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What is Corrosion? Some Aspects of Corrosion Corrosion and Welding

Corrosion is the degradation of materials (esp. metals) by its combination with a non-metal such as oxygen , sulfur etc.

Corrosion Steel making

Man sees ore in lowest energy state. Man transforms ore in useful object. Nature wants her dirt back. Nature transforms the object back to dirt.

Smelted, heated and beated, forged, ground, drilled and machined

Useful life!

Left out in the rain

ygrenE

Ore

Rusted away

Time

Gas explosion caused by charged soil (crater size: 15 m x 34 m) due to microbial corrosion of gas pipeline (Carlsbed, New Mexico, USA, Aug. 19, 2000)
Source: National Transportation Safety Board (USA) www.ntsb.gov

The leak caused by corrosion at this elbow started the fire that destroyed this refinery

Kansai Electric Power Co. 7

Cost of corrosion (1998, USA)

Highway Bridges Gas and Liquid Transm. Pipelines Waterways and Ports $0.3 Hazardous Materials Storage Air Ports Railroads Gas Distribution Drinking Water and Sewer System Electrical Utilities Telecommunication Motor Vehicles Ships Aircraft Railroad Cars Hazardous Materials Transport Oil and Gas Expl. And Production Petroleum Refining Chem., Petrochem., Parm. Pulp and Paper Agricultural Food Processing Electronics Home Appliances $1.5 $20.0 $10 $20 $30 $40 Defense Nuclear Waste Storage $0.1 $0 $2.7 $2.2 $0.5 $0.9 $1.4 $3.7 $1.7 $6.0 $1.1 $2.1 $6.9 $23.4 $7.0 $8.3 $7.0

Total 276 billion $ !! 3.1% of GDP

$5.0

$36.0

Mining $0.1

Corrosion Cost and Preventive Strategies in the United States, G.H. Koch, M.P.H. Brongers, N.G. Thompson, Y.P. Virmani and J.H. Payer, FHWARD-01-156, Office of Infrastructure Research and Development Federal Highway Administration, Department of Transportation, 2003

Cost of Corrosion Per Analyzed Economic Sector, ($ x billion)

Corrosion rate

mm/yr <0.127 0.127~1.27 >1.27 <0.11 <1.12 <3.37 >3.37 <0.05 <0.5 0.5~1.27 >1.27 <0.45 <0.6

Class A (resistant) Class B (acceptable) Class C (unavailable) (g/m2/day) <4.5 <2.4 favorable <45 <24 acceptable <13.5 <72 poor >13.5 >72 unavailable <2 Favorable <20 Acceptable 20~50 Usable >50 unavailable (g/m2/hr) <18 <0.42 (304,316,317) <24 <0.57 (347cast steel)

mpy <5 5~50 >50

Classification

References

3 4
Sensitization test in concentrated nitric acid

1. H.H.Uhlig, Corrosion Handbook, John Wiley & Sons Inc., New York (1969) 2. E.Rabald, Corrosion Guide, Elsevier, New York (1968) 3. Shell Development Co., Corrosion Data Survey (1960) 4. R.W.Swanby, Corrosion Charts (1962) 5. Du Pont Internal Report

Corrosion is electrochemical Anode (Oxidizing losing electrons) Electrode Cathode (Reducing gaining electrons) Electrode Need Short circuit for electrons between terminals And need a medium for ion transport Electricity and chemicals are main drivers Influenced by other factors

Nearly all metallic corrosion processes are electrochemical, in nature, which involve transfer of electronic charge.
Wollaston (circa 1815) regarded corrosion to be an electrochemical process. In 1824, Davy showed galvanic effect.

Not just chemical but electrochemical process.

Comprehensive understanding of corrosion mechanism Development of various test methods and preventive measures

Attack of Zn in HCl Zn + 2HCl ZnCl2 + H2 This overall reaction can be split into:
Anodic reaction : Zn Zn2+ + 2eCathodic reaction: 2H+ + 2eH2

Both reactions must occur simultaneously and at the same rate!!!

Figure 2.6 Electrochemical reactions occurring during the corrosion of zinc in air-free hydrochloric acid.
Corrosion Basics: An Introduction, NACE, 1984, pg 28.

electrical connection anode cathode

No corrosion if one of these is missing: anode cathode electrolyte electrical connection closed circuit

electrolyte

Corrosion rates are almost initially very high Polarization something to slow down reactions

Cathodic and anodic surface polarization Film thickness of corrosion product Rate of hydrogen or oxygen diffusion to and from surfaces Rate of corrodant ion diffusion away

Areas of reaction (anode to cathode) Oxygen content (cathodic depolarizer) Temperature every 10C = 2 x corrosion rate Velocity effects moving species to & fro

P/S potential measurement

Pipe to Soil potential Reference electrode: Sat. Cu/CuSO4 ref. electrode

Potential measurement at test post (point)

Ref. electrode

voltmeter

pipe

Test post (box)

Electrochemical corrosion vs. Direct combination (oxidation) WET vs. DRY corrosion It is often classified according to the forms of corrosion:

Uniform or localized corrosion Pitting, crevice corrosion, intergranular corrosion (IGC), SCC Mechanically induced corrosion: erosion, cavitation, fretting Hydrogen related problems: embrittlement, blistering, HIC

Intergranular Corrosion ( ) Galvanic & Concentration Cell Crevice Corrosion () Pitting Corrosion () Erosion-Corrosion Environmentally Induced Cracking Uniform Corrosion Hydrogen damage Dealloying (Dezincification)

Microstructure

Environment

Stress

Geometry

Time

The even removal of metal. Allows great planning

Monitoring Replacement and scheduling

Unfortunately, rare in the real world.

What general corrosion might look like!

Most common form of localized attack Break down of protective scale Localized attack in break Pit sets up its own environment Draws in chlorides and sulfates Can form caps over pits Low corrosion rates are deceitful

Pitting corrosion small and large

Pit , , density

(a) Narrow & dip (b) Elliptical (c) Wide and shallow (d) Subsurface (e) Undercutting (f) Shapes determined by microstructural orientation 39

Specimens of various stainless steels after G 48 testing at 80C for 24 hours.

Standard Test Methods for Pitting and Crevice Corrosion Resistance of Stainless Steels and Related Alloys by Use of Ferric Chloride Solution, A: Ferric chloride pitting test
Shell ES/247 Revision 2, 2003

SS 6% FeCl3 (, )
222 or 502C 72 hrs /

Specimens of various stainless steels after G 48 testing at 80C for 24 hours. 40

(Epit)
Critical pitting potential (CPP)

scan repassivation potential(Erp)

Pitting Epit=Erp Pitting hysteresis loop .

Epit Erp

a. E>Epit : Pits nucleation occurs. b. Erp<E<Epit : New pits can not be formed, but the existing pits may propagate c. E<Erp : the metal remains passive (or pits repassivate)

ASTM G61: Standard Test Method for Conducting Cyclic Potentiodynamic Polarization Measurements for Localized Corrosion Susceptibility of Iron-, Nickel-, or Cobalt-Based Alloys

log i

Epit = A log [Cl-] + B

42

SS Cr, Mo, N content PRE

%Cr + 3.3 (%Mo + 0.5%W) + 16~30 %N Superalloy

43

1500

1000

Al-6X
E , mV (SC E) .
500

904L 317L

-500

-1000 -10 -9 -8 -7 -6 -5 -4 -3 -2

log i, A /cm 2

PRE 317L: 30.2 904L: 35.3 Al-6X: 40.7 44

Critical pitting temperature

Pitting corrosion CPT pitting corrosion CPC (oC) = 2.5 %Cr + 7.6 %Mo + 31.9 %N 41.0 0~85oC 72h(C, 24h/E) ( 5oC )

45

1M NaCl 700mVSCE 1C/min 100 A/cm2 60

1. Cooling coil 2. Gas distributor 3. Reference electrode 4. Test specimen 5. Counter electrode 6. Temperature sensor 7. Immersion heater 8. Specimen holder with connection 9. Reflux cooler
46

47

Epit Erp

log i

48

49

Simulating natural seawater 50

51

Supplementary technical requirements for the supply of components in 6% Mo Austenitic, 22% Cr Duplex and 25% Cr Super Duplex Stainless Steel Requires

Impact testing Hardness testing Microstructure examination and ferrite phase balance (not 6Mo) Pitting corrosion testing (additionally, stress corrosion cracking for 25Cr if specified)

Base Metal: ASTM G48 method A test required for each lot. Test temperature shall be 122F (50C) and the exposure time 24 hours. Corrosion test specimens shall be at same location as those for tension tests. The test shall expose the external and internal surfaces in the as delivered condition (including pickling) and a cross section surface in full wall thickness. Weld Corrosion test shall be performed on one sample from each of the 3 and 6 oclock welding locations in accordance with ASTM G48 method A. A sample including the root shall be taken and be exposed to the solution. Test temperature shall be 104F (40C) and exposure time 24 hours.

No pitting at 20X magnification & weight loss shall be less than 4.0 g/m2.
Procurement Spec. for MWP 52

CSTL Pipe SS Nozzle

Soot blower metallographic sample

Copper alloys Brasses with >30% zinc (bath sink tap screws) Copper nickel alloys (nickel removed) Cast iron (graphitization) Almost any alloy can have the problem Two Theories One element is leached from solution Both elements corroded but more noble plates back.

Brass River Water Impellor suffering from dealloying and cavitation

Crevice attack on titanium from fluorinated o-ring

Severe crevice attack as well as general

Crevice corrosion of socket weld at gap formed between type 304L pipe and type 316L valve

ASTM G78: Standard Guide for Crevice Corrosion Testing of Iron-Base and Nickel-Base St ainless Alloys in Seawater and Other Chloride-Containing Aqueous Environments [0.5M FeCl3 + 0.05M NaCl] 30

304SS

81

ASTM G48D/F
MCA CPT .

82

Specimens of various stainless steels after G 48 testing at 80C for 24 hours.

83

84

2003 Brooks/Cole, a division of Thomson Learning, Inc. Thomson Learning is a trademark used herein under license.

Figure 22.11 Alternative methods for joining two pieces of steel: (a) Fasteners may produce a concentration cell, (b) brazing or soldering may produce a composition cell, and (c) welding with a filler metal that matches the base metal may avoid the formation of galvanic cells (for Example 22.8)

86

Very similar to crevice corrosion but a larger Usually an unplanned occurrence

Tools left on floor River water silt buildup in bottoms

Sometimes called poultice corrosion Sometimes called oxygen concentration cell

2.0

1.5

Counts (Arb. Unit)

1.0

Fe

0.5

Fe C

Si Al

P Fe
2 4 6 8 10

0.0 0

Energy (keV)

SRB

Fe-Cr alloy in boiling 50% H2SO4 with Fe2(SO4)3 93

PRACTICE A B Streicher C Huey

TEST Oxalic acid etch Screening test Fe2(SO4)3 50% H2SO4 65% HNO3

TEMP. Ambient

TIME 1.5 m

APPLICABILITY Chromium carbide sensitization Only (1.5A/cm2) Chromium carbide Chromium carbide and phase Chronium carbide in 316, 316 L, 317 and 317 L

EVALUATION Microscopic: classification of etch Structure (screening test) Weight loss corrosion rate Weight loss corrosion rate Corrosion ratio compared to solution annealed specimen

Boiling Boiling 70C

120 h 240 h 4h

D 10% HNO3 Mod. Strau 3% HF 6% CuSO4 10% H2SO4 Metallic copper

E Strau

Boiling

24 h

Chromium carbide

Examination for fissures after bending

CuSO4 50% H2SO4 Metallic copper

Boiling

120 h

Chromium carbide in cast 316 and 316 L

Weight loss corrosion rate

99

100

Source: http://www.sandvik.com

101

IGC TTC . (according to ASTM G28, Streicher, ferric sulfate+sulfuric acid)

102

Stress

No SCC SCC

Strain

105

Weld metal

Knife line attack Transgranular chloride SCC in 316 stainless steel

Intergranular caustic SCC in 304L stainless steel finned tube.

Starts with an alternating stress state Protective oxide breaks open Corrosive species attack and form products Next cycle repeats:
crack growth more corrosion product accelerated fatigue failure

Seen in rotating shafts

Corrosion fatigue, cracks can be oriented the other direction depending on stress state of shaft.

Mostly found at
Pump impellor tips Boat propellers Constriction in fast fluids

Caused by formation of low pressure bubble Bubble is a vacuum Collapse of bubble slams the metal

Breaking protective oxide Causing great mechanical damage

Piece of pump impellor with tip cavitation

Valve trim diffuser with cavitation

Centrifuge feed nozzle

Can be from
Gaseous vapor (steam cuts on flanges) Liquid Solids (Coal slurry)

Removes the protective oxide layer faster than it can heal

Look for comet tails! Water was flowing from right to left in copper water pipe.

Visual examination for leaks Lab testing Field testing (Corrosion racks with coupons) Corrosion probes
ER (electrical resistance) LPR (linear polarization resistance) New technology

Metals analysis in process fluids

All kinds of materials and shapes

Metals Plastics Fiber reinforced plastics Ceramics Elastomers Glass

Homemade or store bought coupons Welds Heat treatments

Coupons Lab testing at many temps but low pressure Heat flux testing to simulate exchangers High pressure labs Ingenious bench scale or pilot plant testing Key question - What do you want to know?

Agitator blades as corrosion coupons

Weld wires as coupons

Corrosion racks Electrical resistance probes Linear polarization resistance probes New technology
Using electrical noise LPRs ERs

Metals analysis in solutions

Typical field corrosion rack for insertion through a nozzle.

V = I*R

Electrical resistance probe

R = *l/A

Gives instantaneous corrosion rates Only used in conductive solutions Based on the current flow between two or more electrodes Requires the surface to become passivated (or polarized) and current resistance is measured. Sometimes probe has a reference electrode as well.

Honeywells SmartCET uses a sensor for background electrochemical noise to detect pitting along with LPR probe and a sophisticated computer program. http://hpsweb.honeywell.com/NR/rdonlyres/8418C7B6-EBB94948-8441-C3803B06BA2E/44686/ChemEngJune07.pdf

Newer Technology

Electron Microscopy Elemental analysis Surface features FTIR for identification X-ray Diffraction X-ray Fluorescence

Looking for clues by

Metals in fluids Fluids in plastics Corrosion products

Material selection, e.g., CS to CRA Coatings & linings (organic, inorganic) Cathodic & anodic protection Corrosion inhibitor Design Factors, etc.

If an active-passive alloy is maintained in the passive region with the potentiostat, its corrosion rate will reduced to ipass. This technique is based on the formation of protective film on metals by externally applied anodic currents.

An inhibitor is a chemical substance that, when added in small concentration to an environment, effectively decreases the corrosion rate. A minimum conc. of inhibitor must be present to maintain the inhibiting surface film. Thus, good circulation and the absence of any stagnant areas are necessary to maintain the required level of inhibitor concentration. An addition of inhibitors reduces icorr by increasing the Tafel slope and/or by reducing the exchange current density.

Anodic inhibitor

log i Cathodic inhibitor

log i

A. Adsorption-type inhibitors Organic compounds which adsorb on the metal surface and suppress metal dissolution and reduction reactions. Typical of this class of inhibitors are the organic amines. B. Hydrogen evolution poisons The susbstances such as As, Sb, P, and S retard hydrogen recombination reaction, thereby reducing corrosion rate of a metal in acid solutions.

C. Scavengers These substances act by removing corrosive species from solution : Sodium sulfite : 2Na2SO3 + O2(sol.) 2Na2SO4 Hydrazine : N2H4 + O2 N2 + 2H2O D. Oxidizers or passivators - effective only in metals showing active/passive transition. : CrO42- , NO2-, MoO42- , WO42- , and ferric salt

Oxidation
Flux Inert environment

Stress Build-up
Choose appropriate material for welding rod to reduce mechanical

stress

Weld Decay
De-zincification Grain Boundary Chromium Depletion Knifeline Attack

Weldment Corrosion

Weldments have a high sensitivity to environmentally induced corrosion. Residual stresses can cause Stress Corrosion Cracking (SCC) Stress risers and inclusions due to welding can increase the sensitivity to Corrosion Fatigue Cracking (CFC) Welding in the presence of water or organic molecules can trap hydrogen in the weld, leading to Hydrogen Induced Cracking (HIC) Misoriented welding geometry can cause crevice corrosion/pitting corrosion.

Susceptibility to environmentally induced corrosion is increased by improper welding technique. Defects include:

Stress risers Inclusions Incomplete welding Improper filler metal or flux used

Causes:
Residual tensile stresses Stress risers caused by improper

welding

Prevention:
Use a metal that is resistant to

SCC in environment Specify post welding heat treatment Ensure smooth weld bead

Possible when weld is subjected to variable loads Stress risers at the weld will increase the sensitivity to CFC Prevention:

Smooth weld area Minimization of inclusions

Hydrogen present in water or organic molecules is released at high temperatures Monatomic Hydrogen is infused in the weld pool Hydrogen combines within metal and causes HIC

Prevention:
Store welding rods in dry environment Use low-hydrogen electrodes (non-organic binders and flux) Local heat treatment before & after welding

Arc Welding
Atmosphere Surface contaminants Welding rod
H2 O

WELD

Heat breaks down Water.

H2O O2 H

WELD

Hydrogen causes cracking Oxygen creates crevice

O2

WELD

Mechanism
Environment High P, high T hydrogen environment
Petrochemical plants Hydrocarbon processing at 21 MPa, 540C

Stress level, exposure time, steel composition

Mechanism Hydrogen reacts with carbides to form methane Methane bubbles form at grain boundaries Bubbles merge to create fissures

Characteristics
Symptoms Unexpected failure Microstructure Decarburization along grain boundaries Fissuring along grain boundaries Embedded methane bubbles

Case Study
Hydrogen attack at the ID weld

in a high pressure carbon steel boiler tube

Case Study
Cracking due to hydrogen attack

at the ID weld in a high pressure carbon steel boiler tube

Transgranular Cleavage

The filler metal is usually of a different composition than the base metal. Making the filler metal noble to the base metal will cathodically protect the weld. Oxidation and diffusion will lower the alloy. concentration in weld, so filler metal should also have higher amounts of alloying elements than the base metal.

In the Unmixed Zone, non-equilibrium cooling can cause potential problems:

Grain boundary segregation Primary phase structures Precipitation of alloying elements

Prevention:
Pre and post heating avoids unequilibrium cooling

Stress Corrosion Cracking Hydrogen Induced Cracking Crevice corrosion Intergranular Cracking
Sensitization from welding heat & stress Carbide precipitation

(Cl-, H2S, etc)
Materials
Composition Heat Treatment Microstructure Surface Condition

Environment Corrosion
Composition Temperature Electrode Potential Flow rate

SCC
Acid chloride solution Seawater Condensing steam from chloride waters H2S + chloride Polythionic acid (sensitized material) NaCl H2O2 NaOH - H2S
Fatigue

SCC CorrosionFatigue

Stress, Strain
Service Stress Fit-up Stress Residual Stress Strain Rate

162

Offshore Structure Weld Decay Solar Power Plant Chloride Corrosion Gas Pipeline SCC Pipes Crevice Corrosion Chloride Stress Corrosion Cracking

Welded Steels Stress from sea and Corrosive Environment Problems

Weld decay Weld cracking Pitting

Painting Structure Better choice of weld material Cathodic Protection Zinc bar Better welding of steels Better weld geometry

Stress Corrosion Cracking

Caused by tough environment Operation of load and stresses Stress are either mechanical or chemical Mechanical Stresses: scratches, rivets, residual stresses Chemical Stresses: cracks, corrosion in the media

Stress Corrosion Cracking in weld

Stress cracks under operation. Cracking is longitudinal along the weld

Crevice Corrosion in Duplex Steel Corrosion due to Heating Internal oxide layer created Crevice
Caused pipe to corrode and burst

Aggressive media increased corrosion

Crevice corrosion of socket weld at gap formed between type 304L pipe and type 316L valve

Use an oxygen-free backing gas to prevent scale formation during welding Annealing Use specific filler metals
Increase in Ni increases resistance to SCC, but also

becomes brittle Find stability between heat and nickel concentration

3-4 cm

8-10 cm

Intergranular crack propagation in welded region Stressed region Unprotected region to environment. Chlorine accumulation

High chloride concentration found If compared to other parts of the sample there is no cracking Chloride enhances cracking mechanisms

Molten lead is held in thick steel pots during refining. In this case, the molten lead has attacked a weld in a steel plate and cracks have developed. Eventually, the cracks propagate through the steel, and molten lead leaks from the pot.
177

Materials Selection Weld Geometry

Effective welding mechanisms (heat input, cooling rate) Cathodic Protection

Annealing De-sensitizing stainless steel

Metallurgical effects
Preferential corrosion of HAZ

Geometrical effects
Stress concentration at weld toe Creation of crevice due to joint design

Environmental effects
Temperature, conductivity, etc.

Metallurgical + Geometrical effects

SCC

More common in carbon and C-Mn steel than in higher-alloy steels

Tramline corrosion High conductive aqueous solution pH below 7 and 8 (acidic mine water)

Seawater Higher tensile residual stresses allow corrosion to proceed slightly faster than in the less highly stressed steel.

Galvanic Corrosion Occurs in ERW/HFI pipe Attack of seam weld line in aqueous environment or when exposed to the water phase in a mixed-phase system due to flow conditions or water dropout in low points. Unstable Inclusion (MnS) produced during the welding cycle.
Galvanic corrosion (1 to 10 mm/y) Potential difference between 30 to 70mV, but high C/A area ratio

Low S content, alloying element such as Cu, REM

Highest corrosion rate Shielded metal are electrodes using a basic coating In seawater, a weld made using a basic-flux-coated consumable has a higher corrosion rate.

In boilers and other vessels producing water at high temperature together with free alkalis (usually NaOH)
50 80oC Residual stress Local evaporation of water

can lead to high conc. of NaOH

PWHT
Residual stress relieving Reducing HAZ attack

Selection of appropriate materials or welding procedure

When PWHT is impractical

Alloying
Base metal (grooving corrosion) Make weld more cathodic to the adjacent base metal

 How to Select an Optimum Filler Metal Welding of stainless steel can cause sensitization and hence intergranular corrosion in heat affected zone (HAZ) As a filler metal, Select more resistive one to corrosion than base metal. (i.e., With higher Ecorr) (Small cathode large anode)

filler metal 308L SS (20Cr-11Ni) 347 SS (18Cr-11Ni-Nb)

base metal 304L SS (18Cr-8Ni)

The most widespread type is hydrogen induced SCC when H2S is present, particularly in acidic solutions (oil & gas industry) Sulfide Stress Cracking (SSC) Risk of cracking increases with the max. hardness.
Max 22 HRC (~ 248 HV) Alloy steel need to be PWHTed at a temp. exceeding

620oC.

Cycling of heating and cooling during welding results:

Microosegragation Precipitation of secondary phases Formation of unmixed zones Recrystalization and grain growth in the weld heat affected zone (HAZ) Volatilization of alloying elements from the molten weld pool Contamination of the solidifying weld pool

Corrosion resistance maintenance

Balancing alloy compositions to inhibit certain precipitation reactions Shielding molten and hot metal surfaces from reactive gases in the weld

environment Removing chromium-enriched oxides and chromium-depleted base metal from thermally discolored (heat tinted) surfaces Choosing the proper welding parameters

Main problem
Precipitation effect Chemical segregation

Remedy
Control of base metal metallurgy Control of welding practice Selection of proper filler metal

.esnecil rednu niereh desu kramedart a si gninraeL nosmohT .cnI ,gninraeL nosmohT fo noisivid a ,eloC/skoorB 3002

The peak temperature surrounding a stainless-steel weld and the sensitized structure produced when the weld slowly cools

Voids where ferrite Has been attacked.

Preferential weld ferrite attack & less severe attack in the sensitized HAZ Acid cleaning of 304SS and 316SS black liquor evaporators in the pulp and paper industry with poorly inhibited HCl can lead to weld metal -ferrite attack.

In alloy depleted regions of weld metal austenite Moderately oxidizing environments Microsegragation or coring of weld metal dendrites Most likely:
In autogenous (no filler) GTA welding In 4 to 6% Mo alloys When the recommended filler metal has the same composition as

the base metal When higher-heat-input welding leaves a coarse microstructure with surface-lying dendrites. Such a microstructure is avoided by use of a suitably alloyed filler metal.

CPT vs. %Mo in 10% FeCl3.

Pitting of underalloyed (relative to the base metal) type 308L weld metal. The type 316L stainless steel base metal is unaffected Tap water environment

Defects such as:

Residual welding flux Microfissures, etc.

Especially in chloride-containing environments Example

Slags from the basic- coated electrodes for out-of-position welding can be difficult to remov

Crevice corrosion under residual slag (S) in IN-135 weld metal after bleach plant exposure.

Microfissure caused by thermal contraction stress during weld solidification When P & S content are higher (>0.015%) High-heat-input welding

Microfissure corrosion on IN-135 weld metal on an alloy 904L test coupon after bleach plant exposure

Weld spatter is most troublesome when it is loose or poorly adherent.

Weld decay and methods for its prevention. The four different panels were joined by welding and then exposed to a hot solution of HNO3/HF. Weld decay, such as that shown for the type 304 steel (bottom right), is prevented by reduction of the carbon content (type 304L, top left) or by stabilizing with titanium (type 321, bottom left) or niobium (type 347, top right)

Selective attack of a type 317L stainless steel weldment and chloride stress-corrosion cracking of the adjacent 317L base metal. The environment was a bleaching solution (7 g/L Cl2) at 70oC

Chloride stress-corrosion cracking of type 304 stainless steel base metal and type 308 weld metal in an aqueous chloride environment at 95oC. Cracks are branching and intergranular

When the caustic concentration exceeds approximately 25% and temperatures are above 100 C Cracking occurs most often in the weld HAZ.

316L reactor vessel failed repeatedly by caustic SCC in 50% sodium hydroxide (NaOH) at 105 C (220 F). Failure was restricted to the weld HAZ adjacent to bracket attachment welds used to hold a steam coil. The stresses caused by the thermal expansion of the Nickel 200 steam coil at 1034 kPa (150 psig) aggravated the problem. It was recommended that the vessel be weld overlayed with nickel or that the existing vessel be scrapped and a replacement fabricated from Nickel 200.

Caustic SCC in the HAZ of 316L SSNaOH reactor vessel. Cracks are branching and intergranular

Found at
Cooling water system Aqueous waste treatment Groundwater left in new equipment or piping after hydrotest

Characteristics
Underdeposit corrosion (discrete mound) Subsurface cavities with minute pinhole penetration at the surface Natural, untreated water containing one or more culprit species of

microorganisms.

MIC of butt weld in water tanks 304L or 316L to resist HNO3 organic acid and to maintain product purity Hydrotest with water containing 200 ppm chlrodie. No drain of piping after hydrotest Reddish brown deposit and corrosion (& leakage) after 1 to 4 months a tiny mouth at the surface and a thin shell of metal covering a bottle-shape pit that had consumed both weld and base metal.
Moundlike microbiological deposits along a weld seam in the bottom of a type 304L stainless steel tank after several months of exposure to well water at ambient temperature

Moundlike microbiological deposits along a weld seam in the bottom of a type 304L stainless steel tank after several months of exposure to well water at ambient temperature

Close-up of a wet deposit Deposit was slimy and gelatinous

Cross section through a pitted weld seam from a type 304L tank showing a typical subsurface cavity

Radiograph of a pitted weld seam in a type 304L stainless steel tank bottom

Well water: high count of

Iron bacteria (Gallionella) Iron-manganese bacteria (Siderocapsa) No SRB & SOB

Corrosion products contain large amount of

Fe, Mn, Cl

Nearly all biodeposits and pits were found at the edges of, or very close to, weld seams

R. Fernandez, E. Rege and M. Beatty, Weldment Corrosion. University of Berkeley D.H. Lister and W.G. Cook, Reactor Chemistry and Corrosion, Department of Chemical Engineering, University of New Brunswick. 3. R.J. Sinko, Corrosion Basics, AIChE, Jan. 21, 2009, http://www.tnengineering.net. 4. D.R. Askeland and P.P. Phule, 5. W.H. Weber, Guided Wave Ultrasonics (GWUT) An Effective Screening Tool, 40th Annual SIEO/NACE Winter Symposium 2005. 6. N. Bailey, Weldability of Ferritic Steels, Abington Publishing, 1994. 7. , , , 1997. 8. C.G. Arnold, Galvanic Corrosion of Weldment, CORROSION/80, NACE Internatial, 1980. 9. P.R. Roberge, Handbook of Corrosion Engineering, McGraw-Hill, NY, 1999. 10. T.G. Gooch and P.H.M. Hartt, Review of Welding Practices for Carbon Steel Deaerator Vessels, Paper no. 303, CORROSION/86, NACE International. 11. http://en.wikipedia.org/wiki/Deaerator 12. M.A. Streicher, Theory and Application of Evaluation Tests for Detecting Susceptibility to Intergranular Attack in Stainless Steels and Related AlloysProblems and Opportunities, Intergranulur Corrosion of Stainless Alloys, STP 656, American Society for Testing and Materials, 1978, p 70.
1. 2.

Questions?

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