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Alloy UNS N07718 (hereafter abbreviated as 718) is one of the most versatile precipitation-hardened nickel-based corrosion-resistant alloys (CRAs) used for both surface and sub-sea components in oil and gas production service. API 6ACRA provides heat treatment windows and acceptance criteria for 718 in these oil and gas production environments, in which the heat treatment is intended to homogenize the microstructure and obtain the correct microstructure for targeting the desired mechanical properties. For fabricating high temperature materials via additive manufacturing (AM), alloy 718 is a primary focus due to its widespread applications in the past 60 years and excellent weldability in either age hardened or annealed condition.
Additive manufacturing (AM) provides a new approach to the design and manufacture of components from metal powder and provides unique advantages over traditional manufacturing. An industry joint project was recently conducted to investigate the performance of AM’d alloy 718 (UNS N077168) in sour conditions specified in NACE MR0175/ISO 15156. The evident variation of properties and performance was noticed on three batches of AM 718 samples from different vendors, even though they were solution annealed and aged individually to meet the same specification of API 6ACRA 150K grade. A thorough microstructure characterization were performed on three AM 718 materials to reveal the differences in γ grains, strengthening γ’ and γ” precipitates, other precipitates, and microstructural features. All three AM 718 materials showed different microstructures from each other, and they were also different from wrought 718 150K grade. The results suggest specific heat-treatment for AM 718 to achieve comparable microstructure and thus properties to wrought 718.
The U.S. has more than 2.6 million miles of pipelines that transport natural gas and petroleum products. These pipelines are subjected to various potential threats (e.g., aging, harsh environment, natural hazard) during their service lives. Particularly, corrosion that results in loss of metal on external or internal surfaces of pipelines is one of the leading causes of the pipeline failure.
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Integrated computational materials engineering (ICME) has provided materials developers with new virtual tools for exploring the space of novel materials. ICME is typically rooted in computation of phase diagrams (CalPhaD) using thermodynamic databases as well as thermodynamic data that can be generated from first-principles. CalPhaD provides the opportunity to determine stable materials compositions that may have targeted properties, which can be predicted using other computational search techniques, depending on the criteria of interest.
Drag Reducing Agents (DRA) usage in liquid petroleum pipelines has increased over the past few decades, as they improve the mechanical efficiency of flow systems, but their potential impact on different aspects affecting corrosion management has not been fully evaluated. For example: DRA may a) decrease mass transfer and velocity near-wall, reducing flow induced localized corrosion or erosion-corrosion; b) introduce changes in the oil/water interface, affecting water-in-oil stratification and water-oil phase inversion point; c) affect the function of corrosion inhibitors by adsorbing to surfaces or direct chemical interaction.
The potential effect on water accumulation was not included in the model developed for the Pipeline Research Council International, Inc (PRCI) or in other models that are typically used6 for the indirect inspection step of the Liquid Petroleum Internal Corrosion Direct Assessment methodology (LP-ICDA).