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It has been established that material porosity is a critical factor negatively affecting corrosion resistance. To compensate for this effect, copper infiltration technology is used in traditional powder composites (see photo). However, when exposed to temperatures between 60 and 80°C, the copper component degrades under the influence of chloride ions and hydrogen cations. This process is accompanied by:
- Increased Nickel and Chromium content provides improved resistance to aggressive environments
- Extended service life of pump stages in highly corrosive environments
- Stability of performance over a wide range of operating parameters
- Reduced surface roughness compared to traditional casting
- Highly accurate geometric parameters of flow channels
- Optimal material structure without casting defects
- Possibility of recycling spent stages using existing Ni-resist facilities
- Maintaining market value during recycling on par with traditional Ni-resist
- Avoid additional costs for specialized recycling
- Reducing disposal costs
- Recovering a portion of the cost through scrap metal recycling
- Optimizing equipment maintenance costs
- Full integration into the existing recycling system
- Economic feasibility of material use
- No additional investment in recycling infrastructure
- Reduced surface roughness results in reduced flow turbulence.
- Highly accurate geometry ensures optimal flow conditions.
- The absence of casting defects promotes uniform load distribution.
- Increased efficiency by 5-10%
- Low hydraulic losses in the flow path
- Optimization of the working fluid flow
- Reduction in energy costs for pumping liquids
The proposed PrimeRezist powder alloy with a Nickel content of >14% and Chromium >17% demonstrates significant superiority over traditional cast Ni-resist in the following parameters:
The technological advantages of powder metallurgy provide a significant improvement in the performance characteristics of the flow parts of pumping equipment.
- Thus, the use of PrimeRezist material not only provides technical advantages, but also creates additional economic value due to the possibility of standard recycling on par with traditional Ni-resist.
Powder technology ensures:
- Optimization of materials utilization efficiency
- Minimum tooling costs
- Reduction of production cycles
- Reduction of production costs
- Optimization of production costs
- Increased competitiveness
- Excellent material strength
- Increased resistance to hydrodynamic loads
- Reduced risk of mechanical damage to working parts
- Damage to the integrity of the copper matrix
- Dissolution of the copper component
- Formation of structural defects
- Active penetration of aggressive environmental components
- Exponential growth in the number of local microgalvanic couples
The new PrimeRezist material from Keramet-Perm LLC will completely replace alloyed cast iron.
Corrosion resistance:
Key performance factors:
Key economic benefits:
Financial aspects:
Practical result:
Results of application:
Mechanism of action:
Mechanical properties:
Manufacturing advantages:
The electrochemical aspect of the problem is that copper, being a cathodic inclusion in the structure of the powder alloy, intensifies corrosion processes.
The innovative PrimeRezist material, developed by Keramet-Perm, ensures the maintenance of optimal density and porosity without the use of copper impregnation, while maintaining target parameters.
ANALYSIS OF THE ADVANTAGES OF THE PrimeRezist MATERIAL
INFLUENCE OF SURFACE QUALITY ON THE ENERGY EFFICIENCY OF PUMPING EQUIPMENT
ECONOMIC EFFICIENCY OF USING PrimeRezist MATERIAL
PK10Chromium11Nickel8Cuprum20PR
PrimeRezist
Corrosion rate Km, [g/(m2•h)•10-3]
PrimeRezist
(Keramet-Perm)
(Keramet-Perm)
12Ch18N10Т
PK10Ch11N8Cu20
Gray cast iron
Ni-resist
N1-PS
CORROSION RESISTANCE (T=20°C, 10 days, NaCl 3%)
