Microstructure and pitting corrosion of similar and dissimilar stainless steel welds

Abstract

Pitting Corrosion behaviour of similar and dissimilar metal welds of three classes of stainless steels, namely, austenitic stainless steel (AISI 304), ferritic stainless steel (AISI 430) and duplex stainless steel (AISI 2205), has been studied. Three regions of the weldment, i.e. fusion zone, heat affected zone and unaffected parent metal, were subjected to corrosion studies. Electron beam and friction welds have been compared. Optical, scanning electron microscopy and electron probe analysis were carried out to determine the mechanism of corrosion behaviour. Dissimilar metal electron beam welds of austenitic–ferritic (A–F), ferritic–duplex (F–D) and austenitic–duplex stainless steel (A–D) welds contained coarse grains which are predominantly equiaxed on austenitic and duplex stainless steel side while they were columnar on the ferritic stainless steel side. Microstructural features in the central region of dissimilar stainless steel friction welds exhibit fine equiaxed grains due to dynamic recrystallisation as a result of thermomechanical working during welding and is confined to ferritic stainless steel side in the case of A–F, D–F welds and duplex stainless steel side in the case of D–A welds. Beside this region bent and elongated grains were observed on ferritic stainless steel side in the case of A–F, D–F welds and duplex stainless steel side in the case of D–A welds. Interdiffusion of elements was significant in electron beam welding and insignificant in friction welds. Pitting corrosion has been observed to be predominantly confined to heat affected zone (HAZ) close to fusion boundary of ferritic stainless steel interface of A–F electron beam and D–F electron beam and friction weldments. The pitting resistance of stainless steel electron beam weldments was found to be lower than that of parent metal as a result of segregation and partitioning of alloying elements. In general, friction weldments exhibited better pitting corrosion resistance due to lower incidence of carbides in the microstructure.     

Corrosion of Stainless Steels in Fatty Acid Media at Elevated Temperatures and Pressures

Abstract

Natural fatty acids were separated and purified by steam distillation at 250–300°C. Corrosion rates were determined for three stainless steels 316L, 317L and Ti-stabilised 321, using weight-loss measurements after 14 days in three fatty acid fractions at 260°C. These results for stainless steels were compared with corrosion rates obtained for nickel, molybdenum and manganese by similar weight-loss measurements. Scanning electron microscopy was used to confirm pitting corrosion at the metal surface. The effects of water, low molecular weight fatty acids and impurities such as sodium salts are discussed in relation to the overall corrosion processes in steel steam distillation columns.     

Comparison of corrosion scales formed on KO8OSS and N8O steels in CO2/H2S environment

Abstract

Scanning electron microscopy (SEM), energy dispersive spectroscopy (EDS) and X-ray diffraction (XRD) were applied to analyse the microstructure and composition of the corrosion scale formed on KO80SS and N80 tubes with carbon dioxide (CO₂) and hydrogen sulphide (SO₂). The corrosion scales of both KO80SS and N80 tubes were of the double layer structure, and not only uniform corrosion but also localised corrosion was observed. The crystal of the surface layer is laminar. The main phase in the outer layer is calcium carbonate (CaCO₃), and the inner scale consisted of iron carbonate (FeCO₃) for KO80SS steel and FeS_0·9 with a little amount of FeCO₃ for N80 steel respectively. Additionally, the electrochemical techniques were used to investigate the characteristics of the corrosion scales. The results indicated that the polarisation resistance R_p of KO80SS steel film was nobler than that of N80 steel film. Finally, the corrosion current I_corr of KO80SS steels was lower than that of N80 steels. Corrosion scale of KO80SS tube steels is more protective to the matrix than that of N80 tube steels.     

Corrosion Behavior of Weldments of Ti and Ti- 5Ta for Nuclear Fuel Reprocessing Plants

Corrosion studies on specimens of nuclear- grade type 304L stainless steel, titanium, Ti- 5Ta, and their respective weldments were carried out in a boiling nitric acid medium, as well as in boiling nitric acid containing hexavalent chromium and divalent silver ions. The weldments were prepared using a tungsten inert gas welding process. Titanium and its weldment showed excellent corrosion resistance in both media compared to 304L stainless steel. Specimens of Ti- 5Ta alloy base showed excellent corrosion resistance, whereas its weldment showed higher corrosion rates in boiling nitric acid medium. Scanning electron microscopy and x- ray diffraction analyses were carried out on the tested specimens to examine the scale morphology and the phases present on the surface.     

Corrosion behaviour of Lotus-type porous high nitrogen nickel-free stainless steels

Corrosion behaviour of three austenitic Lotus-type porous high nitrogen Ni-free stainless steels exposed to an acidic chloride solution has been investigated by electrochemical tests and weight loss measurements. Polarization resistance indicates that the corrosion rate of Lotus-type porous high nitrogen Ni-free stainless steels is an order of magnitude lower than that of Lotus-type porous 316L stainless steel in acidic environment. The localised corrosion resistance of the investigated high nitrogen Ni-free stainless steels, measured as pitting potential, E_b, also resulted to be higher than that of type 316L stainless steel. The influences of porous structure, surface finish and nitrogen addition on the corrosion behaviour were discussed.     

经济型铁素体不锈钢焊接接头组织与耐蚀性能

采用ER-309焊丝焊接了TCS345,T4003,Nirosta 4003,JFE410RW四种铁素体不锈钢,用金相方法分析了四种母材、接头的显微组织,通过电化学极化曲线测量,对母材和焊接接头的耐腐蚀性能进行了评价.结果表明,TCS345和T4003铁素体不锈钢与Nirosta 4003和JFE410RW铁素体不锈钢的主要区别是钛和锰含量偏低,尤其是钛含量少,导致TCS345和T4003铁素体不锈钢的晶粒长大倾向较Nirosta 4003和JFE410RW铁素体不锈钢的明显.铁素体不锈钢焊接接头存在较大的热影响区,热影响区的组织与母材晶粒相比,其晶粒明显粗大;TCS345铁素体不锈钢的晶粒长大严重,Nirosta 4003和JFE410RW铁素体不锈钢的铁素体晶粒尺寸比TCS345略小,晶粒长大不明显.在1mol/L Na2SO4溶液中,TCS345和JFE410RW不锈钢母材的腐蚀性能优于T4003和Nirosta 4003.     

Corrosion of stainless steels and carbon steel by molten mixtures of commercial nitrate salts

The isothermal corrosion behavior of two stainless steels and a carbon (C) steel in mixtures of NaNO₃ and KNO₃ was evaluated to determine if the impurities found in commodity grades of alkali nitrates aggravate corrosivity as applicable to an advanced solar thermal energy system. Corrosion tests were conducted for approximately 7000 hours with Types 304 and 316 stainless steels at 570 °C and A36 C steel at 316 °C in seven mixtures of NaNO₃ and KNO₃ containing variations in impurity concentrations. Corrosion tests were also conducted in a ternary mixture of NaNO₃, KNO₃, and Ca(NO₃)₂. Corrosion rates were determined by descaled weight losses while oxidation products were examined by scanning electron microscopy (SEM), electron microprobe analysis (EPMA), and x-ray diffraction (XRD). The nitrate mixtures were periodically analyzed for changes in impurity concentrations and for soluble corrosion products. Results of these tests indicated that the short-term corrosion rates of the stainless steel specimens in many of the mixtures could be described in terms of parabolic kinetics. However, no single rate law could be assigned to the corrosion kinetics resulting from exposure in all of the mixtures. For engineering applications, corrosion rates over the entire exposure period are best described as linear with respect to time. In the binary nitrate mixtures, the annualized rates of metal loss were found to be between 6 and 15 μm/year for the stainless steel specimens at 570 °C depending on the particular mixture. Metal loss for the C steel specimens immersed in these same mixtures at 316 °C extrapolated to approximately 1–4 μm/year. SEM and XRD revealed that the complex, multiphase surface oxides formed on the stainless steel coupons were composed primarily of iron-chromium spinel, iron oxides, and sodium ferrite. Magnetite was the principal corrosion product formed on the carbon steel specimens. Overall, for the typical range of impurities in commercially available nitrate salts, corrosion rates for solar thermal energy applications remained acceptable for all of the materials examined.     

A new steel with good low‐temperature sulfuric acid dew point corrosion resistance

In this work, new steels (1#, 2#, and 3#) were developed for low‐temperature sulfuric acid dew point corrosion. The mass loss rate, macro‐ and micro‐morphologies and compositions of corrosion products of new steels in 10, 30, and 50% H₂SO₄ solutions at its corresponding dew points were investigated by immersion test, scanning electron microscopy (SEM) and energy‐dispersive spectrometry (EDS). The results indicated that mass loss rate of all the tested steels first strongly increased and then decreased as H₂SO₄ concentration increased, which reached maximum at 30%. Corrosion resistance of 2# steel is the best among all specimens due to its fine and homogeneous morphologies of corrosion products. The electrochemical corrosion properties of new steels in 10 and 30% H₂SO₄ solutions at its corresponding dew points were studied by potentiodynamic polarization and electrochemical impedance spectroscopy (EIS) techniques. The results demonstrated that corrosion resistance of 2# steel is the best among all the experimental samples due to its lowest corrosion current density and highest charge transfer resistance, which is consistent with the results obtained from immersion tests.     

Corrosion behavior of martensitic and precipitation hardening stainless steels treated by plasma nitriding

Plasma nitriding is a well established technology to improve wear and corrosion properties of austenitic stainless steels. Nevertheless, in the case of martensitic stainless steels, it continues being a problem mainly from the corrosion resistance viewpoint.In this work, three high chromium stainless steels (M340, N695 and Corrax) were hardened by ion nitriding at low temperature, intending to preserve their corrosion resistance.Corrosion behavior was evaluated by CuSO₄ spot, salt spray fog and potentiodynamic polarization in NaCl solution. Microstructure was analyzed by optical microscopy, SEM (EDS) and glancing angle X-ray diffraction. All the samples showed an acceptable corrosion resistance in experiments with CuSO₄, but in salt spray fog and electrochemical tests, only Corrax showed good behavior. The poor corrosion performance could be explained by chromium carbides formed in thermal treatment stage in martensitic steels and chromium nitrides formed during nitriding, even though the process was carried out at low temperature.     

节镍型不锈钢的耐腐蚀性能比较

通过3.5%NaCl溶液中动电位极化曲线测定和中性盐雾试验,对200系列奥氏体不锈钢和400系列铁素体不锈钢两类节镍型不锈钢与304不锈钢的耐腐蚀性能进行了对比研究。结果显示,400系列铁素体不锈钢的耐点蚀性能优于200系列奥氏体不锈钢,两种节镍型不锈钢的耐点蚀性能均不如304不锈钢好;200系列奥氏体不锈钢的耐均匀腐蚀性能最差,443不锈钢耐均匀腐蚀性能与304不锈钢相当,439不锈钢比304不锈钢耐均匀腐蚀性能稍差。201、202、304、439和443不锈钢在3.5%NaCl溶液中的点蚀电位分别为(vs.SCE)-32 mV、-22 mV、312mV、165 mV和227 mV,腐蚀速率分别为0.0071 mm/a、0.0062 mm/a、0.0026 mm/a、0.0038 mm/a和0.0024mm/a。     

Oberflächenbehandlungsverfahren und deren Einfluß auf die Korrosionsbeständigkeit nichtrostender Stähle

Surface treatments and their influence on the corrosion resistance of stainless steel The surface treatments pickling, grinding and glass beading were investigated on several stainless austenitic steels and one ferritic/austenitic steel. The different surface treatments were used on two different prepared types of samples:

• 1 high temperature oxidized samples
• 2 welded samples

The quality of the surface treatments has been examined by means of potentiodynamic, ferric chloride, dip and spray tests made in series. The corrosion resistance was highly depending on the used treatments. All in all the examination showed that a higher corrosion resistance was achieved by pickling than by grinding or glass beading.     

不锈钢海水潮汐区16年腐蚀行为

在青岛、厦门和榆林3个试验站的潮汐区对5种不锈钢暴露16年，总结其腐蚀行为和规律。在潮汐区暴露的不锈钢受点蚀和缝隙腐蚀破坏。不锈钢在潮汐区暴露1至4年的点蚀速度较大，以后点蚀速度减慢。耐点蚀性能较好的不锈钢，耐缝隙腐蚀性能也较好。不锈钢在潮汐区的腐蚀随暴露地点的海水温度升高而加重。增加Cr含量、添加Mo能明显提高不锈钢在潮汐区的耐蚀性。Ni对提高的耐蚀性有效，但影响效果较小。海生物污损能引起不锈钢的局部腐蚀，它对不锈钢在潮汐区的腐蚀有显著影响。     

Localized corrosion properties of low interstitial ferritic,high purity austenitic and high chromium duplex stainless steels

Within the framework of a research aimed at characterizing the behaviour of new materials to pitting and crevice corrosion, an investigation has been made, using electrochemical techniques, of the following materials: ELI ferritic stainless steels (18 Cr-2 Mo-Ti; 21 Cr-3 Mo-Ti; 26 Cr-1 Mo); high chromium duplex stainless steel (Z 5 CNDU 21-08) and high chromium-nickel austenitic stainless steel (Z 2 CNDU 25-20); commercial austenitic stainless steels (AISI 304 L and 316 L) and laboratory heats of austenitic stainless steels with low contents of interstitials (LTM/18 Cr- 12 Ni, LTM/16 Cr- 14 Ni-2 Mo). It was possible to graduate a scale of resistance to pitting and crevice corrosion in neutral chloride solutions at 40 C; in particular the two experimental austenitic stainless steels LTM/18 Cr- 12 Ni and LTM/16 Cr- 14 Ni-2 Mo are at the same level as the AISI 316 L and 18 Cr-2 Mo-Ti, respectively. An occluded cell was developed and used for determining the critical potential for crevice corrosion (E_{localized corrosion}). For the steels under investigation E_{localized corrosion} is less noble than E_pitting especially for ELI ferritic 18 Cr-2 Mo-Ti and 21 Cr–3 Mo-Ti.     

An efficient protection of stainless steel against corrosion: Combination of a conversion layer and titanium dioxide deposit

In the present work, a novel process has been developed to improve the corrosion properties of ferritic stainless steels. Titanium oxide coatings have been deposited onto stainless steel by sol-gel process after a pre-functionalization of the substrate in a conversion bath. Gel titania was prepared by hydrolysis of a titanium butoxide through a sol-gel process. Duplex systems “conversion layer/uniform TiO₂ coating” have been prepared on stainless steels using a dipping technique and thermal post-treatments at 450 °C. The preparation of sol-gel coatings with specific chemical functions offers tailoring of their structure, texture and thickness and allows the fabrication of large coatings. The morphology and structure of the coatings were analysed using scanning electron microscopy with field effect gun (SEM-FEG), Mass spectroscopy of secondary ions (SIMS) and X-ray diffraction (XRD). The anticorrosion performances and the ageing effects of the coatings have been evaluated in neutral and aggressive media by using several normalized tests.The results show that the conversion layer was not sufficient to protect steel but sol-gel TiO₂ coatings, anchored on the metal substrate via the conversion layer, show good adhesion with the substrate and act as a very efficient protective barrier against corrosion. So, duplex layers with TiO₂ nanoparticle coatings on steels exhibit an excellent corrosion resistance due to a ceramic protective barrier on metal surface. Analysis of the data indicates that the films act as geometric blocking layers against exposure to the corrosive media and increase drastically the lifetime of the substrate.     

典型不锈钢晶间腐蚀敏化温度的研究

用电化学动电位再活化（EPR）法、硫酸—硫酸铜法及扫描电镜研究了典型的202、304奥氏体不锈钢与409、430铁素体不锈钢在不同敏化温度下晶间腐蚀的敏感性。结果表明,奥氏体与铁素体不锈钢敏感温度区间不同,奥氏体不锈钢诱发晶间腐蚀的敏感温度约为650℃,铁素体不锈钢诱发晶间腐蚀的敏感温度约为950℃。研究结果为正确地评判不锈钢晶间腐蚀敏感性及优化生产工艺提供了科学依据。     

The influence of alloying elements on the corrosion behaviour of ferritic steels in simulated combustion atmospheres

The low‐chromium steels (Cr content 0.7–1.4 wt.%) are usually being used in low temperature boiler applications where the environments are not so aggressive as in waste‐fire boilers. To improve their mechanical properties and corrosion resistance several alloying elements have been used. In the present study the new low‐chromium steels modified with Si, Ni and Ce have been investigated. These steels were compared with the common boiler steel – 2.25Cr1M. The multi‐sample exposure tests were made in moist air (8% O₂ + 15% H₂O) with and without 200 ppm SO₂ or 2000 ppm HCl addition at the isothermal temperature of 500°C. Corrosion products were analysed by Scanning Electron Microscope with Energy Dispersive Spectrometer (SEM/EDS) and XRD techniques. The results of the study show that addition of Ni and Si to the steels studied could improve their corrosion resistance, but only in moist air atmospheres. In SO₂‐containing atmospheres the corrosion resistance seems to remain the same, when in HCl‐containing atmospheres Ni and Si additions seem to have a negative effect on the corrosion behaviour. As could by seen from SEM analysis, the scales formed, on the steels with above elements, are more adherent to the metallic core. The cerium was added to the studied materials mainly to improve their mechanical properties. This alloying element seems to increase the corrosion rate of materials, especially in atmospheres containing Cl.     

Effect of Mo and Mn additions on the corrosion behaviour of AISI 304 and 316 stainless steels in H2SO4

The work addresses the influence of Mn and Mo additions on corrosion resistance of AISI 304 and 316 stainless steels in 30 wt.% H₂SO₄ at 25 and 50 °C. Corrosion mechanism was determined by gravimetric tests, DC polarization measurements and electrochemical impedance spectroscopy (EIS). The morphology and nature of the reaction products formed on the material surface were analysed by scanning electron microscopy (SEM), energy-dispersive spectroscopy (EDX) and X-ray photoelectron spectroscopy (XPS). Reduction of temperature from 50 to 25 °C drastically decreased the corrosion rate of AISI 304 and 316 stainless steels in sulphuric acid solution. Mn additions did not affect significantly the general corrosion resistance due to its low ability to form insoluble compounds in acid medium. Meanwhile, the formation of molybdenum insoluble oxides enhanced the corrosion performance.     

Influence of inclusion and grain boundary on corrosion behaviour of low alloy steel in cargo oil tank bottom plate environment

Corrosion behaviours of low alloy steels with various alloying element contents were studied in simulated corrosion environment (pH?=?0·85, 10% NaCl solution) of cargo oil tank (COT) bottom plate corrosion environment. Corrosion rate was measured, and the surface morphology of test steels was characterised using scanning electron microscope (SEM). The electrochemical results were investigated using polarisation curves and electrochemical impedance spectroscopy (EIS). The corrosion behaviour of inclusion was investigated using in situ SEM images and energy disperse spectroscopy (EDS) analysis. The effect of misorientation distribution on corrosion resistance of steel was evaluated using electron backscattered diffraction microscopy. The results showed that MnS dissolved into the simulated COT corrosion solution before steel matrix, whereas TiO₂ would not be dissolved. A 10–20 μm area was formed as a circular cathode around inclusion centre. The corrosion was inclined to occur in the place where curvature radius of inclusion is small. An increase in the proportion of low energy grain boundaries was conducive to the improvement of corrosion resistance especially in the early stages of corrosion.     

Electrochemical study of corrosion behaviour of carbon steel A106 and stainless steel 304 in aqueous monoethanolamine

Abstract

Corrosion behaviour of carbon steel A106 and stainless steel 304 (SS304) in aqueous monoethanolamine was studied by performing electrochemical polarisation experiments. Potentiodynamic curves were studied and compared under conditions with different temperatures, carbon loading and O₂ percentage in purging gases. It was found that corrosion of A106 and SS304 was promoted under conditions with higher temperature. While the presence of O₂ speeds the corrosion of A106, it has a negligible impact on SS304 at 80°C and lowers the corrosion rate at 40°C. Corrosion rates and other important parameters were calculated based on the electrochemical curves for A106. Sample surfaces after tests were examined by scanning electron microscopy and energy dispersive spectroscopy. Mechanisms involved in iron dissolution and passivation from oxide films were discussed.     

常减压装置常用钢材在高温原油馏分中的腐蚀研究

利用高压釜模拟常减压装置中的腐蚀环境,采用腐蚀失重法并结合SEM,研究了4种常减压装置常用钢材在高温原油馏分中的腐蚀行为,分析了馏分、材质、温度的影响规律。结果表明,原油馏分的酸值、S含量和盐含量越高,对20钢腐蚀性越强,3种原油馏分对20钢的腐蚀性强弱为：脱盐后原油＞常二线馏分＞常一线馏分。提高钢材中Cr,Ni和Mo等合金元素的含量有助于提高其抗腐蚀能力,4种钢材在高温原油馏分中的抗腐蚀性能优劣为：316钢＞304钢＞1Cr5Mo钢＞20钢。温度对钢材在高温原油馏分中的腐蚀行为会产生多方面的影响,腐蚀速率总体上随着温度的升高而增大,某些温度范围内可能出现腐蚀速率极值。