On-line detection of 3D non-uniform erosion-corrosion damage in a reducer using an innovated ring-pair-electrical-resistance-sensor array

• Published in: Measurement : journal of the International Measurement Confederation 2025-02, Vol.243, p.116433, Article 116433
• Main Authors: Liu, Liang, Song, Guang-Ling, Xu, Yunze, Huang, Yi
• Format: Article
• Language: English
• Subjects: Damage detection; Erosion-corrosion monitoring; Reducer; RPERSA
• ISSN: 0263-2241
• DOI: 10.1016/j.measurement.2024.116433

[Display omitted] •An innovated RPERSA is developed to detect the 3D erosion-corrosion damage of reducers.•Erosion-corrosion hotpot regions in a reducer can be detected by using the RPERSA.•Local erosion and corrosion rates are decoupled from the overall damage.•Causes of the non-uniformity in erosion-corrosion are unveiled. A specially designed ring-pair-electrical-resistance-sensor array (RPERSA) was used to mimic the geometry of a reducer and detect the three-dimensionally distributed erosion-corrosion damage in a lab loop. With such a RPERSA, the real time local erosion and corrosion rates could be separated from the overall damage. After exposure to a 3.5 % NaCl slurry in the loop at inlet flow velocity 2.2 m/s, it was found that the bottom areas over the junctions of the large end/contraction section and the contraction section/small end were erosion-corrosion hotpots, and the sudden geometry changes in these areas together with gravity effect could be mainly responsible for the non-uniform damage. Also, the synergistic effect between corrosion and erosion could be better understood after the erosion ratio equation was adopted to predict the hotpot areas in the reducer under the erosion-corrosion condition.