Ferritic stainless steels pitting corrosion

Rarey, C. R. and Aronson, A. H., Pitting Corrosion of Sensitised Ferritic Stainless Steel , Corrosion, 28, 255 (1972)... 

Steel phases have an influence on the rate of corrosion. Ferrite has a weak resistance to pitting. The presence of martensite can increase the hydrogen fragilization of steel. Intermetallic phases as Fe2Mo in high Ni content alloys can influence the corrosion resistance. The precipitate CuA12 in aluminum alloys the series 2000 is more noble than the matrix, with corrosion around the precipitate. The majority of case histories reported in the literature have involved austenitic stainless steels, aluminum alloys, and to a lesser degree, some ferritic stainless steels and nickel-based alloys.31... 

McDonald et al. studied the performance of solid stainless steel rebars (types 304 and 316) and found that they performed well while ferritic stainless steels (types 405 and 430) developed pitting (15). Studies by McDonald et al. reported investigations on a 10-year exposure of 304 stainless steel in Michigan and Type 304 stainless steel clad rebar in a bridge deck in New Jersey and found no corrosion (15). In a study by Virmani and Clemena, the type 316 stainless steel-clad rebar extended the estimated time to the cracking of the concrete beyond 50 years, but not as much as solid types 304 and 316 stainless steels (100 years) (16). 

Mechanical preparation techniques such as grinding can introduce significant cold work into the surface layers e.g. the pitting resistance of ground austenitic [3] and ferritic stainless steel surfaces [4] has been shown to be inferior to that of electropolished surfaces. This was attributed to the presence of cold worked surface layers from grinding, although chemical or electrochemical surface treatments can preferentially remove less resistant phases, e.g.inclusions, which would otherwise be responsible for an inferior corrosion performance. ... 

Molybdenum in combination with chromium increases the corrosion-resistant properties of ferritic stainless steel in chloride electrolytes and is effective in increasing the resistance to pitting and crevice corrosion. Cr-Ni-Mo-Cu alloys increase the passivity in sulfuric acid concentrations with concentrations between 20% and 70%. Nickel... 

Stainless steels are resistant to corrosion by most salts. The exceptions are the halide salts that cause pitting, crevice corrosion, and SCC. Of these salts, those containing chlorides are the most corrosive, followed by fluoride, bromide, and iodide salts. Stainless steels with higher chromium, molybdenum, and nitrogen concentrations will resist pitting and crevice corrosion more effectively. Austenitic stainless steels with higher molybdenum and nickel, ferritic stainless steels with no nickel or copper, and duplex stainless steels will resist SCC. 

In addition to its impact on mechanical properties nitrogen also improves resistance to pitting and crevice corrosion. This is expressed by the pitting resistance equivalent index (Kearns, 1987 Grafen, 1996 DIN 81 249,1997). Foraustenitic stainless steels with Mo <3% and austenitic-ferritic stainless steel X3CrNiMoN27-5-2 ... 

Field studies (exposure tests) in marine or simulated marine environments demonstrated the much better corrosion resistance of stainless steels in concrete. After 4.5 years in natural marine conditions no cracking and no pitting corrosion occurred on an Fe-11% Cr alloy (Hewitt and Tull-min, 1994). Under accelerated chloride ingress the same alloy showed some pitting corrosion after one year, whereas specimens with plain carbon steel had already cracked. A 9.5 years exposure program on steels embedded in concrete containing up to 3.2% chloride additions with respect to the cement content showed that ferritic stainless steel with 13 % Cr showed corrosion at chloride levels over 1.9% (Treadaway etal., 1989). 

The chloride pitting resistance of this alloy is similar to that of type 316 stainless steel and superior to that of types 430 and 439L. Like all ferritic stainless steels, t)/pe 444 relies on a passive film to resist corrosion, but exhibits rather high corrosion rates when activated. This characteristic explains the abrupt transition in corrosion rates that occur at particular acid concentrations. For example, it is resistant to very dilute solutions of sulfuric acid at boiling temperature, but corrodes rapidly at higher concentrations. 

Duplex stainless steel alloys are a mixture of ferritic (400 series) and austenitic (300 series) metals. They provide 1) resistance to stress corrosion and fatigue, 2) pitting resistance, 3) are suitable for a wide temperature range (-50°C to 280°C) and 4) are cost effective. In urea plants, duplex stainless steel is used to construct strippers, decomposers, condensers and pipe lines88. 

Duplex stainless steels have a mixed microstructure of ferrite and austenite with chromium content in the range between 19% and 32%, molybdenum up to 5%, and lower nickel contents than austenitic stainless steels. They exhibit better corrosion resistance to pitting, stress corrosion cracking, and crevice corrosion than austenitic stainless steels, and are approximately twice as strong. 

Chromium (Cr). Chromium increases the overall corrosion resistance of steel. Stainless steels contain in excess of 12% by weight of chromium. The corrosion resistance increases with increase in chromium content. The presence of chromium leads to the formation of a regenerative passive protective layer of chromium oxide that prevents further corrosion of steel. Chromium also contributes to increasing the hardenability of steel. It is a ferrite stabilizer, which means it promotes the formation of ferrite. Ferrite is resistant to the propagation of cracks. Presence of chromium increases the resistance of steel to pitting attacks. 

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