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CONTROL
MATERIAL SELECTION
ALTERATION OF ENVIRONMENT
PROPER DESIGN
CATHODIC PROTECTION
ANODIC PROTECTION
COATINGS & WRAPPING
(1) MATERIAL SELECTION
(selection of proper material for a
particular corrosive service)
1. Chromium
Minimum concentration of Cr in a
stainless steel is 12-14wt.%
Structure : BCC (ferrite forming element)
Sigma phase
formation which
is initially formed
at grain
boundaries has to
be avoided
because it will
increase
hardness,
decrease ductility
and notch
toughness as well
as reduce
2. Nickel
Silicon
Reduce susceptibility of SS to pitting and crevice
corrosion as well as SCC.
Influence of alloying elements on
pitting corrosion resistance of
stainless steels
Influence of alloying elements on
crevice corrosion resistance of
stainless steels
Influence of alloying elements
on SCC resistance of stainless
steels
Five basic types of stainless
steels :
Austenitic - Susceptible to SCC. Can be hardened
by only by cold working. Good toughness and
formability, easily to be welded and high corrosion
resistance. Nonmagnetic except after excess cold
working due to martensitic formation.
Martensitic - Application: when high mechanical
strength and wear resistance combined with some
degree of corrosion resistance are required. Typical
application include steam turbine blades, valves
body and seats, bolts and screws, springs, knives,
surgical instruments, and chemical engineering
equipment.
Ferritic - Higher resistance to SCC than austenitic
SS. Tend to be notch sensitive and are susceptible to
embrittlement during welding. Not recommended for
service above 3000C because they will loss their
room temperature ductility.
Duplex (austenitic + ferritic) – has enhanced
resistance to SCC with corrosion resistance performance
similar to AISI 316 SS. Has higher tensile strengths than
the austenitic type, are slightly less easy to form and have
weld ability similar to the austenitic stainless steel. Can be
considered as combining many of the best features of
both the austenitic and ferritic types. Suffer a loss impact
strength if held for extended periods at high temperatures
above 3000C.
Susceptible
Tensile
material
stress
Stress
Corrosive corrosion
Corrosive environment
environment is cracking
often specific to
the alloy system
Typical micro cracks formed during
SCC of sensitized AISI 304 SS
Surface morphology
Example of crack propagation during
transgranular stress corrosion cracking (TGSCC)
brass
Example of crack
propagation during
intergranular stress
corrosion cracking
(IGSCC) ASTM A245
carbon steel
Fracture surface of
intergranular SCC on
carbon steel in hot nitric
solution
Fracture surface of
transgranular SCC on
austenitic stainless steel in
hot chloride solution
Fracture surface due to Fracture surface due to
intergranular SCC local stress has reached its
tensile strength value on the
remaining section
Electrochemical effect
Usual region for TGSCC,
mostly is initiated by
pitting pitting corrosion
Zone 1
(transgranular cracking
propagation needs higher
energy)
cracking passive
zones
Zone 2
Usual region for IGSCC,
active SCC usually occurs where
the passive film is relatively
weak
Note that non-susceptible alloy-environment
combinations, will not crack the alloy even if held in
one of the potential zones.
Temperature and solution composition (including
pH, dissolved oxidizers, aggressive ions and
inhibitors or passivators) can modify the anodic
polarization behavior to permit SCC.
Susceptibility to SCC cannot be predicted solely
from the anodic polarization curve.
Models of stress corrosion
cracking
Slip step dissolution model
Discontinuous intergranular crack growth
Cathodic protection
Alteration of Environment