Susceptibility to Stress Corrosion

Several standardised tests are available for assessing the susceptibility to stress corrosion see Table B.4.1. The test pieces are strained by stretching or bending, depending on the type of test. The applied load is typically equal to 75% of Rpo.2- Testing at a lower load, 50% and 25% of Rpo.2, makes it possible to determine the threshold stress below which no stress corrosion is observed. 

In the laboratory, testing is done in a solution containing 3.5% NaCl with alternating immersion and emersion. The maximum duration, 30-60 days, depends on the alloy and the loading conditions. 

The propagation rate of stress corrosion cracks is very low, between 10 and 

10 m-s . However, propagation, even at this low rate, may lead to catastrophic mechanical failure, due to the weakening of the structures. 

By analogy with failure mechanics, two criteria can be determined for assessing the susceptibility to stress corrosion of aluminium alloys  

---

Zirconium resists attack by nitric acid at concentrations up to 70 wt % and up to 250°C. Above concentrations of 70 wt %, zirconium is susceptible to stress-corrosion cracking in welds and points of high sustained tensile stress (29). Otherwise, zirconium is resistant to nitric acid concentrations of 70—98 wt % up to the boiling point. 

Stress corrosion is cracking that develops in sensitive aHoys under tensile stress which is either internally imposed or is a residual after forming, in environments such as the presence of amines and moist ammonia. The crack path can be either intercrystaHine or transcrystaHine, depending on aHoy and environment. Not aH aHoys are susceptible to stress corrosion (31). 

Table 8. Relative Susceptibility to Stress Corrosion and Dealloying of Commercial Copper Alloys...

Figure 15.19 shows various crack orientations that can occur in connection and attachment welds. Applied stresses from external loading of these components can add to the residual weld stresses, producing still higher stress loads. This can increase the susceptibility to stress-corrosion cracking and can affect orientation and location of crack paths. 

If, after fabrication, heat treatment is not possible, materials and fabrication methods must have optimum corrosion resistance in their as-fabricated form. Materials that are susceptible to stress corrosion cracking should not be employed in environments conducive to failure. Stress relieving alone does not always provide a reliable solution. 

Tensile strength diminishes rapidly with increasing temperature above 200°C. The high-magnesium alloys N5, N6 and N8 should not be used above 65°C because higher temperatures make them susceptible to stress corrosion cracking. 

The presence of stress raisers, including sharp comers and imperfect welds, produces locally high stress levels. These should be avoided where possible or taken into account when designing the materials for use in environments in which they are susceptible to stress corrosion cracking or corrosion fatigue. 

Single-phase a-brasses are susceptible to stress-corrosion cracking in the presence of moist ammonia vapour or certain ammonium compounds Here the predominant metallurgical variable is alloy composition, and in... 

In practice, by far the most common case of stress corrosion is that occurring when austenitic stainless steels are simultaneously exposed to tensile stresses and hot, aqueous, aerated, chloride-containing environments. In this case the major variable is alloy composition and structure virtually all austenitic stainless steels are more or less susceptible to stress-corrosion cracking in these environments, while ferritic and ferritic/austenitic stainless steels are highly resistant or immune. 

The 18% Ni maraging steels do not display passivity and normally undergo uniform surface attack in the common environments. Of more serious consequence, however, for all high strength steels, is the degree of susceptibility to stress corrosion cracking (s.c.c.). 

Alloys containing only a few per cent of zinc may fail if the stresses are high and the environment sufficiently corrosive. Most types of brass, besides the plain copper/zinc alloys, appear to be susceptible to stress corrosion. An extensive investigation of the effect of additions to 70/30 brass was carried out by Wilson, Edmunds, Anderson and Peirce , who found that about 1% Si was markedly beneficial. Other additions were beneficial under some circumstances and none of the 36 additions tested accelerated stress-corrosion cracking. Further results are given in later papers ... 

In general, the susceptibility to stress corrosion appears to increase with increase in zinc content, but in some circumstances alloys containing 64-65% Cu were found to be rather more affected than those containing 60% Cu . 

Thompson and Tracy carried out tests in a moist ammoniacal atmosphere on stressed binary copper alloys containing zinc, phosphorus, arsenic, antimony, silicon, nickel or aluminium. All these elements gave alloys susceptible to stress corrosion. In the case of zinc the breaking time decreased steadily with increase of zinc content, but with most of the other elements there was a minimum in the curve of content of alloying elements against breaking time. In tests carried out at almost 70MN/m these minima occurred with about 0-2% P, 0-2% As, 1% Si, 5% Ni and 1% Al. In most cases cracks were intercrystalline. 

Clearly the variables that may influence or the threshold stress for initially plain specimens, and hence the susceptibility to stress-corrosion cracking, are P and rj, i.e. 

It is not surprising that hardness is important because the mechanical toughness can be expected to decrease with increasing hardness, and the level of residual stress present will also depend on the hardness of the steel, especially for welded components. Thus, the important role of the microstructure in influencing susceptibility to stress-corrosion cracking is consistent with the observation that hardness levels are a good guide to stress-corrosion resistance, but they should not be used universally without due consideration of the specific alloy and the environment in which it is to be used. 

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...

In addition to the alloy compositions being of importance with regard to susceptibility to stress-corrosion cracking, the resistance of the alloy can be altered by microstructural factors. Hanninen has reviewed the available literature quite thoroughly and has concluded that a fine grain size is likely to be beneficial. Strain imposed prior to use tends to be deleterious because deformed material usually acts anodic with respect to unstrained material and because the introduction of plastic deformation may also... 

Many titanium alloys are susceptible to stress-corrosion cracking in aqueous and methanolic chloride environments. 

Al-Mg-Si alloys are strengthened by precipitation hardening in which MgjSi is formed. They are not very susceptible to stress-corrosion cracking which only occurs in specimens subjected to a high solution-treatment temperature followed by a slow quench Ageing such material eliminates susceptibility . 

In common with many of the alloy-environment systems described so far, if the alloy is not susceptible to stress-corrosion cracking under constant stress or stress intensity, then little or no effect of environment on fatigue crack growth is observed. In these cases, frequency, R ratio and potential within the passive or cathodically protected ranges for titanium have no effect on growth rates. 

The heat-affected zone may become susceptible to stress-corrosion cracking, particularly the high-strength alloys, and expert advice is necessary... 

---