemical tests
rm stability of the P-RE potential under testing conditions and
suitability of using the Pt wire as the pseudo-reference. 3.1.1. Effect of abrasion time on current
The potentiostatic tests were preceded by 2 min of cathodic Current changes with time were recorded before, during and
pre-conditioning (at approx. 0.8 V/SSE) aimed at reducing the after delivery of the abrasive particles to the interface. The abrasion-
thickness of oxide lm formed in air (note that in neutral solu- corrosion tests were continued for approximately 1800 s (30 min)
tions complete cathodic stripping of the oxide is not practically to investigate the effect of abrasion time. The current with time
possible [46]). Following pre-conditioning, the sample was anod- trends for the tests with GB, SS and AO particles are shown in Fig. 3;
ically polarized at the desired potential, and once a stable anodic the tests were conducted at 0.5 N load, 61 mm/s tangential speed,
current was attained, load was applied and the abrasion-corrosion while the potential was held constant against the P-RE (Pt wire)
test was commenced. The current with time changes were recorded to achieve approx. 0.1 V/SSE (0.02). It can be seen in Fig. 3 that
at a sampling frequency of 5 Hz. The current evolved due to abra- the curves exhibit two distinct stages: 1) running-in and 2) steady
sion was calculated by subtracting the corrosion-only current from state. Running-in is distinguished by a sudden current rise at the
the average current measured during at least 180 s of steady-state onset of abrasion, followed by a gradual current decay until a steady
abrasion-corrosion. state is reached. The running-in stage was only prominent at 0.5 N
The mechanical test conditions were selected with aim to inves- load; it was not visible at higher loads. Once unloaded, the anodic
tigate the dynamic disruption and regeneration of the passive lm. current rapidly returns to the pre-abrasion values, indicating that
Nominal normal loads ranging between 0.5 and 2.5 N for GB and the samples have repassivated.
between 0.5 and 10 N for SS and AO were applied to the wear Although at the steady state the measured anodic current oscil-
samples, as shown in Fig. 1. The counterface rotational speed lates frequently, the average current remains constant relative to
was controlled to achieve the targeted tangential speeds of 30, time. For the tests with GB particles, occasional higher amplitude
61, 122, and 204 mm/s while the abrasives were delivered to the current spikes are also visible. Fig. 3 shows that the steady state
G.B. Stachowiak et al. / Corrosion Science 111 (2016) 690702 693

140
Abrasion (1) Alumina
(1)ca Sand
(2) Sili
started
120 (3) Glass beads

100 Abrasion

Current (A)
stopped
80

60
(1)

40

20 (2)

(3)
0
0 200 400 600 800 1000 1200 1400 1600 1800 2000 2200
Time (s)
Fig. 3. Current changes with time, measured potentiostatically in the presence of different abrasive particles at 0.5 N load and 61 mm/s counterface tangential speed.

a) 6 b) 2200
SS
2000 AO
5 Slope: 219.83
Slope: 2.39 1800 2
2 R =0.99
R =0.91 1600
4
Current (A)

Current (A)

1400
1200 Slope: 176.17
3 R2=0.99
1000
800
2
600

1 400
200
0 0
0.0 0.5 1.0 1.5 2.0 2.5 0 2 4 6 8 10
Load (N) Load (N)

Fig. 4. Relationship between the average current evolved and normal load measured potentiostatically under three-body abrasion-corrosion of SS316L at 61 mm/s tangential
speed in the presence of: a) glass beads (GB), b) silica sand (SS), and alumina (AO) particles.

amplitude of current oscillations and the average current evolved 3.1.4. Contour maps of current
are the functions of particle angularity. The combined effects of the mechanical variables (normal load
and tangential speed) on the current evolved for the three types of
particles tested are summarized in Fig. 6. It can be seen that the cur-
3.1.2. Effect of load on current rent increases with increasing load and tangential speed for all the
Changes in the current evolved were measured at different loads particles; the value of current depends on the particle angularity.
for the tests with GB, SS and AO particles. The values of the average
current evolved at each load at 61 mm/s tangential speed are plot-
ted in Fig. 4. For all three particle types, a proportional increase of 3.2. Surface and sub-surface examination
the average current with load is evident. At each load tested, abra-
sion by the angular AO particles has resulted in the highest amount In Fig. 7, the average roughness Ra values of the worn surfaces,
of current evolved. measured on conclusion of the potentiostatic abrasion-corrosion
experiments at 0.5 N load and 61 mm/s tangential speed (see Fig. 3),
are correlated with the particles ASPQ values. As shown in Fig. 7,
3.1.3. Effect of tangential speed on current increasing the angularity of the abrasives resulted in rougher worn
Experiments were performed to determine the effect of tangen- surfaces. Small imperfections found on the GB surfaces (see Fig. 2a)
tial speed on the current evolved in the presence of GB, SS and AO have contributed to the roughness increase.
particles. The average currents evolved at constant loads are plot- Next, the effects of the abrasive particles angularity on the wear
ted in Fig. 5 against tangential speed. For all three particle types, surface morphology and sub-surface deformation of the SS316L
a proportional increase of current with tangential speed was mea- samples were studied using optical prolometry, SEM, FIB-SEM and
sured. TOF-SIMS.
694 G.B. Stachowiak et al. / Corrosion Science 111 (2016) 690702

a) 14 b) 700
0.5 N 0.5 N
1N 1N
12 Slope: 0.07 600 Slope: 3.56
2N 2N
R2=0.99 R2=0.97
10 500

Current (A)
Current (A)

Slope: 0.05
2
R =0.99
8 400
Slope: 1.63
2
6 300 R =0.99
Slope: 0.03
R2=0.97
4 200
Slope: 0.26
2 100 2
R =0.99

0 0
0 20 40 60 80 100 120 140 160 180 200 220 0 20 40 60 80 100 120 140 160 180 200 220
Speed (mm/s) Speed (mm/s)

c)

Fig. 5. Relationship between the average current evolved and tangential speed in three-body abrasion-corrosion of SS316L in the presence of: a) glass beads (GB), b) silica
sand (SS), and c) alumina (AO) particles.

3.2.1. Round GB particles load of 0.5 N the round GB particles deform the SS316L surface pre-
Representative secondary electron SEM images of the surfaces dominantly by shallow ploughing, with almost no actual material
worn during abrasion-corrosion tests at low and high loads are removal.
compared in Fig. 8a and b, respectively. Shallow grooves and small For comparison, similar examination was carried out on the
round indents generated by the GB particles at the low load of 0.5 N SS316L surface after multiple passages of GB particles while the
can be seen in Fig. 8a. After an abrasion-corrosion test during which load was increasing from 0.5 N to 2 N by steps (the corresponding
the load was gradually increased to 2 N, surface grooving by indi- wear surface morphology can be seen in Fig. 8b at a lower mag-
vidual GB particles was no longer discernible, as shown in Fig. 8b. nication). SEM image in Fig. 11a shows the crater FIB-milled in
Instead, there was evidence of superimposed plastic deformation the worn surface, and details of the sub-surface section are shown
and delamination. in Fig. 11b and c. It is clear from Fig. 11 that prolonged abrasion-
Optical prolometry measurements of the worn surface area corrosion by GB particles generated a highly deformed tribolayer
containing a shallow groove generated by a loaded GB particle are with a higher degree of deformation than that observed underneath
shown in Fig. 9. A single prole across the groove in Fig. 9b indicates a single-passage groove at a lower load of 0.5 N (Fig. 10b). Evidence
that the round GB particle depressed the material underneath and of material compaction, extrusion, folding over and microfrac-
displaced it sideways. The prole shows a 1.7 m level difference ture can be found in the images. Strain hardening decreased the
between the side and bottom of the groove. materials ductility, resulting in sub-surface microfracture and
Fig. 10 shows the section FIB milled across a shallow groove delamination seen in Fig. 11b. The ISE channelling contrast image
generated by a round GB particle in the test using 0.5 N nor- in Fig. 11c indicates that repeated plastic deformation generated
mal load and 61 mm/s tangential speed. The secondary electron highly-strained submicron-sized grains. The deformation extends
SEM image in Fig. 10a indicates that the original grinding marks below the nely-grained layer, as revealed by the light-coloured
are attened inside the groove and there is evidence of material areas indicating distorted grains orientation.
smearing. Ion beam induced secondary electron (ISE) imaging was Possible embedment of broken GB fragments in the worn sur-
used subsequently to study sub-surface deformation. ISE images face was investigated by mapping the concentration of silicon at
reveal orientation contrast between adjacent grains facilitating the different depths below the surface using TOF-SIMS (within the FIB-
assessment of deformation to the crystal structure due to abra- SEM instrument). It can be seen in Fig. 12 that the tribolayer is
sion. The ISE image in Fig. 10b indicates that the crystal structure enriched in Si which indicates material transfer between the GB
beneath the groove has been deformed, especially in the middle of particles and the worn surface, or even an embeddment of very
the groove. Both Figs. 9 and 10 conrm that at the relatively low small GB pieces.
G.B. Stachowiak et al. / Corrosion Science 111 (2016) 690702 695

Fig. 6. Current contour maps showing the combined effect of tangential speed and normal load in three-body abrasion-corrosion of SS316L in the presence of a) glass beads
(GB), b) silica sand (SS), and c) alumina (AO) particles.

3.2.2. Semi-round SS and angular AO particles


Representative secondary electron SEM images taken from the
centre of wear scars after abrasion-corrosion by SS and AO particles
are shown in Fig. 13. For both types of particles the SS316L surface
abraded at a low load of 0.5 N (Fig. 13a and b) exhibits irregular
morphology comprised of a mixture of indents and multidirectional
short grooves. Fig. 13c and d indicate that at higher loads grooving
wear dominates, especially for the angular AO particles. Since at the
higher loads the particles are pressed deeper into the rubber coun-
terface, which restricts their movement, the grooves align with the
direction of the rubber ring rotation.
To investigate sub-surface deformation generated by angular
AO particles, a cross-section was FIB-milled in the SS316L sur-
face after abrasion-corrosion at 0.5 N load and 61 mm/s tangential
speed. The SEM image of the FIB-milled sub-surface region in
Fig. 14a shows surface undulation, representing cross-sectional
proles of the grooves scratched by the AO particles, and an exam-
Fig. 7. Correlation between the average roughness, Ra , values of the surfaces worn
ple of wear particle detachment. The ISE image in Fig. 14b shows
during abrasion-corrosion and the angularity (ASPQ ) of the abrasive particles: glass
beads (GB), silica sand (SS), and alumina (AO). a severely-strained top layer with nely-grained microstructure.
Grains distortion, characterized by the elongated white areas below
the nely-grained layer, indicates that plastic deformation extends
to about 4 m underneath the worn surface. Since microcutting
is not efcient at low loads, material is mainly removed by the
accumulation of plastic strain followed by microfracture.
696 G.B. Stachowiak et al. / Corrosion Science 111 (2016) 690702

Fig. 8. Secondary electron SEM images of the SS316L surfaces after abrasion-corrosion by round glass beads at a) constant load of 0.5 N; and b) increasing load up to 2 N.

Fig. 9. Prolometry measurement of the SS316L surface abraded by round glass beads: a) worn surface containing a shallow groove; b) single prole across the groove (the
prole position is marked by an arrow in Fig. 9a). Test conditions: 0.5 N load and 61 mm/s tangential speed.

Fig. 10. a) Secondary electron SEM image of the FIB-milled section across a shallow groove generated by a single glass bead particle at 0.5 N load and 61 mm/s speed; b) ISE
image of the sub-surface area; (i) outside the groove, (ii) inside the groove, (iii) original grinding scratches, (iv) platinum layer deposited prior to FIB milling, (v) sub-surface
deformation due to abrasion-corrosion.

4. Discussion I = Rdep Qp (1)

4.1. Comparison of two- and three-body abrasion-corrosion According to a mechanistic model for two-body abrasion-
corrosion in a dynamic reciprocating contact, the rate of surface
Abrasive wear of stainless steel leads to destruction of the pro- depassivation is [30]:
tective passive lm by its displacement and/or removal from the  F n
surface. Under potentiostatic control, when the potential is held Rdep = kp v (2)
H
at the repassivation region, simultaneously with the destruction
of the lm the surface tries to repassivate. At the steady-state where kp is the proportionality factor, v is the sliding velocity, F
abrasion-corrosion, the anodic current evolved due to  abrasion,
 is the normal force, n varies between 0.5 and 1 depending on the
m2 contact type, and H is the hardness of the metal.
I (A), is equal to the rate of surface depassivation, Rdep s , mul-
 C
 For a rough hard counterface sliding on a at metal sample the
tiplied by the repassivation charge density, Qp , needed to model predicts a square root relationship between the depassiva-
m2
re-establish the destroyed passive lm: tion rate and the normal force [30,47]. However, when a rough
G.B. Stachowiak et al. / Corrosion Science 111 (2016) 690702 697

Fig. 11. a) Secondary electron SEM image of the crater FIB-milled in the worn surface after prolonged abrasion-corrosion by glass beads while the load was increasing up
to 2 N; b) higher magnication secondary electron image of the sub-surface area showing delamination; c) ISE image of the entire FIB-milled sub-surface section. The areas
shown in (b) and (c) are depicted by the rectangles in (a). (i) Platinum deposited layer, (ii) evidence of material delamination, (iii) nely-grained layer, (iv) distorted area and
(v) bulk material.

Fig. 12. a) ISE image of the worn surface (10 10 m) b) TOF-SIMS elemental map of Si at different depths beneath the worn surface.

Fig. 13. Secondary electron SEM images of the SS316L surface after abrasion-corrosion by: a) silica sand & b) alumina at 0.5 N; c) silica sand & d) alumina at the load increasing
up to 10 N; particles were delivered from the top.
698 G.B. Stachowiak et al. / Corrosion Science 111 (2016) 690702

Fig. 14. FIB-milled cross-section of the SS316L surface after abrasion-corrosion by alumina particles at 0.5 N load and 61 mm/s tangential speed a) in-lens SEM image; b) ISE
image. (i) platinum deposited layer, (ii) sub-surface microcracks, (iii) nely-grained top layer, (iv) distorted region, (v) bulk material.

Fig. 15. Relationships between the average current evolved and the product of normal load and counterface tangential speed (FSt ) during abrasion-corrosion using a) glass
beads; b) silica sand; and c) alumina particles.

ceramic ball was sliding on a at stainless steel plate the experi- ing the passive lm damage. The hardness of the metal and the
mental data indicated that the n factor was equal to one [48]. In repassivation charge density are included in the K  factor.
such cases, since Qp is constant for a potentiostatically held pas- In this study, under low-stress three-body abrasion-corrosion
sivating metal (at a certain potential and tribocontact condition) conditions the average current evolved increased approximately
[49], and hardness of the metal is assumed constant, Eq. (1) takes linearly with increasing both the load (normal force) and the coun-
the following form: terface tangential speed (see Figs. 4 and 5 in Results). The average
current data replotted in Fig. 15 against the product of load and tan-
I = K  vF (3)
gential speed, FSt , indicate linear correlations for all three abrasive
where K
is the proportionality factor for the two-body recip- particles tested:
rocating contact. The factor K  accounts for the efciency of
depassivation by an asperity, i.e. the probability of a contact caus- Iavg = KFSt (4)
G.B. Stachowiak et al. / Corrosion Science 111 (2016) 690702 699

a) b)
3.0 3.0

2.5 2.5

2.0 2.0
Slope

Slope
1.5 1.5

1.0 1.0

0.5 0.5

0.0 0.0
0.0 0.1 0.2 0.3 0.4 0.5 0.6 0.01 0.1 1
ASPQ ASPQ
Fig. 16. Slopes of the lines in Fig. 15 (K factor) plotted against the particle angularity values (ASPQ ) on a) linear; b) log scales.

where Iavg is the average current evolved during the steady-state loads are short and randomly oriented. The dominance of grooving
three-body abrasion-corrosion, and K is a proportionality con- wear increases with increasing the load. As the particles are forced
stant representing the efciency of depassivation by the abrasive deeper into the rubber counterface, the grooves become longer and
particles. The depassivation efciency depends on the particle better aligned with the direction of counterface rotation. At the
angularity and the wear mechanisms acting. Similarly to the K  fac- higher loads the constrained abrasive particles act in a way simi-
tor, hardness of the wearing surface and the repassivation charge lar to the hard surface asperities in two-body abrasion. In grooving
density are assumed constant and are included in the K factor. wear, the passive layer and the underlying fresh steel surface are
The empirical correlation described by Eq. (4) is similar to that displaced by ploughing or removed by microcutting. The dominat-
formulated for a two-body abrasion-corrosion reciprocating con- ing mechanism depends on the particle angularity and the load.
tact (Eq. (3)), despite differences in the phenomena occurring at The particle angularity and the normal load affect the depth of par-
the contact interface. Some of the important aspects relevant to ticle penetration and the shape of the groove. Prolonged ploughing
the low-stress three-body abrasion-corrosion are outlined in the results in the accumulation of plastic deformation and subsequent
following sections. delamination of the heavily-strained tribolayer. This is the domi-
nant depassivation mechanism when the round GB particles abrade
4.1.1. Oscillation of current around an average value the SS316L surface.
Oscillation of current was observed in the tribo-electrochemical The running-in stage shown in Fig. 3 was only observed at a
measurements of current evolved with time (see Fig. 3). During the lower load of 0.5 N where the particles were less constrained. Pos-
steady-state abrasion-corrosion, the average current evolved (Iavg ) sibly this stage reects the effect of the original surface roughness
was constant at each load and tangential speed tested. Although on the surface damage and the disruption of passivity. At higher
the degree of depassivation by individual particles varies, it appears loads the abrasives were more rmly gripped by the rubber and
that the average depassivation rate can be assumed constant at con- were forced to groove the wearing surface. Therefore the inuence
stant tangential speed and normal load. The amplitude of current of the wear samples initial surface roughness was less important
oscillation was found to depend on the particles angularity; the and the running-in stage was not observed.
amplitude was reduced for the less angular abrasives such as GB or
SS compared to the highly angular AO particles. The current oscil- 4.1.3. Particle angularity
lation can be related to the abrasives geometry and their alignment It is expected that the attack angle of abrasives (hence, particle
inside the tribocontact. Since the particles are not xed in place but angularity) would have a major effect on the efciency of depassi-
just loosely gripped by the rubber counterface, they may approach vation (represented by K in Eq. (4)). Under the load conditions used,
the wearing surface with varying attack angles. This variation in the round GB particles either indent the SS316L surface or plough
the attack or approach angle is especially prominent in the case it; both actions are accompanied by plastic ow. Therefore, the
of highly angular AO particles which have irregular geometry (see low values of the steady-state current evolved under abrasion are
Fig. 2a). Hence, the severity of depassivation would be different for related to the passivity impairment or degradation due to repeated
different AO particle alignment, giving rise to large oscillations of material displacement by the GB particles. Accumulation of plas-
the current measured. On the other hand, since all round GB parti- tic strain is needed for the GB particles to remove the material by
cles contact the wearing surface at very similar attack angles, there microfracture and delamination. The small imperfections on the GB
is little inuence of their alignment on the severity of depassiva- surface and/or minor microfracture of the tribolayer developed on
tion. As a result, very small oscillations of the current measured are the surface could have given rise to the measured current spikes
observed in Fig. 3. (see Fig. 3).
The loaded angular AO particles, on the other hand, are fairly
4.1.2. Wear mechanisms at different loads effective in material removal. The material removal by microcutting
The SEM images show that the abrasive particles have gener- generates large fresh (unpassive) areas that give rise to a signi-
ated a mixture of grooves and indents on the worn SS316L surfaces. cant current discharge. Semi-round SS particles are less effective in
At the lower loads the particles movement is less restricted and microcutting, especially at lower loads, but can generate grooves
the contribution of indentation to the overall damage is higher deeper than those by GB particles. To determine the inuence
than that at the higher loads. The grooves generated at the lower of particle angularity on the K factor, the slopes of the lines in
700 G.B. Stachowiak et al. / Corrosion Science 111 (2016) 690702

100 become efcient and the substantial accumulation of plastic defor-


Glass beads mation is less likely. This means that changes to the original surface
Silica sand hardness and microstructure depend on the dominating wear
Aluminium oxide mechanisms. As a result, any mechanistic tribocorrosion model for-
mulated for three-body abrasion-corrosion should account for this
10 dependency.
Current (A)

5. Conclusions

1. Electrochemical corrosion of SS316L under three-body abrasion-


1 corrosion conditions, measured in terms of the average current
evolved, was proportional to the load and counterface tangential
speed. It was found empirically that a linear relationship exists
between the average current evolved and the product of normal
load and tangential speed.
2. As the angularity of the abrasive particles increased, the proba-
0.1
bility of passive lm removal/surface depassivation, represented
0.1 1 10 100
by the proportionality constant K, also increased. It was found
Time (s) that the proportionally constant K, exhibits a non-linear (loga-
rithmic) correlation with the particle angularity.
Fig. 17. Repassivation of the worn sample after stopping potentiostatic abrasion- 3. The time taken for surface repassivation after stopping abrasion-
corrosion using different angularity particles under the test conditions given in Fig. 3.
corrosion increases with increasing particle angularity.

Fig. 15 are plotted against the ASPQ values of the particles in Fig. 16. Acknowledgements
Comparison of the plots shown in Fig. 16a and b indicates that a log-
arithmic (rather than linear) correlation exists between the slope The authors wish to thank the Department of Mechanical Engi-
and the particles angularity (ASPQ ). The reason for this behaviour neering, Curtin University, for nancial support of this project. The
needs to be further investigated. authors acknowledge the use of Curtin Universitys John de Laeter
Centre, whose instrumentation has been partially funded by the
4.1.4. Mechano-chemical characteristics of the tribolayer University, State and Commonwealth Governments. Thanks also
Characteristics of the tribolayer, namely hardness and passiv- go to Dr. Tomasz Woloszynski for the surface prolometry mea-
ity, may inuence the depassivation and lm regeneration process. surements.
In the Results it was shown that a nely-grained tribolayer was
formed after prolonged abrasion-corrosion using either round GB
Appendix A
or angular AO particles. The formation of a nely-grained tribo-
layer was also found after erosion-corrosion [50,51] and two-body
abrasion-corrosion [52]. 0.30
It is possible that the dynamic passive lm formed during
abrasion-corrosion, had a modied structure and therefore differ-
0.25 pt vs Ag/AgCl
ent electrochemical properties. This can affect the rate of dynamic
depassivation/repassivation occurring under abrasion-corrosion. It
Potential (V vs Ag/AgCl)

is also evident from Fig. 17 that after stopping abrasion-corrosion 0.20


the time to repassivate the surface depends on the particle
angularitythe surface abraded by the particles with higher angu- 0.15
larity takes longer to repassivate.
The repassivated lm formed after abrasion-corrosion may 0.10
exhibit an improved or poorer pitting resistance. Past studies have
indicated that the nano-crystalline stainless steels exhibit better
0.05
passivity than stainless steels with larger grains [53], particu-
larly when exposed to passivating environments [54]. Different Ag/AgCl vs Ag/AgCl
0.00
mechanisms such as increased surface reactivity [55] or improved
diffusion of chromium through grain boundaries [56] are suggested.
Further research is, however, needed to determine whether a sim- -0.05
ilar phenomenon is relevant for the nano-crystalline tribolayer 0 1000 2000 3000 4000 5000 6000 7000

formed under three-body abrasion-corrosion conditions. Time (s)


Since the nely-grained tribolayer has lower ductility and
Fig. A1. a) Potential stability tests; the change in potential of Pt wire against the
higher hardness than that of the bulk material, its removal occurs
standard Ag/AgCl (sat) reference electrode compared to that of coupled Ag/AgCl
mainly by microfracture and delamination, especially when round (sat) standard reference electrodes.
GB particles are used. At higher loads and with the presence of
angular particles, however, material removal by microcutting can
G.B. Stachowiak et al. / Corrosion Science 111 (2016) 690702 701

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