Contents Stress Corrosion Cracking

Duplex stainless steels (ca 4% nickel, 23% chrome) have been identified as having potential appHcation to nitric acid service (75). Because they have a lower nickel and higher chromium content than typical austenitic steels, they provide the ductabdity of austenitic SS and the stress—corrosion cracking resistance of ferritic SS. The higher strength and corrosion resistance of duplex steel offer potential cost advantages as a material of constmction for absorption columns (see CORROSION AND CORROSION CONTROL). 

These alloys have extensive applications in sulfuric acid systems. Because of their increased nickefand molybdenum contents they are more tolerant of chloride-ion contamination than standard stainless steels. The nickel content decreases the risk of stress-corrosion cracking molybdenum improves resistance to crevice corrosion and pitting. 

The conjoint action of a tensile stress and a specific corrodent on a material results in stress corrosion cracking (SCC) if the conditions are sufficiently severe. The tensile stress can be the residual stress in a fabricated structure, the hoop stress in a pipe containing fluid at pressures above ambient or in a vessel by virtue of the internal hydraulic pressure created by the weight of its contents. Stresses result from thermal expansion effects, the torsional stresses on a pump or agitator shaft and many more causes. 

Ferritic stainless steels have inferior corrosion resistance compared with austenitic grades of equivalent chromium content, because of the absence of nickel. Stress corrosion cracking can occur in strong alkali. 

Nickel-chromium alloys can be used in place of austenitic stainless steels where additional corrosion resistance is required. These alloys are still austenitic but are highly resistant to chloride-induced stress corrosion cracking when their nickel content exceeds 40 per cent. 

In tests lasting for 14 days, Copson found that the susceptibility of steel to stress-corrosion cracking in hot caustic soda solutions increased with increase in nickel content up to at least 8-5%. Alloys containing 28% and more of nickel did not fail in this period. In boiling 42% magnesium chloride the 9% nickel-iron alloy was the most susceptible of those tested to cracking (Table 3.38). Alloys containing 28 and 42% nickel did not fail within 7 days. 

The high strength alloys contain a Zn + Mg content well in excess of 6% and are used in specialist structures such as aircraft. The risk of stress corrosion cracking in these alloys may be accentuated by incorrect heat treatment or composition and they cannot be recommended for general use (Section 8.5). 

However, whilst the effects of change in alloy composition upon stress-corrosion cracking susceptibility in the present context may be partly due to their effect upon stacking-fault energy, this does not constitute a complete explanation, since alloying may have significant effects upon electrochemical parameters. The effect of the zinc content of brasses upon their filming characteristics has already been mentioned, while in more recent... 

Fig. 8.30 Effect of nickel content on the susceptibility to stress-corrosion cracking of stainless steel wires containing 18-20% chromium in a magnesium chloride solution boiling at 154°C...

Fig. 8.36 Minimum strains for initiating stress-corrosion cracks in annealed and in sensitised 316 during slow strain rate tests in S ppm chloride content water...

Alloys of high nickel content also have improved chloride stress-corrosion cracking resistance and Incolloy 825 has replaced type 321 stainless steel for steam bellows on some plants. Occasionally cracking of the latter was experienced due to chloride-contaminated steam condensing in the convolutions on shut-down and being re-evaporated at start-up. 

Stainless steels Thin-walled stainless steel (Fe-18Cr-8Ni) tubes are now frequently used for domestic installations in place of copper pipe . Care is required, however, in the design of stainless steel equipment for use in waters with a high chloride content, or where the concentration can increase, since pitting attack may occur. It may also be susceptible to failure by stress-corrosion cracking under certain conditions. 

Exchangers failed after two weeks operation due to high chloride content of coohng water, causing stress-corrosion cracking of 304 stainless steel. lOne application failed due to unanticipated composition variations. Relatively low unprotected rate did not provide incentive for further work. 

The addition of chromium forms a family of Ni-Cr-Mo alloys such as Hastelloy alloys C-276, C-22, and C-2000. These alloys contain 16 to 22 percent chromium and 13 to 16 percent molybdenum and are very resistant to a wide variety of chemical environments. They are considered resistant to stress-corrosion cracking and very resistant to localized corrosion in chloride-containing environments. These alloys are resistant to strong oxidizing solutions, such as wet chlorine and hypochlorite solutions. They are among only a few alloys that are completely resistant to seawater. The carbon contents are low enough that weld sensitization is not a problem during fabrication. These alloys are also more difficult to machine than stainless steel, but fabrication is essentially the same. 

Replacing some of the nickel with iron produces a family of alltws with intermediate corrosion resistance between stainless steels and the Ni-Cr-Mo alloys. Alloys such as Incoloy 825 and Hastelloy G-3 and G-30 are in this family. Incoloy 825 has 40 percent Ni, 21 percent Cr, 3 percent Mo, and 2.25 percent Cu. Hastelloy G-3 contains 44 percent Ni, 22 percent Cr, 6.5 percent Mo, and 0.05 percent C maximum. These alloys have extensive applications in sulfuric acid systems. Because of their increased nickel and molybdenum contents they are more tolerant of chloride-ion contamination than are standard stainless steels. The nickel content decreases the risk of stress-corrosion cracking molybdenum improves resistance to crevice corrosion and pitting. Many of the nickel-based alloys are proprietary and are coverecf by the following specifications ... 

Duplex, and super-duplex stainless steels, contain high percentages of chromium. They are called duplex because their structure is a mixture of the austenitic and ferritic phases. They have a better corrosion resistance than the austenitic stainless steels and are less susceptible to stress corrosion cracking. The chromium content of duplex stainless steels is around 20 per cent, and around 25 per cent in the super-duplex grades. The super-duplex steels where developed for use in aggressive off-shore environments. 

The use of hydroxyacetic/formic acid in the chemical cleaning of utility boilers is common. It is used in boilers containing austenitic steels because its low chloride content prevents possible chloride stress corrosion cracking of the austenitic-type alloys. It has also found extensive use in the cleaning operations for once-through supercritical boilers. Hydroxyacetic/formic acid has chelation properties and a high iron pick-up capability thus it is used on high iron content systems. It is not effective on hardness scales. 

Chloride content is limited in order to prevent stress-corrosion cracking. 

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