NIROSTA and THERMAX Stainless steels for automobile exhaust systems

A company of ThyssenKrupp Stainless

TK Nirosta

Tk

NIROSTA a proven material for exhaust systems

As far back as 1970-1974 the ADAC test confirmed the good properties of the most advanced material of the day with the number 1.4512 (DIN name X2CrTi12)/ AISI 409. This material met all requirements over the entire test period and at all points on the muffler, and the verdict of the test was: Using NIROSTA 4512 a four- to five-year warranty commitment is possible. The introduction of the 3-way catalytic converter made the corrosion and thermal conditions much more severe. Today higher-quality materials are needed to ensure good durability. As the trend continues, our steels and alloys are in a position to meet increasingly stringent statutory requirements, demands for lightweight designs to reduce fuel consumption, and calls for improved appearance and durability. Materials A wide range of steels offers numerous options to meet the varied demands imposed by different parts of the exhaust system. Stainless steels are primarily classified according to microstructure into ferritic and austenitic steels.

Ferritic

Austenitic

Exhaust manifold NIROSTA 4509 (AISI 441)

NIROSTA 4541 (AISI 321) THERMAX 4828 (AISI 309) THERMAX 4828 mod. (AISI 309 mod.) NIROSTA 4301 (AISI 304) NIROSTA 4541 (AISI 321) THERMAX 4828 (AISI 309)

Manifold pipe NIROSTA 4512 (AISI 409) NIROSTA 4509 (AISI 441)

Catalytic converter NIROSTA 4509 (AISI 441)

NIROSTA 4541 (AISI 321) THERMAX 4828 (AISI 309) CRONIDUR 4767 (foil)

Connecting pipe NIROSTA 4512 (AISI 409) NIROSTA 4509 (AISI 441) Central muffler NIROSTA 4512 (AISI 409) NIROSTA 4510 (AISI 439) NIROSTA 4113 (AISI 434) NIROSTA 4513 NIROSTA 4526 (AISI 436) Connecting pipe NIROSTA 4512 (AISI 409)

NIROSTA 4301 (AISI 304)

NIROSTA 4301 (AISI 304) NIROSTA 4541 (AISI 321)

NIROSTA 4301 (AISI 304)

Rear muffler NIROSTA 4512 (AISI 409) NIROSTA 4113 (AISI 434) NIROSTA 4513 NIROSTA 4526 (AISI 436)

NIROSTA 4301 (AISI 304) NIROSTA 4541 (AISI 321)

Tailpipe

NIROSTA 4301 (AISI 304) NIROSTA 4401 (AISI 316)

Hot corrosion resistance [+Cr +Ti +Si + Nb +Ce]

The graphic on the right gives a basic guide to the classification and main applications of important stainless and heat-resistant steels. The materials are ranked according to the main types of loading, hot corrosion and wet corrosion, and the effects of the alloying elements are also shown.

Austenitic applications

AISI 309 mod. AISI 309

Ferritic applications

AISI 441 AISI 436 1.4513

AISI 321 AISI 304

AISI 444 AISI 316 Ti

AISI 439 AISI 409 AISI 434

Wet corrosion resistance [+Cr +Mo (+Ti +Nb C)]

Applications Front section The hot front section of exhaust systems (manifold pipes, catalytic converter) requires steels with high scaling resistance, elevated-temperature and creep strength and minimum susceptibility to embrittlement. In addition they must be able to resist high oscillating stresses due to vibration.

1,000 950 Temperature [C] X5 CrNi 18-10 900 X2 CrTi 12 X6 CrMoNb 17-1 850 800 750
13 30 mo9 d.
800 C 950 C (900 C) 800 C 900 C 950 C 1,000 C

X1 CrMoTi 16-1

An initial assessment can be made by considering the limiting temperatures for scaling resistance in air under cyclic longterm loading. This can be extended by studying the embrittlement behavior of the main steels under thermal loading.

X2 CrTiNb 18

43 6

Limiting temperatures for scaling resistance in air under cyclic long-term loading Material AISI 409 Ferrite 4411) (436)1) (1.4513) (430 Ti) 304 Austenite 321 309 309 S 309 mod. >900 C Grain growth >1,000 C TiCN dissolution 475 C Embrittlement 600-850 C -phase >950 C Grain growth 600-750 C Grain boundary carbides 650-850 C -phase >1,000 C Grain growth 650-850 C -phase >1,050 C Grain growth 650-900 C -phase >1,050 C Grain growth 650-900 C -phase >1,050 C Grain growth short Microstructure change Exposure time2) EmScaling limibrittlement ting tempeeffect rature in air low

long long low/medium short/medium short long medium long medium medium long medium low low medium/ strong low

1) 850-1,000 C Laves phase with high Nb content 2) short = seconds- minutes, medium = minutes- hours, long = days-months

32

30 9 30 9

40

45

44

30

AISI

X10 CrNiCe 20-20

X15 CrNiSi 20-12 X12 CrNi 23-13

X6 CrNiTi 18-10

0.2% yield strength [MPa]

The final step in material selection is to consider tensile and creep strength at elevated temperatures. Here the austenitic steels show themselves to be generally superior at temperatures above 500 C.

Yield and tensile strength at elevated temperatures (typical values) 400 300

200

409 1.4513 441 436 321 316 Ti 309

100 0 800 700 600 500 400 300 200 100 0

Tensile stress [MPa]

Rear section In the rear section (rear muffler) wet corrosion becomes the main factor. Inside the system condensation of combustion gases produces aggressive mixtures which can lead to corrosion of stainless steels. From the outside the materials are subjected to loads from de-icing salts. The corrosive attack can be intensified by temper colors, deposits and dirt.

Tensile strength [MPa]

Central section In the central section of the exhaust system (central muffler, connecting pipes) both high-temperature strength and resistance to wet corrosion are needed. Depending on running conditions either thermal stressing is particularly high (full load) or corrosion loading predominates (short-distance service).

100

200

300 400 500 600 Test temperature [ C]

700

800

900

Creep strength after 100,000 hours loading(guide value) 250 200 150 100 50 0 550 600 650 Test temperature [ C]

304 316 321 441 409

700

Potential in mVEH

In the graphic on the right steels for the central section are ranked according to pitting resistance in chloride-containing media. The same rankings are obtained under moist/dry loading in weakly acidic chloride-containing water with a pH value 4, although austenitics perform distinctly better than ferritics due to their comparatively low passivation current density.

Pitting resistance in chloride-containing media 1,200 1,000 800 600 400 200 0
3 9 9 4 1 51 6 1.4 40 43 43 44 43 31 6T i

Test medium: aqueous solution with 500 ppm CI (as NaCI) at 50 C Potential increment: 120 mV/H

AISI
30 4

Fabrication properties As well as high-temperature strength and corrosion resistance, steels for exhaust systems need to display good forming and welding properties. Depending on material most of these demands can be met. However the different thermal expansion coefficients of the ferritic and austenitic steels must be taken into account in component design and during welding in the exhaust system. Low-notch welding provides greater strength under oscillating loads. Proper fabrication and design combined with the right choice of material guarantee long component life. Causes of failure and possible remedies Our extensive investigations into exhaust system failures show that as well as use of inappropriate materials, many problems are caused by incorrect design and fabrication. The chart on the right lists the most frequent causes of exhaust system failure and possible remedies. Get in touch with us: As materials specialists well be glad to help.

Main causes of failure Rear muffler corrosion (internal) Causes: Corrosion attack too severe for AISI 409. Pitting in twin-wall designs. Pitting in conjunction with intercrystalline corrosion. Change design, e.g. single-wall design. Use higher-alloyed steels, e.g. AISI 316 Ti

Remedies:

Embrittlement in manifold area Cause: Remedy: Sigma phase embrittlement under incorrect temperature loading. Use steels with higher resistance to embrittlement

Notch-induced fatigue failure Causes: Remedies: Notches caused by poor welds, design factors or production errors. Avoid notches. Change design. Use high-strength steels.

Destruction of catalyst substrate by metal particles Cause: Remedy: Scale particles in exhaust manifold. Use alloys with increased scaling resistance. Special alloying additions.

Destruction through incorrect design Cause: Remedy: Overheating due to incorrect exhaust routing. Change design, deflect gas flow in muffler.

ThyssenKrupp Nirosta GmbH Oberschlesienstr. 16 47807 Krefeld, Germany Key account postal code: 47794 Krefeld, Germany Tel. +49(0)21 51 83-01 Fax +49(0)21 51 83-20 22 www.nirosta.de marketing.nirosta@thyssenkrupp.com

Range of products Cold-rolled strip and sheet Hot-rolled strip and sheet Precision strip in the steel grades NIROSTA stainless THERMAX heat-resistant

All ThyssenKrupp Nirostas plants are certified acc. to ISO 9001.

All statements as to the properties or utilization of the materials and products mentioned in this brochure are for the purpose of description only. Guarantees in respect of the existence of certain properties or utilization of the material mentioned are only valid if agreed upon in writing. Responsible for contents: Marketing and Materials and Applications Development departments.

Edition 3, Stand 12/2007