Corrosion nickel-based alloys

Some of the nickel-based alloys were designed to withstand high temperature and dry or gaseous corrosion whereas others are mainly designed to resist low-temperature (aqueous) corrosion. Nickel-based alloys used for low temperature aqueous or condensed systems are generally known as corrosion-resistant alloys (CRA). Only the corrosion performance of commercially available CRA will be addressed in this chapter. 

It is used in certain nickel-based alloys, such as the "Hastelloys(R)" which are heat-resistant and corrosion-resistant to chemical solutions. Molybdenum oxidizes at elevated temperatures. The metal has found recent application as electrodes for electrically heated glass furnaces and foreheaths. The metal is also used in nuclear energy applications and for missile and aircraft parts. Molybdenum is valuable as a catalyst in the refining of petroleum. It has found applications as a filament material in electronic and electrical applications. Molybdenum is an... 

Many instances of intergranular stress corrosion cracking (IGSCC) of stainless steel and nickel-based alloys have occurred in the reactor water systems of BWRs. IGSCC, first observed in the recirculation piping systems (21) and later in reactor vessel internal components, has been observed primarily in the weld heat-affected zone of Type 304 stainless steel. 

An especially insidious type of corrosion is localized corrosion (1—3,5) which occurs at distinct sites on the surface of a metal while the remainder of the metal is either not attacked or attacked much more slowly. Localized corrosion is usually seen on metals that are passivated, ie, protected from corrosion by oxide films, and occurs as a result of the breakdown of the oxide film. Generally the oxide film breakdown requires the presence of an aggressive anion, the most common of which is chloride. Localized corrosion can cause considerable damage to a metal stmcture without the metal exhibiting any appreciable loss in weight. Localized corrosion occurs on a number of technologically important materials such as stainless steels, nickel-base alloys, aluminum, titanium, and copper (see Aluminumand ALUMINUM ALLOYS Nickel AND nickel alloys Steel and Titaniumand titanium alloys). 

HEAT RESISTANT NICKEL-BASE ALLOYS AND THE PRODUCTS OF THEIR CORROSION COMPOSITION DETERMINATION... 

Flange face areas experience stagnant conditions. Additionally, some gasket materials, such as asbestos fiber, contain leachable chloride ions. This creates crevice and stress corrosion cracking problems on sealing surfaces. Where necessary, flange faces that are at risk can be overlaid with nickel-based alloys. Alternatively, compressed asbestos fiber gaskets shrouded in PTFE may be used. 

Normally the corrosion of lead-tin soldered seams is not significantly increased by their contact with the nickel-base alloys, but under a few immersed conditions the seams may suffer enhanced corrosion. 

Fig. 3.73 Average corrosion rates of amorphous Ni-P alloys measured in 1 n HCl at 30°C. Included are average corrosion rates of crystalline nickel and nickel-base alloys ...

With regard to stress-corrosion cracking in the Ni-Cr-Fe system, including both nickel-base alloys and stainless steels, a vast number of papers has been published. A detailed review of work published before 1969 is available and the authors have since published additional data . 

While the few examples quoted provide some general guidance as to the behaviour of nickel-rich materials in contact with molten metals and salts, it cannot be over-emphasised that such behaviour can be very considerably modified by the presence of very small amounts of contaminants in the liquid media (see Sections 2.9 and 2.10). The effect of very small contents of sodium chloride on the corrosion of nickel-base alloys by sodium sulphate has been referred to previously and other reported examples involving trace amounts, particularly of gaseous impurities, underline the need for great care in interpretation of experimental results. 

Henthorne, M., Intergranular Corrosion of Iron and Nickel Base Alloys, Localised Corrosion-Cause of Metal Failure, ASTM STP 516, ASTM, 66 (1972)... 

Compared with ferritic carbon and low-alloy steels, relatively little information is available in the literature concerning stainless steels or nickel-base alloys. From the preceding section concerning low-alloy steels in high temperature aqueous environments, where environmental effects depend critically on water chemistry and dissolution and repassivation kinetics when protective oxide films are ruptured, it can be anticipated that this factor would be of even more importance for more highly alloyed corrosion-resistant materials. 

Corrosion in these areas is sometimes effectively controlled by cathodic protection with zinc- or aluminium-alloy sacrificial anodes in the form of a ring fixed in good electrical contact with the steel adjacent to the non-ferrous component. This often proves only partially successful, however, and it also presents a possible danger since the corrosion of the anode may allow pieces to become detached which can damage the main circulating-pump impeller. Cladding by corrosion-resistant overlays such as cupronickel or nickel-base alloys may be an effective solution in difficult installational circumstances. 

Nickel-based alloys-Determination of resis-ance to intergranular corrosion Corrosion tests in artificial amospheres at very low concentrations of polluting gas(es) Test /. .-sulphur dioxide test for contacts and connectors... 

The precise chemistry selected depends on the system design and the propensity for corrosion problems such as denting, tube or tube sheet crevice corrosion, and SCC of stainless steel (by chlorides) and nickel-based alloys (by lead). 

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 ... 

Aircraft turbines in jet engines are usually fabricated from nickel-based alloys, and these are subject to combustion products containing compounds of sulphur, such as S02, and oxides of vanadium. Early studies of the corrosion of pure nickel by a 1 1 mixture of S02 and 02 showed that the rate of attack increased substantially between 922 K and 961 K. The nickel-sulphur phase diagram shows that a eutectic is formed at 910 K, and hence a liquid phase could play a significant role in the process. Microscopic observation of corroded samples showed islands of a separate phase in the nickel oxide formed by oxidation, which were concentrated near the nickel/oxide interface. The islands were shown by electron microprobe analysis to contain between 30 and 40 atom per cent of sulphur, hence suggesting the composition Ni3S2 when the composition of the corroding gas was varied between S02 02 equal to 12 1 to 1 9. The rate of corrosion decreased at temperatures above 922 K. 

An important industrial interest is in the corrosion of metals and ceramics by molten sodium sulphate/vanadate solutions. This is because turbines, which are usually nickel-based alloys, operating in a marine atmosphere, containing... 

Nickel barium titanium primrose priderite, formula and DCMA number, 7 347t Nickel-based alloys, properties of, 77 848t Nickel-base superalloys, 77 103 Nickel battery technology, 77 111 Nickel-beryllium alloys, 3 656-659 Nickel-boron deposition, 9 693-695, 708 Nickel brass, corrosion, 7 812 Nickel bromide, 77 110... 

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