Sulphide stress cracking behaviour of weldments produced by indirect electric arc welding

Abstract

The aim of the present study was to evaluate the corrosion resistance of weldments produced by the Indirect Electric Arc technique. The material studied was API grade X-65 steel, which was corroded in NACE solution saturated with H₂S. Three different temperatures were employed, room temperature (25°C), 37°C and 50°C. The test methods used included potentiodynamic polarisation curves, hydrogen permeation measurements and slow strain rate tests. The anodic corrosion current density and sulphide stress cracking susceptibility of the weldments were found to be unaffected by temperature over the range 25–50°C. However, values of the steady-state hydrogen permeation current, hydrogen permeation rate, effective diffusion coefficient, and the concentration of hydrogen atoms at the entrance side all increased with temperature. The cracking of the X-65 weldments is explained in terms of a hydrogen embrittlement mechanism.     

The effect of H2S concentration on the corrosion behavior of carbon steel at 90 °C

The electrochemical behavior of SAE-1020 carbon steel in 0.25 M Na₂SO₄ solution containing different concentrations of H₂S at 90 °C was investigated using the methods of weight loss, electrochemical measurements, scanning electron microscopy (SEM) and X-ray diffraction (XRD). The results showed that the corrosion rate of carbon steel increased significantly with the increase of H₂S concentration. H₂S accelerated the corrosion rate of SAE-1020 carbon steel by a promoted hydrogen evolution reaction. Severe corrosion cavities were observed on the carbon steel surface in the solutions containing H₂S due to cementites stripped off from the grain boundary. The loose corrosion products formed on the steel surfaces were composed of mackinawite.     

Effect of Temperature on the Corrosion Behavior of API X120 Pipeline Steel in H<Subscript>2</Subscript>S Environment

The corrosion behavior of newly developed API X120 C-steel that is commenced to be used for oil pipelines was studied in a H₂S saturated 3.5 wt.% NaCl solution between 20 and 60 °C using potentiodynamic polarization and electrochemical impedance spectroscopy techniques. The corrosion products formed on the surface of the alloy were characterized using x-ray diffraction and scanning electron microscopy. It has been noticed that the formation of corrosion product layer takes place at both lower and higher temperatures which is mainly comprised of iron oxides and sulfides. The electrochemical results confirmed that the corrosion rate decreases with increasing temperature up to 60 °C. This decrease in corrosion rate with increasing temperature can be attributed to the formation of a protective layer of mackinawite layer. However, cracking in the formed mackinawite layer may not be responsible for the increase in the corrosion rate. More specifically, developed pourbaix diagrams at different temperatures showed that the formed protective layer belongs to mackinawite (FeS), a group of classified polymorphous iron sulfide, which is in good agreement with the experimental results. It is also noticed that the thickness of corrosion products layer increases significantly with decrease in the corrosion rate of API X120 steel exposed to H₂S environment. These findings indicate that API X120 C-steel is susceptible to sour corrosion under the above stated experimental conditions.     

P110钢在CO2／H2S环境中的适用性研究

采用高温高压实验设备辅以失重法,研究了CO2／H2S腐蚀环境中P110钢的腐蚀性能,用SEM、EDS和XRD等分析了腐蚀产物．分别用电化学充氢及NACE TM0177A法对P110钢进行耐氢损伤试验．结果表明,虽然P110钢在试验环境中的均匀腐蚀速率很小,未发生点蚀,但随着充氢量的增加,强度、伸长率及断面收缩率均降低．...     

Corrosion behaviour of carbon steel in different concentrations of HCl solutions containing H2S at 90 °C

The corrosion behavior of SAE-1020 carbon steel in H₂S-containing solutions with different concentration of HCl at 90 °C was investigated by weight loss, electrochemical measurements, SEM and XRD analysis. The results showed that the corrosion rate of carbon steel increased with increasing HCl concentration. Uniform corrosion was found on the carbon steel surface in H₂S + HCl solutions, while corrosion cavities were observed in the solution only containing H₂S. The ratio of Faradaic process of total corrosion process increased with the increase of HCl concentration. The corrosion products were solely composed of mackinawite in the H₂S-containing solutions with or without HCl.     

Corrosion Behavior of Low-Alloy Pipeline Steel Exposed to H<Subscript>2</Subscript>S/CO<Subscript>2</Subscript>-Saturated Saline Solution

Immersion experiments were carried out to study H₂S/CO₂ corrosion behavior of low-alloy pipeline steel in terms of microstructure, corrosion kinetics, corrosion phases, microscopic surface morphology, cross-sectional morphology and elemental distribution. The experimental results indicated that the microstructure of designed steel was tempered martensite. The corrosion rate followed exponential behavior. H₂S corrosion dominated the corrosion process, and the corrosion products were mackinawite, greigite and troilite. The corrosion products changed from mackinawite/greigite to mackinawite/troilite, and mackinawite dominated the corrosion phases. The corrosion products became more compact with immersion time, which led to decrease in corrosion rate. The chromium and molybdenum content in the corrosion product was higher than that in the steel substrate.     

2205双相不锈钢在酸性H2S环境下的应力腐蚀行为及开裂机理研究

_{摘要:采用C型环实验研究了2205双相不锈钢在饱和H2S环境下的应力腐蚀行为及开裂机理。研究结果表明,2205双相不锈钢在NACE标准A溶液中有良好的抗应力腐蚀能力。通过OM}、_{SEM、EDS及电化学手段分析得出2205双相不锈钢的应力腐蚀开裂经历了表面点蚀,蚀坑形成,H2S解离,H原子吸附并从蚀坑位置扩散进入金属基体,在金属基体中聚集,通过氢致开裂机制导致裂纹萌生,并逐渐扩展。}     

A method for the inhibition of sulphide stress corrosion cracking in steel-i. electrochemical aspects

Fluorinated Ethylene Propylene-bonded NiCO₂S₄, WS₂ and MOS₂ were evaluated as active H₂ evolution coatings for reducing the amount of H₂ evolution on the surface of EN 42 steel in NACE solution, 1 atmosphere H₂S. Steady state polarization, hydrogen diffusion and weight loss experiments showed that FEP/MoS₂ coatings give the best overall results and that the use of active hydrogen evolution coatings do not increase the long term corrosion rates of steel but can significantly reduce the amount of hydrogen diffusion into steel.     

Corrosion behaviour of X52 pipeline steel in high H2S concentration solutions at temperatures ranging from 25°C to 140°C

Abstract

High temperature and high pressure immersion tests in an autoclave were employed to study the corrosion behaviour of X52 pipeline steel in aqueous solutions containing high concentrations of H₂S. The corrosion products generated were characterised using scanning electron microscope, energy dispersive spectroscopy and X-ray diffraction. It was seen that at a constant H₂S concentration of 22 g/l, the corrosion rate increased with increasing temperature up to 90°C, thereafter decreased at 120°C and slightly increased again at 140°C while the corrosion rate increased with H₂S concentration at a temperature of 90°C. When the temperature and H₂S concentration increased, the corrosion product converted from iron rich to sulphur rich products in the following sequence: mackinawite→troilite→pyrrhotite, where the microstructure and stability of the corrosion products had an important effect on the corrosion rate. The corrosion film was formed through the combination of the outward diffusion of Fe²⁺ ions and the inward diffusion of H₂S and HS^? species.     

Inhibition of mild steel corrosion in CO2 and H2S-saturated acidic media by a new polyurea-based material

Oil well acidizing is a common practice used to boost oil well productivity in the industry. This practice, however, exposes the mild steel components of the wells to extremely harsh corrosive environments. Under such conditions, highly efficient inhibitors are used to minimize corrosion attack. In the present study, corrosion inhibition of mild steel in simulated acidic medium saturated with CO₂ and H₂S gases by a newly synthesized polyurea-based material (PUCorr-1) was investigated. Electrochemical studies supported with quantum chemical density-functional theory calculations and surface characterization revealed that PUCorr-1 adsorbs onto mild steel through a chemisorption mechanism yielding a stable protective film. The polyurea exhibited an excellent efficiency of 99.9% at a temperature of 50°C and a low concentration of 100 ppm, yielding a corrosion current density of 0.3 µA/cm². In the presence of CO₂ and H₂S gases, PuCorr-1 exhibited a remarkable performance (>93% efficiency) making it a potential corrosion inhibitor in industrial processes that involve the use of acid solutions in the presence of CO₂ and H₂S gases.     

304不锈钢在H2S介质条件下的应力腐蚀

用电化学测试及慢应变速率拉伸试验（SSRT）方法对304不锈钢在饱和H2S溶液和NACE标准溶液中的应力腐蚀行为进行研究.结果表明,Cl-能显著降低304不锈钢在饱和H2S溶液中的腐蚀电位和点蚀电位,增加点蚀倾向,并降低抗H2S应力腐蚀能力.     

Hydrogen entry into pipeline steel under freely corroding conditions in two corroding media

Hydrogen permeation through API 5L X65 pipeline steel was studied under freely corroding conditions in NACE solution (simulated seawater) and poisoned 1 N H₂SO₄. A steady state condition with regards to permeation flux is not obtained due to the presence of corrosion product, changing sample dimension and a possible change in hydrogen availability on the corroding surface. A unique way of calculating the sub-surface hydrogen concentration (C₀) under non-steady state freely corroding conditions has been developed. The C₀ has been evaluated as a function of exposure time in NACE solution and poisoned H₂SO₄ solution. The sub-surface hydrogen concentration (C₀) increased initially but then decreased with increasing exposure to the corroding solutions, after demonstrating an early maximum. The changes in C₀ have been explained taking into consideration the corrosion products that developed, the possible anodic reactions, the changes in sample thickness and other issues in the dynamic system.     

几种常用管线钢在CO2及H2S/CO2环境中的腐蚀行为

对带状组织级别不同的管线钢在CO2及H2S/CO2饱和的NACE溶液中的腐蚀速率和腐蚀形貌进行了比较分析。结果表明,在CO2饱和的NACE溶液中,带状组织级别越低的材料,发生均匀腐蚀的特征越明显,通过生成保护性膜抵抗腐蚀的能力越强。而带状组织级别越高的材料,发生局部腐蚀,尤其是点蚀的特征越明显。在H2S/CO2饱和的NACE溶液中,带状组织级别越低的材料,越不易发生氢致开裂现象。为了提高管线钢抗CO2及H2S/CO2腐蚀的性能,应控制其带状组织。     

The erosion-corrosion of carbon steel in aqueous H2S solutions up to 120°C and 1.6 MPa pressure

The erosion-corrosion of carbon steel in aqueous H₂S solutions at 120°C and 1.6 MPa has been studied by the rotating disc technique. Loss of iron from the carbon steel disc increases with the speed of rotation. However, the amount of iron sulphide adhering to the carbon steel (the scale) remains the same at different speeds of rotation, as a fresh layer of iron sulphide (mackinawite) replaces the dissolved one almost instantaneously. A preconditioned carbon steel disc with a pyrite surface, however, suffers no measurable metal loss or erosion-corrosion.Fluid velocity affects the nature of the film of iron sulphide formed on carbon steel surfaces exposed to H₂S solutions. Mackinawite is the predominant phase of the surface film formed at high fluid velocities but it transforms into pyrrhotite and pyrite at low velocities or in stagnant solution. Transformation of mackinawite to pyrrhotite and pyrite is accelerated in films under aqueous H₂S bubbles.     

The erosion-corrosion of carbon steel in aqueous H2S solutions up to 120°C and 1.6 MPa pressure

The erosion-corrosion of carbon steel in aqueous H₂S solutions at 120°C and 1.6 MPa has been studied by the rotating disc technique. Loss of iron from the carbon steel disc increases with the speed of rotation. However, the amount of iron sulphide adhering to the carbon steel (the scale) remains the same at different speeds of rotation, as a fresh layer of iron sulphide (mackinawite) replaces the dissolved one almost instantaneously. A preconditioned carbon steel disc with a pyrite surface, however, suffers no measurable metal loss or erosion-corrosion.Fluid velocity affects the nature of the film of iron sulphide formed on carbon steel surfaces exposed to H₂S solutions. Mackinawite is the predominant phase of the surface film formed at high fluid velocities but it transforms into pyrrhotite and pyrite at low velocities or in stagnant solution. Transformation of mackinawite to pyrrhotite and pyrite is accelerated in films under aqueous H₂S bubbles.     

Electrochemical and Sulfide Stress Corrosion Cracking Behaviors of Tubing Steels in a H2S/CO2 Annular Environment

The electrochemical and sulfide stress corrosion cracking (SSCC) behaviors of 13Cr stainless steel and P110 steel were investigated in a simulated acidic annular environment with low-temperature and high-pressure H₂S/CO₂ using electrochemical methods, U-bend immersion tests, and scanning electron microscopy. In the solution containing high pressure CO₂, 13Cr, and P110 steels exhibited general corrosion and severe pitting, respectively. Compared with sweet corrosion, additional H₂S in the solution enhanced the corrosion of 13Cr steel but inhibited the corrosion of P110 steel. By contrast, in a solution containing 4 MPa CO₂ and different $ {P}_{{{\text{H}}_{ 2} {\text{S}}}}$ (0-0.3 MPa), the susceptibility of both 13Cr stainless steel and P110 steel toward SSCC was significantly promoted by increases in H₂S partial pressure. The 13Cr stainless steel exhibited higher susceptibility toward SSCC than P110 steel under a H₂S/CO₂ environment but lower susceptibility under a pure CO₂ environment.     

Emulgin as an Inhibitor of Corrosion and Hydrogenation of Carbon Steel in Weakly Acidic H2S-Containing Solutions

The protection effect of emulgin (a technological mixture of some primary and secondary aliphatic amines) in concentrations of 0.078 to 0.625 mmol/l from acid, carbon dioxide, and hydrogen sulfide corrosion and hydrogenation of carbon steel St3 was studied. In a 0.005–0.05 M solution of HCl saturated with hydrogen sulfide, the protective value was 97%, no local damage being observed. At higher concentrations of HCl and H₂S, the anodic reaction is inhibited more effectively. The simultaneous presence of H₂S and CO₂ produces virtually the same (or only slightly reduced) effect. Under optimum conditions, steel hydrogenation is suppressed almost completely, especially at high concentrations of HCl and H₂S and at elevated temperatures.     

Strength characteristics of copper/aluminium alloy friction welded joints

The susceptibility to hydrogen-induced cracking in hydrogen sulphide (H₂S) environment of welded API X80 steel was studied. The flux-cored arc welding process was employed with E71-T1 and E71-T8K6 wires. The welding parameters were kept constant, but the samples were welded using different preheat temperatures (room temperature and 100°C). The gapped bead-on-plate (G-BOP) test was used. The specimens of modified G-BOP tests were exposed to an environment saturated with H₂S, as recommended by the NACE TM0284 standard. The weld beads were characterized by optical microscopy and the level of residual hydrogen in the samples was measured. The fracture surface areas of hydrogen-induced cracking were calculated and the fracture mode was discussed. It was found that the preheating temperature of 100°C was enough to avoid cracking, even in the presence of H₂S. It was also found that the E71-T8K6 wire was more susceptible to cracking, and the typical mixed-mode fracture was predominant in all samples.     

Study on the impact toughness and diffusible hydrogen of G105 drill pipe steel in wet H2S environment

In order to investigate the influence of wet H₂S environment on impact toughness of G105 drill pipe steel, the impact test of drill pipe exposed to NACE A solution for different time was carried out. Meanwhile, the diffusible hydrogen concentration was measured to study the relationship between diffusible hydrogen and impact toughness damage. The results suggest that with the increase of corrosion time, the impact energy of G105 drill pipes decreases from 107.7 to 88.4?J, and the dynamic fracture toughness decreases gradually. The impact toughness damage increases as the diffusion hydrogen concentration increases. However, the impact energy recovery happened after hydrogen releasing. The quasi-cleavage features occur with the increasing of hydrogen concentration.     

Autoklaven-Untersuchungen der Spannungsrißkorrosion von Fe-Cr-Ni-Legierungen in NaCl/Co2/H2S-Medien

Autoclave investigation of stress corrosion cracking behaviour of Fe-Cr-Ni alloys in NaCl/CO₂/H₂S-environment In oil and gas production, the corrosion problems increase as the depth of the reservoirs increases. The oil and gas products contain chloride-rich waters and mixtures of H₂S and CO₂ at high pressures and temperatures. Materials that can be used under these conditions are only high strength high alloy steels and nickel base alloys. These materials must be assessed for corrosion resistance under these conditions. The environment contain chloride ions and hydrogen sulphide, which are known to be critical components for SCC. With the aid of autoclave experiments, the fields of corrosion resistance for the materials no. 1.4462, 1.4563 and 2.4618 were determined as a function of temperature and hydrogen sulphide pressure. The base environment was a 5 Molar sodium chloride solution at 20 bar carbon dioxide. While the corrosion resistance of the duplex steel, material no. 1.4462, decreases markedly as the strength of the material and the hydrogen sulphide pressure increase, the two austenitic materials are completely resistant up to 300 °C and hydrogen sulphide pressure of 15 bar. Only at 300 °C and high partial pressures of hydrogen sulphide the material no. 1.4563 did fail, when stressed to stress levels higher than the YS. The crack path was predominantly transgranular with minute fractions of intergranular cracking. The microstructure appears to have no effect. All results indicate that a mixed mechanism of hydrogen- and chloride induced SCC is operting, while a corrosion enhancement due to interaction of both critical components takes place.