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Dr. Ihsan Ulhaq Toor
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Corrosion
Stainless Steel
erosion-corrosion

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Journal article
Published: 25 May 2021 in Energies
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Erosion causes substantial damage in many industrial equipment such as pump components, valves, elbows, and plugged tees. In most cases, erosion is coupled with corrosion, resulting in major financial loss (nearly 3.4% of the global gross domestic product) as evidenced in oil and gas industries. In most cases, the erosion occurs in a submerged water medium. In this paper, erosion characteristics of stainless steel 316 were investigated computationally in a water-submerged jet impingement setup. The erosion profiles and patterns were obtained for various parameters over ranges of inlet velocities (3 to 16 m/s), nozzle diameters (5 to 10 mm), nozzle–target distances (5 to 20 mm), nozzle shapes (circular, elliptical, square, and rectangular), impingement angles (60° to 90°), and particle sizes (50 to 300 µm). The range of Reynolds number studied based on nozzle diameters is 21,000–120,000. The Eulerian–Lagrangian approach was used for flow field prediction and particle tracking considering one-way coupling for the particle–fluid interaction. The Finnie erosion model was implemented in ANSYS-Fluent 19.2 and used for erosion prediction. The computational model was validated against experimental data and the distributions of the erosion depth as well as the locations of the of maximum and minimum erosion points are well matched. As expected, the results indicate an increase in loss of material thickness with increasing jet velocity. Increasing the nozzle diameter caused a reduction in the maximum depth of eroded material due to decreasing the particle impact density. At a fixed fluid inlet velocity, the maximum thickness loss increases as the separation distance between the nozzle outlet and target increases, aspect ratio of nozzle shape decreases, and impingement angle increases. The erosion patterns showed that the region of substantial thickness loss increases as nozzle size/stand-off height increases and as particle size decreases. In addition, increasing the aspect ratio and impingement angle creates skewed erosion patterns.

ACS Style

Rached Ben-Mansour; Hassan Badr; Abdulrazaq Araoye; Ihsan Toor. Computational Analysis of Water-Submerged Jet Erosion. Energies 2021, 14, 3074 .

AMA Style

Rached Ben-Mansour, Hassan Badr, Abdulrazaq Araoye, Ihsan Toor. Computational Analysis of Water-Submerged Jet Erosion. Energies. 2021; 14 (11):3074.

Chicago/Turabian Style

Rached Ben-Mansour; Hassan Badr; Abdulrazaq Araoye; Ihsan Toor. 2021. "Computational Analysis of Water-Submerged Jet Erosion." Energies 14, no. 11: 3074.

Journal article
Published: 11 May 2020 in Materials
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Most oil and gas production wells have plenty of corrosive species present along with solid particles. In such production environments, CO2 gas can dissolve in free phase water and form carbonic acid (H2CO3). This carbonic acid, along with fluid flow and with/without solid particles (sand or other entrained particles), can result in unpredictable severe localized CO2 corrosion and/or erosion–corrosion (EC). So, in this work, the CO2 EC performance of API 5L X-65 carbon steel, a commonly used material in many oil and gas piping infrastructure, was investigated. A recirculating flow loop was used to perform these studies at three different CO2 concentrations (pH values of 4.5, 5.0, and 5.5), two impingement velocities (8 and 16 m/s), three impingement angles (15°, 45°, and 90°), and with/without 2000 ppm sand particles for a duration of 3 h in 0.2 M NaCl solution at room temperature. Corrosion products were characterized using FE-SEM, EDS, and XRD. The CO2 EC rates were found to decrease with an increase in the pH value due to the increased availability of H+ ions. The highest CO2 erosion–corrosion rates were observed at a 45° impingement angle in the presence of solid particles under all conditions. It was also observed that a change in pH value influenced the morphology and corrosion resistance of the corrosion scales.

ACS Style

Ihsan UlHaq Toor; Zakariya Alashwan; Hassan Mohamed Badr; Rached Ben-Mansour; Siamack A. Shirazi. Effect of Jet Impingement Velocity and Angle on CO2 Erosion–Corrosion with and without Sand for API 5L-X65 Carbon Steel. Materials 2020, 13, 2198 .

AMA Style

Ihsan UlHaq Toor, Zakariya Alashwan, Hassan Mohamed Badr, Rached Ben-Mansour, Siamack A. Shirazi. Effect of Jet Impingement Velocity and Angle on CO2 Erosion–Corrosion with and without Sand for API 5L-X65 Carbon Steel. Materials. 2020; 13 (9):2198.

Chicago/Turabian Style

Ihsan UlHaq Toor; Zakariya Alashwan; Hassan Mohamed Badr; Rached Ben-Mansour; Siamack A. Shirazi. 2020. "Effect of Jet Impingement Velocity and Angle on CO2 Erosion–Corrosion with and without Sand for API 5L-X65 Carbon Steel." Materials 13, no. 9: 2198.

Journal article
Published: 03 March 2020 in Metals
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Duplex stainless steels (DSSs) exhibit excellent corrosion resistance and are being used in a variety of industrial applications. Reducing/eliminating the amount of nickel in such alloys will contribute significantly to its economic viability. Moreover, a well-established wear behavior for these alloys is also an essential development in most of their applications. Hence, in this work, the Taguchi technique was effectively implemented to investigate the effect of operating factors such as sliding speed and applied load on the wear behavior of different compositions of nickel-free DSSs. It was observed that the composition had a higher contribution of 33.66% to the wear rate (WR) and the contribution of the sliding speed to the coefficient of friction (COF) was found to be 68.17%. With a good agreement, a regression model was also developed to predict the WR and COF within a certain range of factors. Wear tests have also shown that the developed nickel-free DSS is a promising candidate in terms of wear resistance as compared to austenitic stainless steels (ASS).

ACS Style

Hammam Daraghma; Mohammed Abdul Samad; Ihsan Ul Haq Toor; Farid M. Abdallah; Faheemuddin Patel. Tribological Characterization of Ni-Free Duplex Stainless Steel Alloys Using the Taguchi Methodology. Metals 2020, 10, 339 .

AMA Style

Hammam Daraghma, Mohammed Abdul Samad, Ihsan Ul Haq Toor, Farid M. Abdallah, Faheemuddin Patel. Tribological Characterization of Ni-Free Duplex Stainless Steel Alloys Using the Taguchi Methodology. Metals. 2020; 10 (3):339.

Chicago/Turabian Style

Hammam Daraghma; Mohammed Abdul Samad; Ihsan Ul Haq Toor; Farid M. Abdallah; Faheemuddin Patel. 2020. "Tribological Characterization of Ni-Free Duplex Stainless Steel Alloys Using the Taguchi Methodology." Metals 10, no. 3: 339.

Research article mechanical engineering
Published: 19 August 2019 in Arabian Journal for Science and Engineering
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The electrochemical properties of three Ni-free duplex stainless steel alloys, designed in-house, were investigated in chloride (0.2M NaCl) solution at room temperature. The corrosion performance was measured in terms of pitting potential (Epit), passive current density (ip), polarization resistance (Rp) and susceptibility to metastable pitting. The results obtained showed that alloy 2 (Fe–16Cr–5Mn–1Mo–1Si–1Cu–0.22N) exhibited the highest corrosion resistance (highest Epit, lowest ip, highest Rp and lowest metastable pitting susceptibility) among the designed alloys. Alloy 2 was also found to be free of any secondary phase precipitations (sigma phase, Cr nitrides, chi phase) when aged at 600–900 °C for 3–50 h owing to its optimized composition.

ACS Style

Farid M. Abdallah; Ihsan-Ul-Haq Toor. Evaluation of Pitting Susceptibility and Secondary Phase Formation in Newly Designed Ni-Free (Fe–16Cr–1Mo–1Si–0.2N–xMn–xCu) Duplex Stainless Steel Alloys. Arabian Journal for Science and Engineering 2019, 45, 599 -608.

AMA Style

Farid M. Abdallah, Ihsan-Ul-Haq Toor. Evaluation of Pitting Susceptibility and Secondary Phase Formation in Newly Designed Ni-Free (Fe–16Cr–1Mo–1Si–0.2N–xMn–xCu) Duplex Stainless Steel Alloys. Arabian Journal for Science and Engineering. 2019; 45 (2):599-608.

Chicago/Turabian Style

Farid M. Abdallah; Ihsan-Ul-Haq Toor. 2019. "Evaluation of Pitting Susceptibility and Secondary Phase Formation in Newly Designed Ni-Free (Fe–16Cr–1Mo–1Si–0.2N–xMn–xCu) Duplex Stainless Steel Alloys." Arabian Journal for Science and Engineering 45, no. 2: 599-608.

Research article mechanical engineering
Published: 15 February 2019 in Arabian Journal for Science and Engineering
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The hydrodynamic corrosion inhibitive performance of two imidazole derivatives 2-ethyl-4-methylimidazole and 1-benzylimidazole was investigated on API X65 steel in 1.0 M HCl solution. Structural features of the molecules derived from density functional theory (DFT) calculations at B3LYP/6-31G(d.p) showed that 1-benzylimidazole possess high electron density due to \(\pi \) network which lies flat on the surface and tends to form a stronger interaction with the metal. The addition of the inhibitor molecules in 1 M HCl solution shifted the corrosion potential \(({E}_{\mathrm{corr}})\) in the noble direction. Tafel polarization and electrochemical impedance spectroscopy (EIS) experiments performed at 0–1500 rpm and 50–500 ppm of inhibitor concentration revealed that the corrosion rate was increased with an increase in rotation speed in the absence of inhibitor molecules. However, upon the addition of the inhibitor molecules in the solution minimized the corrosion rate with an efficiency of 82% in the case of 1-benzylimidazole at 500 ppm and 500 rpm electrode rotation. It was concluded that simple imidazole molecules could serve as corrosion inhibitors under extreme hydrodynamic conditions.

ACS Style

A. Ismail; H. M. Irshad; A. Zeino; I. H. Toor. Electrochemical Corrosion Performance of Aromatic Functionalized Imidazole Inhibitor Under Hydrodynamic Conditions on API X65 Carbon Steel in 1 M HCl Solution. Arabian Journal for Science and Engineering 2019, 44, 5877 -5888.

AMA Style

A. Ismail, H. M. Irshad, A. Zeino, I. H. Toor. Electrochemical Corrosion Performance of Aromatic Functionalized Imidazole Inhibitor Under Hydrodynamic Conditions on API X65 Carbon Steel in 1 M HCl Solution. Arabian Journal for Science and Engineering. 2019; 44 (6):5877-5888.

Chicago/Turabian Style

A. Ismail; H. M. Irshad; A. Zeino; I. H. Toor. 2019. "Electrochemical Corrosion Performance of Aromatic Functionalized Imidazole Inhibitor Under Hydrodynamic Conditions on API X65 Carbon Steel in 1 M HCl Solution." Arabian Journal for Science and Engineering 44, no. 6: 5877-5888.

Journal article
Published: 31 May 2018 in Metals
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Erosion corrosion performance of API 5L-X65 carbon steel was investigated at three different impingement velocities (3, 6 & 12 m/s), five different angles (15, 30, 45, 60, & 90°), and with/without solid particles (average particle size of 314 µm). The experiments were conducted in 0.2 M NaCl solution at room temperature for a duration of 24 h and the results showed that the maximum erosion corrosion rate was observed at 45° irrespective of the velocity. The highest erosion corrosion rate at 45° was due to the balance between the shear and normal impact stress at this angle. Ploughing, deep craters, and micro-forging/plastic deformation were found to be the main erosion corrosion mechanisms. The maximum wear scar depth measured using optical profilometery was found to be 51 µm (average) at an impingement angle of 45°.

ACS Style

Ihsan UlHaq Toor; Hafiz Muzammil Irshad; Hassan Mohamed Badr; Mohammed Abdul Samad. The Effect of Impingement Velocity and Angle Variation on the Erosion Corrosion Performance of API 5L-X65 Carbon Steel in a Flow Loop. Metals 2018, 8, 402 .

AMA Style

Ihsan UlHaq Toor, Hafiz Muzammil Irshad, Hassan Mohamed Badr, Mohammed Abdul Samad. The Effect of Impingement Velocity and Angle Variation on the Erosion Corrosion Performance of API 5L-X65 Carbon Steel in a Flow Loop. Metals. 2018; 8 (6):402.

Chicago/Turabian Style

Ihsan UlHaq Toor; Hafiz Muzammil Irshad; Hassan Mohamed Badr; Mohammed Abdul Samad. 2018. "The Effect of Impingement Velocity and Angle Variation on the Erosion Corrosion Performance of API 5L-X65 Carbon Steel in a Flow Loop." Metals 8, no. 6: 402.

Journal article
Published: 01 October 2016 in Journal of Alloys and Compounds
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Highlights•Fe-18CrxSi(0–3) ternary alloys have been prepared by mechanical alloying.•Phase evolution of the milled alloys was studied using XRD, SEM and FE-TEM.•Different phases evolved with increase in milling time, i.e. solid solution formation .→ amorphization→mechanical crystallization•Increase in Si content decreased the lattice parameter, and crystallite size, while micro-strain was increased. AbstractIron based alloys Fe(82−x)-Cr18-Six (x = 0, 1, 2, 3) wt. % were developed by mechanical alloying (MA). Phase evolution studies on the milled powders were conducted using X-ray diffraction (XRD) and field emission transmission electron microscopy (FE-TEM). Scanning electron microscope (SEM) was used to carry out morphological investigations. Results showed an initial solid solution formation at 5 h of milling and with continued milling to 35 h, an amorphous phase was formed. The amorphous phase was mechanically crystallized to α-phase at 85 h and 100 h of milling for Fe(82−x)-Cr18-Six (x = 0) and Fe(82−x)-Cr18-Six (x = 1, 2, 3) wt. % alloys respectively. Both the lattice parameter and crystallite size were decreased with an increase in Si content of the alloys. With continued milling, micro-strain was increased and crystallite size of the alloys was decreased. Graphical abstract

ACS Style

Ihsan-Ul-Haq Toor; Junaid Ahmed; Mohammed Hussein; F. Patel; N. Al-Aqeeli. Phase evolution studies during mechanical alloying of Fe(82−x)-Cr18-Six (x = 0, 1, 2, 3) alloy. Journal of Alloys and Compounds 2016, 683, 463 -469.

AMA Style

Ihsan-Ul-Haq Toor, Junaid Ahmed, Mohammed Hussein, F. Patel, N. Al-Aqeeli. Phase evolution studies during mechanical alloying of Fe(82−x)-Cr18-Six (x = 0, 1, 2, 3) alloy. Journal of Alloys and Compounds. 2016; 683 ():463-469.

Chicago/Turabian Style

Ihsan-Ul-Haq Toor; Junaid Ahmed; Mohammed Hussein; F. Patel; N. Al-Aqeeli. 2016. "Phase evolution studies during mechanical alloying of Fe(82−x)-Cr18-Six (x = 0, 1, 2, 3) alloy." Journal of Alloys and Compounds 683, no. : 463-469.

Journal article
Published: 01 October 2016 in Powder Technology
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Highlights•Fe-18Cr-2Si ferritic alloy was developed by a combination of MA and SPS.•Process parameters were optimized in terms of densification, hardness and corrosion resistance.•Optimized sintering temperature was found to be 1100 °C .•Optimized sintering time was found to be 15 min at 1100 °C.•Optimized pressure was 60 MPa at 50°./min heating rate. AbstractSpark plasma sintering (SPS) process parameters were optimized in terms of densification, microhardness and corrosion resistance to develop a nano-structured Fe-18Cr-2Si ferritic alloy. The powders were mechanically alloyed (MA) in a planetary ball mill and subsequently SPS was carried out under different processing conditions. Powders and sintered samples were characterized using X-Ray Diffraction (XRD), Scanning electron microscopy (SEM) and transmission electron microscopy (TEM). XRD phase evolution studies on ball milled powders confirmed the formation of a crystallized alloy after 100 h milling. XRD of sintered alloy confirmed the development of a nano-structured ferritic alloy with a crystallite size in the range of 20 ~ 40 nm. Maximum densification of 96.0%, Vickers hardness of 710 HV and pitting potential (Epit = − 430 mVSCE) was achieved at a sintering temperature of 1100 °C, for 15 min holding time, at 50 °C/min of heating rate and at an applied pressure of 60 MPa. Graphical abstract

ACS Style

Ihsan-Ul-Haq Toor; Junaid Ahmed; M.A. Hussein; N. Al-Aqeeli; Junaid Ahmad. Optimization of process parameters for spark plasma sintering of nano-structured ferritic Fe-18Cr-2Si alloy. Powder Technology 2016, 299, 62 -70.

AMA Style

Ihsan-Ul-Haq Toor, Junaid Ahmed, M.A. Hussein, N. Al-Aqeeli, Junaid Ahmad. Optimization of process parameters for spark plasma sintering of nano-structured ferritic Fe-18Cr-2Si alloy. Powder Technology. 2016; 299 ():62-70.

Chicago/Turabian Style

Ihsan-Ul-Haq Toor; Junaid Ahmed; M.A. Hussein; N. Al-Aqeeli; Junaid Ahmad. 2016. "Optimization of process parameters for spark plasma sintering of nano-structured ferritic Fe-18Cr-2Si alloy." Powder Technology 299, no. : 62-70.

Book chapter
Published: 05 December 2014 in Metal Chalcogenide Nanostructures for Renewable Energy Applications
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ACS Style

Ihsan-Ul-Haq Toor; Shafique Khan. Optical and Structural Properties of Metal Chalcogenide Semiconductor Nanostructures. Metal Chalcogenide Nanostructures for Renewable Energy Applications 2014, 123 -145.

AMA Style

Ihsan-Ul-Haq Toor, Shafique Khan. Optical and Structural Properties of Metal Chalcogenide Semiconductor Nanostructures. Metal Chalcogenide Nanostructures for Renewable Energy Applications. 2014; ():123-145.

Chicago/Turabian Style

Ihsan-Ul-Haq Toor; Shafique Khan. 2014. "Optical and Structural Properties of Metal Chalcogenide Semiconductor Nanostructures." Metal Chalcogenide Nanostructures for Renewable Energy Applications , no. : 123-145.

Research article
Published: 13 March 2014 in Journal of Chemistry
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The corrosion behavior of two specially designed austenitic stainless steels (SSs) having different Nickel (Ni) and Manganese (Mn) contents was investigated. Prior to electrochemical tests, SS alloys were solution-annealed at two different temperatures, that is, at 1030°C for 2 h and 1050°C for 0.5 h. Potentiodynamic polarization (PD) tests were carried out in chloride and acidic chloride, whereas linear polarization resistance (LPR) and electrochemical impedance spectroscopy (EIS) was performed in 0.5 M NaCl solution at room temperature. SEM/EDS investigations were carried out to study the microstructure and types of inclusions present in these alloys. Experimental results suggested that the alloy with highest Ni content and annealed at 1050°C/0.5 hr has the highest corrosion resistance.

ACS Style

Ihsan-Ul-Haq Toor. Effect of Mn Content and Solution Annealing Temperature on the Corrosion Resistance of Stainless Steel Alloys. Journal of Chemistry 2014, 2014, 1 -8.

AMA Style

Ihsan-Ul-Haq Toor. Effect of Mn Content and Solution Annealing Temperature on the Corrosion Resistance of Stainless Steel Alloys. Journal of Chemistry. 2014; 2014 ():1-8.

Chicago/Turabian Style

Ihsan-Ul-Haq Toor. 2014. "Effect of Mn Content and Solution Annealing Temperature on the Corrosion Resistance of Stainless Steel Alloys." Journal of Chemistry 2014, no. : 1-8.

Research article
Published: 23 September 2013 in Journal of Chemistry
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Corrosion behavior of nano-coblat-coated Ni sheet was compared with pure Ni and 20% Fe-Ni alloy sheet using potentiodynamic polarization and linear polarization technique in 0.1 M NaCl solution at room temperature. Results showed that corrosion resistance properties of nano-Co-coated Ni sheet were almost same as that of pure Ni sheet, however corrosion resistance of 20% Fe-Ni sheet was decreased significantly. Pitting potential of 20% Fe-Ni sheet was subsequently decreased as compared to pure Ni sheet as well as nano-cobalt-coated Ni sheet. SEM/EDS analysis of the corroded surfaces showed that both pure Ni and nano-coblat-coated Ni sheet did not show any appreciable corrosion however significant corrosion was observed in the case of 20% Fe-Ni sheet.

ACS Style

Nasser Al-Aqeeli; Ihsan-Ul-Haq Toor. Comparison of Corrosion Behavior of Electrochemically Deposited Nano-Cobalt-Coated Ni Sheet. Journal of Chemistry 2013, 2013, 1 -6.

AMA Style

Nasser Al-Aqeeli, Ihsan-Ul-Haq Toor. Comparison of Corrosion Behavior of Electrochemically Deposited Nano-Cobalt-Coated Ni Sheet. Journal of Chemistry. 2013; 2013 ():1-6.

Chicago/Turabian Style

Nasser Al-Aqeeli; Ihsan-Ul-Haq Toor. 2013. "Comparison of Corrosion Behavior of Electrochemically Deposited Nano-Cobalt-Coated Ni Sheet." Journal of Chemistry 2013, no. : 1-6.