A Study of Erosion–Corrosion Behaviour of Friction Stir-Processed Chromium-Reinforced NiAl Bronze Composite

Corrosion is frequently viewed as a catastrophic and unavoidable disaster in marine applications. Every year, a huge cost is incurred on the maintenance and repair of corrosion-affected equipment and machinery. In the marine environment, as-cast nickel-aluminium bronze (NAB) is susceptible to selective phase corrosion. To solve this problem, chromium-reinforced nickel-aluminium bronze was fabricated using the friction stir process (FSP) with improved microstructures and surface properties. A slurry erosion-corrosion test on as-cast and FSPed composites demonstrated that the developed surfaced composite has lower erosion and corrosion rates than the as-cast NAB alloy. The erosion-corrosion rate increased with a decrease in the impact angle from 90° to 30° for both as-cast NAB and prepared composites, exhibiting a shear mode of erosion. The specimens at impact angle 30° experienced more pitting action and higher mass loss compared with those at impact angle 90°. Due to increases in the mechanical properties, the FS-processed composite showed higher erosion resistance than the as-cast NAB alloy. Furthermore, corrosion behaviour was also studied via the static immersion corrosion test and electrochemical measurements under 3.5 wt.% NaCl solution. In a static immersion corrosion test, the FSPed composite outperformed the as-cast NAB composite by a wide margin. The FSPed composite also demonstrated a reduced electrochemical corrosion rate, as revealed by the polarization curve and electrochemical impedance spectroscopic (EIS) data. This reduced rate is attributed to the formation of a Cr oxide film over its surface in the corrosive environment.