Field repair and corrosion protection by cold spray process · Field repair and corrosion...

Field repair and corrosion protection by cold spray process

EDIST 2017 CONFERENCE & EXHIBITION

Electricity, Distribution, Information Systems and Technology

DRIVING INNOVATION TOGETHER

Content

IntroductionIDIREnWin Utilities Ltd.EnWin/IDIDR collaboration program

Process OverviewDeposition MechanismCoating Structure and Properties

Application Case StudiesCorrosion Protection of welded pipe joints (Windsor Utility Commission) Substation transformer leak repair (EnWin) Transformer enclosure restoration (EnWin and Enersource) Enhancing Electrical Connector Conductivity

Future Initiative

Institute for Diagnostic Imaging Research (IDIR)

IDIR was established in 2008 in Windsor, Ontario, by the Ontario Ministry of Research, Innovation

and Science.

IDIR’s Mission Statement is three-fold:1. To conduct novel imaging research and innovation projects that encompass all elements of the innovation value chain, from fundamental discovery to the commercialization of globally competitive products and services.2. To foster the growth of collaborative partnerships and commercialization opportunities, locally, nationally and globally.3. To provide enhanced learning opportunities that will assist with the development of highly qualified personnel, or HQP, who will nurture the IDIR’s legacy while continuing its journey of discovery.

Institute for Diagnostic Imaging Research

IDIR is a multi-disciplinary, collaborative research and innovation center;

IDIR conducts applied research, develops products, and handles product commercialization for a

growing list of regional, national and international clients.

IDIR has expertise in the areas of acoustical imaging, quantitative material characterization, real-

time non-destructive quality control, coatings, nano-structured materials, and cold gas dynamic

spray.

IDIR has formed three spin off Company – Tessonics, True Phantom Solution and The Signal Valley .

All three companies are located in Windsor, Ontario.

Personnel: IDIR currently consists of 11 graduate students; 4 Post doctorate Fellow; 16 Research Staff

and 3 Admin staff.

The ENWIN Group of Companies - Corporate Structure

The City of Windsor

Windsor Canada Utilities Ltd.

ENWIN Energy Ltd.

ENWIN Utilities Ltd.

Windsor Utilities Commission

WSOA*

(OEB Regulated)

Water Division

District Energy

* Water System Operating Agreement

EnWin/IDIDR collaboration program

Collaborative Research and Development Grant (2013-2016)

The project has the following main objectives:

Develop optimal powder compositions and low pressure cold spray (LPCS) process

parameters for forming corrosion resistant coatings intended for protection of welded pipe

joints.

Develop the optimal powder composition and LPCS process parameters for forming highly

conductive coatings to minimize power loses in different types of electrical connectors.

Design and build a LPCS machine for field repair and maintenance applications.

Conduct trials of the developed technology and the LPCS machine at EnWin Utilities’

designated sites.

How the Cold Spray process worksThe Cold Spray process basically uses the energy of compressed gas to propel fine metal or ceramic particles (1-100 microns) at veryhigh/supersonic velocities (350 - 1200 m/s). Upon impact, metal particles get attached to the substrate forming a dense coating. Theparticles are not melted (remain solid) during spraying and original powder composition is retained. The low temperature processimparts no oxidation to the spray material, which considerably improves bonding with the substrate.

Process Gas: Air, Nitrogen, Helium. Pressure: 6-10 bars. Gas Preheat Temperature: 20-650 0C. Powder Feed Rate: 1-6 g/min

Introduction to the Cold Spray Process Technology

Coatings are produced by entraining metal or metal-ceramic powder mixtures in an accelerated gas (e.g. air, nitrogen, etc.) stream, through a converging-diverging de Laval type nozzle and projecting them against a target substrate. The particles are accelerated in the supersonic velocity gas stream by the drag effect. It is important to note that the particles are solid (not melted) prior to impingement onto the substrate. Thus, the LPCS deposition is a low temperature process allowing to obtain thick coatings with high adhesion due to significantly reduced compressive stress between the coating and substrate.

* Low temperature process, no bulk particles melting (temperature of the particles up to 100 0C

during spraying process);

* A variety of powders Metal or Metal-Ceramic Composite coatings can be formed;

* High density coatings (porosity less than 5%);

* Performs grind blasting, spray coating, and shot peening in a single operation;

* Eliminates stresses, enables deposition of thick coatings up to several mm;

* Compressed air or nitrogen are used as carrier gasses (100-150 PSI);

* Allows a wide range of substrate materials;

* Minimal or no substrate surface cleaning/preparation is required;

* Lower heat input to work piece (up to 130 0C) reduces cooling requirement.

Process Advantages

The unique capabilities of the process include:

Corrosion protection: indoor and in field conditions

Leakage sealing: indoor and in field conditions

Material buildup: indoor in field conditions

The indicated capabilities enable the application of the cold spray process in such diverse areas as:

Municipal electrical & water supply services

Oil & Gas offshore platform and pipeline repair & maintenance

Vehicle, aircraft and yacht/ship body repair & maintenance

Cultural heritage objects restoration

Capabilities and main areas of application

Coating Structure and Mechanical Properties

Adhesion strength 35-50MPa

Microhardness HV0.2 80-130 MPa

Al-based Coating

(25%vol. reinforced particles in powder blend)

Aluminium Coating

Build up composition

Applied Standards:

MIL-STD-3021: Department Of Defense Manufacturing Process Standard - Materials

Deposition, Cold Spray;

ASME B31.4: Pipeline Transportation Systems For Liquid Hydrocarbons And Other Liquids

(Chapter VII and VIII);

API 650: Welded Steel Tanks For Oil Storage;

API 653: Repair And Rework Of Existing Tanks;

ASTM E1003: Standard Test Method for Hydrostatic Leak Testing;

ASTM D1598: Standard Test Method for Time-to-Failure of Plastic Pipe Under Constant Internal

Pressure;

ASTM G69: Standard Test Method for Measurement of Corrosion Potentials of Aluminum Alloys;

ASTM B117: Standard Practice for Operating Salt Spray (Fog) Apparatus;

ASTM C633: Standard Test Method for Adhesion or Cohesion Strength of Thermal Spray

Coatings;

ASTM E384: Standard Test Method for Microindentation Hardness of Materials;

ASTM E1588: E1588-08 Standard Guide for Gunshot Residue Analysis by Scanning Electron

Microscopy/ Energy Dispersive X-ray Spectrometry.

Coating Structure and Properties

ASTM B117 (200hours)

All electrochemistry measurements were made in accordance with ASTM G69 standards using the Biologic SP-150 system.

Accelerated corrosion tests was made in accordance with ASTM B117 (salt fog)standards using the ATLAS CCX system.

Corrosion Investigation Methods:•Open Circuit Potential (OCP)•DC Polarization (Tafel extrapolation)•Zero Resistance Ammeter (ZRA)•Electrochemical Impedance Spectroscopy (EIS)

0 30000 60000 90000

-1.2

-1.1

-1.0

-0.9

-0.8

-0.7

-0.6

-0.5

-0.4

-0.3

Al foil (reference)

1

2

3

4

AISI 1010

Ew

e v

s A

g/A

gC

l (V

)

time (sec)

-1.2 -1.1 -1.0 -0.9 -0.8 -0.7

-6

-5

-4

-3

-2

-1

0

1

2

Al foil (reference)

1

2

3

4

AISI 1010

Log

I (

mA

/cm

2)

Ecorr (V vs Ag/AgCl)

Pilot trials of the cold spray process using a specially mobile unit for field applications

Mobile LPCS unit 2Mobile LPCS unit 1 Mobile LPCS unit 3

Application Case Studies


Corrosion protection of welded jointsOctober 2013


August 2014Corrosion Protection of welded joints (Hanna Water Tower, Windsor, ON)

Problem Description:- Intensive corrosion of the seam between welded water tank metal sheets. Problem Solution:- A specially developed, LPCS-based corrosion-resistant coating has been applied over the seam along the perimeter of the water tank.


Corrosion Protection of welded metal sheet joints (Hanna Water Tower, Windsor, ON)August 2014

CS Corrosion Protection Coating

Overlay metal sheet


Substation Transformer

Problem Description:- 30 MVA transformer with an oil leak at a tank weld;- Corrosion spots on the enclosure panel; and- Leakages

Leak area

Leak area after grit blasting*

* Oil leak is clearly seen in the grit blasted area;Leak repair process was performed while oil is leaking.

Transformer housing oil leak repair process

Repaired areaRepaired area after painting




Transformer Enclosure

•Corrosion Is Expensive•Potential Safety Issue

November 2015

November 2016



Description:• Oil leak;• Whole through;• Multiples area of corrosion.



On site pilot trials: Enhancing Electrical Connector Conductivity

AMPACT aluminum wedge pressure connectors

Terminal lugs

Micro-Ohm-Meter, Multi-amp M400

19 days of subject to Accelerated Corrosion testin accordance to ASTM B117


Improvement in ~ 18%




Before Corrosion Test After 19 days of Corrosion TestLu

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on

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cto

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MPA

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Contact Information:

John WladarskiVice President, Asset Management

EnWin Utilities Ltd.

[email protected]

Dr. Roman Maev

Director General

Institute for Diagnostic Imaging Research

[email protected]

mailto:[email protected]

mailto:[email protected]

Thank you

Questions?

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