Corrosive effects of supercritical carbon dioxide and cosolvents on metals

With the eventual phase-out of chlorofluorocarbons and hydrochlorofluorocarbons, and restrictive regulations concerning the use of other volatile organic compounds as cleaning solvents, it is essential to seek new, environmentally acceptable cleaning processes. We are investigating supercritical carbon dioxide (CO2) as an alternative solvent for precision cleaning of machined metal parts in governmental and industrial cleaning processes. The compatibility of metals in supercritical-fluid cleaning media with respect to corrosion must be addressed. In this work, a screening study of the corrosive effects of supercritical CO2 and several supercritical cosolvents on selected metals was conducted. Sample coupons of stainless steel (grades 304LSS, 316SS), aluminum (grades 2024, 6061, 7075), carbon steel (1018), and copper (CDA 101) were statically exposed to pure supercritical CO2, water-saturated supercritical CO2, 10 wt % methanol/CO2 cosolvent, and 4 wt % tetrahydrofurfuryl alcohol (THFA)/CO2 at 24,138 kPa (3500 psig) and 323 K (50 degrees C) for 24 h. Gravimetric analysis and magnified visual inspection of the coupons were performed before and after the exposure tests. Surface analyses including electron microprobe analysis (EMPA), X-ray photoelectron spectroscopy (XPS), and Auger electron spectroscopy (AES) were done where visual and gravimetric changes were indicative of corrosive attack. The metal alloys were found to be compatible with the supercritical test media barring a few exceptions. Corrosive attack was observed on 1018 carbon steel in the water-saturated CO2 environment, and also on 2024 aluminum and CDA 101 copper, both in the 10 wt % methanol-CO2 cosolvent. The results of all compatibility testing are reported, and hypotheses are formed in an attempt to explain possible corrosion mechanisms.