Technical knowledge
Erosion corrosion in elbows and tees: where velocity attacks first
How velocity, entrained solids and two phase flow remove the protective film at changes of direction, why elbows and tees fail first, and the material and layout measures that control it.
The mechanism in two steps
The protective film forms, then mechanical action removes it, then it reforms, then it is removed again. Each cycle consumes metal. The rate is governed by velocity, by the presence of entrained solids or droplets, by the geometry and by how quickly the alloy can rebuild its film.
Where it attacks first
| Location | Why | Measure |
|---|---|---|
| Outer wall of an elbow | Particles impinge where the flow turns | Long radius elbow, larger radius, harder alloy |
| Tee branch and crotch | Flow impingement and turbulence | Sweep type tee, reinforced branch |
| Downstream of a reducer | Acceleration and turbulence | Gradual transition, adequate straight length |
| Downstream of a valve or orifice | Jet impingement | Straight length, trim selection |
| Pump discharge and recirculation | High velocity and cavitation | Control operating point, avoid throttling |
Material measures
- Duplex and super duplex offer higher strength and good film recovery.
- Nickel alloys such as Inconel 625 rebuild the film quickly in aggressive fluid.
- Hardfacing or overlay on the impingement area extends life where geometry cannot change.
- Increase wall thickness at known impingement points rather than upgrading the whole line.
Layout and operational measures
- Use long radius elbows rather than short radius in erosive service.
- Provide adequate straight length downstream of disturbances before another direction change.
- Fit strainers or separators to remove entrained solids.
- Control velocity within the range recommended for the fluid and the material.
- Inspect known impingement points at defined intervals using thickness measurement.
Questions about this topic
What velocity is too high?
There is no single number. The limit depends on the fluid, the solids content, whether the flow is two phase, and the material. Use the guidance in the project piping class and the alloy producer data for the specific combination.
Why do elbows fail before straight pipe?
Because the flow changes direction, so particles and droplets impinge on the outer wall and turbulence disrupts the protective film. The straight pipe sees parallel flow with film intact.
Can a harder alloy alone solve erosion corrosion?
It helps but rarely solves it. Geometry and velocity controls are usually more effective, with material upgrade as the supporting measure at known impingement points.
Questions about our products
What products does Hangbo Alloy supply?
Four product families, all available in nickel-based alloys, titanium, duplex and special stainless steel: flanges, butt weld pipe fittings, elbows, and seamless tube and pipe. Flanges cover weld neck, long weld neck, slip-on, blind, socket weld, threaded and lap joint patterns. Fittings and elbows cover concentric and eccentric reducers, equal and reducing tees, caps, stub ends, and 45°, 90° and 180° returns in both long and short radius, plus 3D and 5D bends for piggable lines. Seamless tube and pipe is supplied cold drawn or hot finished from 6 mm to 630 mm outside diameter.
Which alloy grades are available for these products?
More than 90 grades are published in our grade library. The most requested are Inconel 625, 718, 600 and X-750, Hastelloy C-276, C-22 and B-2, Monel 400 and K-500, Incoloy 800H, 825 and 925, duplex 2205 and super duplex 2507, 316L, 904L and 254SMO stainless steel, and titanium Grade 2 and Grade 5. Nickel-based grades can also be supplied with VIM plus ESR double melting where cleanliness or fatigue life is critical.
What sizes, wall thicknesses and pressure classes can you supply?
Flanges run from NPS ½ to NPS 24 to ASME B16.5 and from NPS 26 to NPS 60 to ASME B16.47 Series A or B, in pressure classes 150 through 2500. Butt weld fittings and elbows run from NPS ½ to NPS 48 (DN 15 to DN 1200) in wall thickness Schedule 5S through XXS. Seamless tube and pipe covers 6 mm to 630 mm outside diameter, in random lengths of about 5 to 7 metres or fixed lengths up to 12 metres. Non-standard and intermediate sizes are quoted on request.
Which material and dimensional standards do you work to?
Forged flanges to ASTM B564, B381 and A182 with dimensions to ASME B16.5 and ASME B16.47. Butt weld fittings and elbows to ASTM B366 and A403 with dimensions to ASME B16.9 and MSS SP-43. Seamless tube and pipe to ASTM B444, B423, B622, B163, B167, B861, A312, A213 and A790. Marking follows MSS SP-25 and the applicable product standard. If your project is governed by EN, DIN, JIS or a company specification, send the document and we will confirm equivalence before quoting.
Is there a minimum order quantity?
There is no minimum for standard sizes and grades held in stock, and prototypes, spares and small trial batches are accepted. Made-to-order melts and special forgings carry a minimum weight that depends on the alloy and the route, typically from about 500 kg for special grades.
What inspection and certification is issued with the goods?
Every shipment carries an EN 10204 3.1 mill test certificate quoting the actual chemical and mechanical results for the specific heat lot, together with dimensional records and heat treatment data where applicable. Testing is carried out in house by optical emission spectrometry, tensile, impact and hardness testing, plus ultrasonic and eddy current examination, with hydrostatic pressure and intergranular corrosion testing to ASTM G28 or A262 Practice E where the specification requires it. Third party inspection by SGS or another recognised agency can be arranged, and their report is issued alongside the shipment.
What are typical lead times?
Standard stock items ship within days. Common production grades such as Inconel 625 or duplex 2205 are typically a few weeks. Special chemistries, larger forgings and items that require third party inspection take longer and are quoted individually against the requirement.
How are the products packed for export?
Flanges and fittings receive a rust preventive coating, are individually wrapped and are packed in plywood cases secured with steel banding. Tube ends are capped and bundles are strapped. Packing lists quote heat numbers so every case can be cross-checked against the mill certificate on arrival. We quote EXW, FOB, CFR, CIF and DAP, and mixed-alloy orders can be consolidated into one shipment with a single documentation package.
How do I request a quotation or a sample?
Send the grade or UNS number, the dimensions including schedule or wall thickness, the governing material and dimensional standards, quantity, any heat treatment or NDT scope and the certificate type you need; a drawing is ideal for special flanges and fittings. Email demi@nickel-alloy.com or message us on WhatsApp +86 15618279078 and we normally issue a formal quotation within 24 hours on working days. Samples and previous test reports can be arranged before the first order.
Talk to an engineer
Share your duty conditions and we will shortlist candidate alloys within one working day.