Corrosion of Thermal Spray Aluminum Coatings in Subsea Mud

Cross section of TSA after cathodic polarization in mud at 95 °C..Thermal spray aluminum (TSA) coatings have been successfully used in submerged and splash zones on offshore installations since the 1980s. Although it is not immune to corrosion when polarized by sacrificial aluminum anodes, the corrosion rate is usually low due to a protective oxide on the surface of the TSA that keeps it passive. When TSA is exposed in saline subsea mud at elevated temperatures while under cathodic polarization, a number of technical risks have been identified. The main concern is a situation where overly effective cathodic polarization leads to elevated pH at the TSA surface and accelerated TSA dissolution since aluminum is not passive in alkaline environments. On a cathodically protected TSA surface, the cathodic reactions (oxygen reduction and hydrogen evolution) will produce hydroxide. In seawater, hydroxide will be removed by diffusion and water flow; however, there is no water flow in mud and diffusion is probably limited. This may result in accumulation of hydroxide at the TSA/mud interface and activation of the TSA. The cathodic polarization, therefore, may result in decreased lifetime of the TSA in mud. CORROSION 2014 paper no. 4196, “Corrosion of Cathodically Polarized TSA in Subsea Mud at High Temperature,” by O. Ø. Knudsen, G. Clapp, J. Van Bokhorst, and G. Duncan, discusses corrosion rate of TSA as function of cathodic polarization and temperature when exposed in subsea mud.