Development of Friction Stir Diffusion Cladding Process for Corrosion Resistance Overlay

The oil and gas, petrochemical, and water desalination industries devote considerable efforts and resources in protecting structures and utilities from corrosion. In these industries, a major percentage of the budget is dedicated to corrosion control. These sectors need innovative solutions to mitigate the corrosion problems. Several technologies are used to mitigate corrosion; for example, the use of highly corrosion-resistant alloys, such as duplex stainless steel, or passive protection techniques, such as coatings. Cladding is a surface processing method that is mainly utilized to enhance surface wear and/or corrosion resistance. Fusion cladding methods such as laser processing, plasma transferred arc welding and atmospheric plasma spraying have a number of limitations that arise from the excessive temperatures needed during processing and the melting and solidification of the cladding layer such as: distortion, clade dilution and deposition rate. The application of state of the art solid-state friction stir cladding may reduce melting and solidification problems and allow better surface at higher deposition rates. The main objective of the proposed research project is to develop a cladding process for carbon steel using a novel solid-state cladding technique that utilizes friction stir welding and processing technologies (FSW/FSP). The proposed method has many potential advantages over conventional cladding/surface processing methods: it is cost-effective, environmentally friendly and can produce cladded surfaces with excellent mechanical, electrochemical and corrosion properties. In addition, it can be used to process ferrous and non-ferrous alloy. The specific objective of the present project is to build on the expertise developed in (FSW/FSP) to come up with a new solid-state cladding process to be used in oil, gas, petrochemical, power and desalination industries to mitigate some of corrosion problems. The proposed investigation includes identifying the optimum processing parameters, tools design and materials to achieve effective corrosion-resistant light alloy coatings (such as Al, and Ti-based alloys) on carbon steel while maintaining or improving its mechanical properties. The research team will study and evaluate the effects of the processing parameters on the microstructural and mechanical properties as well as corrosion resistance of cladded carbon steel. The developed methodology will help introduce a novel cladding technology that can mitigate or reduce corrosion problems in equipment and structures used by the water desalination, energy production, and oil and gas industries in the Kingdom of Saudi Arabia. The long-term objective of this effort is to establish and transfer the technology to the above-mentioned industries to help in reducing part of the corrosion cost in Saudi Arabia; estimated at $25 billion in 2011[a]. [a] A. Al Hashem, Corrosion in the Gulf Cooperation Council (GCC) states: statistics and figures, in Proceedings of the Corrosion UAE, Abu Dhabi, UAE, 2011.