Evaluation of the Corrosion Resistance of 904L Composite Plate in a High-Temperature and High-Pressure Gas Field Environment
by
Shuai Wang
1,2,*, 
Ping Mei
1,
Lijing Chang
3,
Chao Wu
4,
Shaoyun Chen
4,
Qingguo Chen
4 and
Guangshan Li
2 1
College of Chemistry & Environmental Engineering, Yangtze University, Jingzhou 434023, China
2
Tubular Goods Research Institute, China National Petroleum Corporation, Xi’an 710065, China
3
Changqing Oilfield Company, PetroChina, Xi’an 710000, China
4
Tarim Oilfield Company, PetroChina, Korla 841000, China
*
Author to whom correspondence should be addressed.
Processes 2024, 12(11), 2372; https://doi.org/10.3390/pr12112372
Submission received: 20 August 2024
/
Revised: 11 September 2024
/
Accepted: 19 September 2024
/
Published: 29 October 2024
(This article belongs to the Section Materials Processes)
Abstract
:In order to study the corrosion resistance of 904L composite plate pressure vessels under a high-temperature and high-pressure gas field environment, the pitting corrosion and stress corrosion cracking resistance of a 904L composite plate body and weld material were compared with those of a 2205 composite plate and 825 composite plate, which are used in high-temperature and high-pressure gas field environments. The results showed that the pitting resistance of the 904L composite plate was lower than that of the 825 composite plate and higher than that of a 2205 solid-solution pure material plate and a 2205 composite plate. The corrosion resistance of the 625 welding material is higher than that of the E385 welding material. In the simulation of the corrosion environment of a high-temperature and high-pressure gas field, the corrosion rates of the 904L composite plate body, welding seam, and surfacing welding were all less than 0.025 mm/a, indicating slight corrosion, and the sensitivity coefficient of chloride stress corrosion cracking was less than 25%, indicating low sensitivity. The 904L composite plate met the requirements of corrosion resistance for pressure vessel materials in a high-temperature and high-pressure gas field environment.
1. Introduction
High-temperature and high-pressure gas fields face high temperature, high pressure, high salinity, high chlorine levels, and other harsh conditions [1,2]. In order to cope with this complex corrosion environment while taking into account economic concerns, current global high-temperature and high-pressure gas field pressure vessel materials mainly use carbon steel + corrosion-resistant-alloy composite plates. The commonly used on-site applications include carbon steel + 316L composite plate, carbon steel + 2205 composite plate, and carbon steel + 825 composite plate [3,4].
Through opening the high-temperature and high-pressure gas field pressure vessels used over the years, it was found that there are serious pitting problems in the coating of 316L composite plate pressure vessels, indicating that the 316L composite plate has a high corrosion risk under high-temperature and high-pressure gas field operating conditions. The process of using a 2205 pure material pipeline in a high-temperature and high-pressure gas field did not lead to obvious corrosion, but due to the carbon steel base and 2205 stainless steel lining, the heat treatment process was significantly different, resulting in a stainless steel lining that is prone to produce harmful precipitates. Some 2205 composite plate pressure vessels are affected by zone-pitting problems due to welding and heat. In the case of an 825 composite plate pressure vessel in operation, after the opening of the vessel, the inspection found that no pitting had occurred on its internal surface; therefore, the 825 composite plate can meet the material corrosion resistance requirements placed on pressure vessels by high-temperature and high-pressure gas field environments. However, the production and manufacturing costs of the 825 composite plate are high. Therefore, it is necessary to carry out the testing and evaluation of new materials in terms of both corrosion resistance and cost.
The 904L alloy is a highly alloyed, super austenitic stainless steel with a very low carbon content. It has been standardized in many countries and has been approved for use in the manufacture of pressure vessels. The 904L alloy, like other commonly used Cr-Ni austenitic steels, has a good resistance to point corrosion, intergranular corrosion, and crevice corrosion, high resistance to stress corrosion cracking, and good workability and weldability. At present, the production technology of 904L composite plates is mature, and they have been used for petroleum and petrochemical storage, sulfuric acid storage, and transportation equipment [5,6,7,8,9,10]. In terms of price, taking the thickness of a 16 mm + 4 mm plate as an example, compared with a 825 + Q345R (a low-alloy plate material similar to SA516Gr70) composite plate, the price of the 904L + Q345R composite plate is about 40% lower. As for the corrosion resistance of 904L stainless steel, some relevant studies have been carried out.
Wang et al. [11] studied the grain boundary sensitization behavior of 904L high-nickel austenitic stainless steel using an electron probe. After sensitizing at 650 °C for different time periods, 904L was corroded at 1 mol/L HCl for 7 days. The results showed that there was an obvious 3 μm-wide corrosion sensitive zone around the grain boundary. The results of EPMA analysis showed that there was no obvious segregation near the grain boundaries, and the analysis of transmission electron microscopy showed that there were σ phases precipitated along the grain boundaries, which led to the discontinuity of 904L’s grain boundary passivation film and grain boundary sensitization.
Al et al. [12] investigated the corrosion behavior of 904L stainless steel in lithium bromide solution. The results showed that the uniform corrosion rate and pitting susceptibility of 904L increased with increasing lithium bromide concentration and temperature, and the rate of uniform corrosion and pitting was decreased by increasing the pH value of the solution.
Wang et al. [13] investigated the corrosion behavior of 904L + 14Cr1MoR (H) and 904L + Q345R stainless steel composite plates used in a CNOOC Huizhou Phase II coal gasification and hydrogen production combined unit after explosive composite and heat treatment. The results showed that the heat treatment system had a great impact on the corrosion performance of 904L. The corrosion resistance of 904L decreased. According to the ASTMG150 [14] method, a point corrosion experiment was carried out to the test critical point corrosion (CPT) of 904L + 14Cr1MoR (H) and 904L + Q345R, two kinds of composite plates with a critical point corrosion temperature CPT ≥ 40 °C. According to the GB/T4334 E method, no intergranular corrosion cracks were detected.
Aiming at the problem that 904L + 14Cr1MoR (H) composite plates need to undergo stress relief heat treatment after explosive welding, Zhang Baoqi et al. conducted a series of heat treatment tests after explosive composite, and they obtained the best heat treatment process through testing tensile, bending, impact, shear, and other mechanical properties and laminar corrosion resistance tests. The results showed that after 620~690 °C heat treatment, 904L had grain boundary coarsening and a carbide precipitation phenomenon in the grain boundary. The degree was different, but the intergranular corrosion test obtained positive results. According to the influence of various heat treatment systems on the mechanical properties and corrosion resistance of the material and the thickness of the composite plate equipment body, the final heat treatment process was selected as follows: (690 ± 14) °C, 180 min holding time (selected according to the actual thickness). The comprehensive performance of 904L was the best, and its mechanical properties and corrosion resistance could fully meet the design requirements [15].
At present, there are no application cases of 904L composite plate in pressure vessels of oil and gas field processing stations. Therefore, it is necessary to carry out corrosion resistance evaluation of the 904L composite plate in simulated high-temperature and high-pressure gas field environments and compare it with the 2205 composite plate and 825 composite plate with mature application experience, providing reference for the selection of materials for high-temperature and high-pressure gas field pressure vessels.
2. Experiment
2.1. Experimental Materials
Considering the effect of explosive welding of 904L composite plate and the heat treatment process on the corrosion resistance of stainless steel in the manufacturing process of composite plate vessels, this experiment used plates with the same heat treatment state as the composite plate pressure vessels as the test material, and the welding manufacturing processes of different parts of the composite plate pressure vessels were taken into account. Five kinds of materials, including the 904L pure material, Q345R + 904L composite plate body, Q345R + 904L composite plate weld (E385 welding material), Q345R + 904L composite plate weld (625 welding material), and Q345R + E385 surfacing, were used for evaluation, and their corrosion resistance was compared with the Q345R + 2205 composite plate, 2205 pure material, and Q345R + 825 composite plate.
A total of eight materials were selected for this experiment: one was the 904L pure material (solid-solution state), the second was the Q345R + 904L composite plate body (the same heat treatment state as the composite plate pressure vessels, simulating the base material of the shells of the pressure vessels), the third was the Q345R + 904L composite plate weld (E385 welding material, the same heat treatment state as the composite plate pressure vessels, simulating the butt welds of the pressure vessels), The fourth was the Q345R + 904L composite plate weld seam (625 welding material, the same heat treatment state as the composite plate pressure vessels, simulating the butt welds of the pressure vessels), the fifth was the Q345R + E385 surfacing (the same heat treatment state with the composite plate pressure vessels, simulating the surfacing welding parts such as the heads of the pressure vessels), the sixth was the Q345R + 2205 composite plate body (the same heat treatment state as the composite plate pressure vessels), the seventh was the 2205 duplex stainless steel pure material (solid-solution state), the eighth was the Q345R + 825 composite plate (the same heat treatment state as the composite plate pressure vessels), respectively marked as samples (a)~(h). The chemical composition, metallographic structure, and mechanical properties of the eight materials have been tested and qualified. The heat treatment parameters of the composite plates and welds are shown in Table 1.
2.2. Experimental Methods
2.2.1. Electrochemical Test
Electrochemical samples were taken from the eight materials and subjected to potentiodynamic polarization curves testing using a C235 electrochemical workstation. A three-electrode system was adopted in the test device, namely the working electrode (sample), the reference electrode Ag/AgCl and the auxiliary electrode Pt (platinum sheet). The platinum sheet area was 1 cm2. The test solution was simulated gas field water, with a chloride ion concentration of 160 g/L, deoxygenation, and a test temperature of 80 ℃. In order to eliminate the interference of dissolved O2 on the test results, high purity N2 (99.99%) was injected into the solution for half an hour before the test, and then CO2 was injected into the solution for 30 minutes to start the test. In order to ensure that the CO2 in the solution remained saturated, the test was started and CO2 was maintained throughout the test process.
2.2.2. Iron Trichloride Pitting Test
According to the ASTM G48-11 (2020) standard [16], method A (6% ferric chloride solution) was selected to conduct corrosion tests on the samples at a temperature of 50 °C, and the test time for each sample was 72 h. The samples were measured and weighed before and after the test, and the corrosion rates were calculated.
2.2.3. Weight Loss Test of High-Temperature Autoclave
According to the ASTM G111-21a standard [17], corrosion simulation tests were conducted on samples using a high-temperature autoclave. The test temperature was 80 °C, the chloride ion concentration was 160,000 mg/L, the CO2 partial pressure was 1.2 MPa, and the total pressure was 10 MPa. There were three samples in each group, and the test period of each group was 336 h.
After the corrosion test, the kettle was removed after cooling and pressure release, and the hanging plates were taken out. The corrosion morphology and product composition on the surface of the hanging plates were analyzed by a scanning electron microscope and energy spectrum analysis system. The corrosion products on the surface of the hanging plates were removed by a solution composed of 0.1 L hydrochloric acid (analytical pure), 7 g hexamethylenetetramine (analytical pure), and 1 L deionized water. The uniform corrosion rate was calculated by Equation (1).
where Δm—weightlessness of the hanging piece, g; ρ—specific gravity of the material, g/cm3; t—test time, h; S—surface area, mm2; V—average corrosion rate, mm/a.
V = Δm × 8.76 × 106/(ρtS)
According to NACE RP 0775, the corrosion rates were classified as shown in Table 2.
2.2.4. Chloride Stress Corrosion Cracking Test
According to the GB/T 15970.1-2018 standard [18], a CORTEST tensile rate tester equipped with high-temperature autoclave was used to perform a slow strain rate tensile test on the samples. The samples were processed into plate-shaped samples as shown in Figure 1. Before the test, the sample were polished step by step with 240#, 400#, 600#, 800#, and 1000# sandpaper in turn. The surfaces of the test pieces were cleaned with acetone, the oil was removed, samples were dried with cold air and weighed, and the actual size of the test pieces was measured with a vernier caliper. The samples were connected to the fixture with pins of the same material, and insulating sleeves were installed between the pins and the fixtures to prevent the galvanic corrosion of the samples. The test solution was simulated gas field water, the chloride ion concentration was 160 g/L, the test temperature was 80 °C, the CO2 partial pressure was 1.2 MPa, and the total pressure was 10 MPa. Before the test, the solution was deoxygenated for no less than 20 h, and then the test gas was injected into the solution for at least 1 h to saturate the solution, and then heated up to the required temperature of the test. When the temperature was stable, the test gas was increased to the required partial pressure of the test, and then pressurized with nitrogen to a total pressure of 10 MPa. The test was continued until the samples broke.
The stress corrosion cracking sensitivity of a material in a certain environment is generally assessed by the stress corrosion sensitivity index ISCC, as shown in Equation (2):
where ISCC—stress corrosion sensitivity index; Ii—test parameters in inert medium; Ic—test parameters in corrosive media.
ISCC = (Ii − Ic)/Ii × 100%
To evaluate the sensitivity index of stress corrosion cracking ISCC, we commonly use indicators such as tensile strength and elongation after fracture, and the general evaluation method to measure the sensitivity of stress corrosion cracking is shown in Table 3.
3. Results
3.1. Pitting Resistance
Figure 2 shows the potentiodynamic polarization curve of the eight kinds of materials. As can be seen from Figure 2, the pitting potential of the 625 weld sample is the highest, followed by the 825 composite plate sample. It can be seen that the pitting resistance of the 625 and the 825 materials is stronger than other materials. Compared with the 904L pure material sample, the pitting resistance of the 904L composite plate sample shows little difference; compared with the 2205 pure material sample, the pitting potential of the 904L composite plate sample is higher and the passive current density is smaller, indicating that the pitting resistance of the 904L composite plate material is stronger than that of the 2205 pure material. The pitting potential of the E385 weld sample and the E385 surfacing sample is slightly lower than that of the 2205 pure material, but the passive current density is less than that of the 2205 pure material. Based on comprehensive analysis, the pitting resistance of 904L composite plate weld (E385) and surfacing (E385) is similar to that of the 2205 pure material, and the results are shown in Table 4.
The results of the iron trichloride pitting test showed that the 825 composite plate had the lowest weight loss and the lowest corrosion rate per unit area, followed by the 625 weld. The corrosion rate of the 904L pure material and the 904L composite plate is lower than that of the 2205 pure material and the 2205 composite plate, but the corrosion rate of E385 weld and E385 surfacing welding is higher than that of the 2205 pure material and the 2205 composite plate. The average corrosion rate from large to small is in the order of E385 surfacing > E385 weld > 2205 composite plate > 2205 pure material > 904L composite plate > 904L pure material > 625 weld > 825 composite plate, as shown in Table 5. The macroscopic morphology comparison of the eight materials before and after the test is shown in Figure 3.
3.2. Corrosion Resistance Under Simulated Working Conditions
As can be seen from the corrosion rate calculation results, the uniform corrosion rates of the eight materials in the simulated high-temperature and high-pressure gas field environment are all less than 0.025 mm/a, indicating slight corrosion, as shown in Table 6. This indicates that the eight materials all have a strong resistance to uniform corrosion under the environment of a high-temperature and high-pressure gas field. Taking the 904L composite plate body as an example, there was only slight scaling on the surfaces of the hanging pieces, and the corrosion products on the surfaces of the corrosion coupons were very few after the corrosion simulation test, as shown in Figure 4a. The surfaces of the corrosion coupons were bright after cleaning and removing the corrosion products, and no obvious pitting corrosion was seen by the naked eye, as shown in Figure 4b. After magnifying 100 times by an ultra-deep field microscope, it was found that the surface morphology of the hanging plate mainly showed scratches polished during the sample processing, with no obvious corrosion marks and no obvious pitting corrosion, as shown in Figure 4 and Figure 5.
3.3. Resistance to Chloride Stress Corrosion Cracking
Table 7 shows the results of slow strain rate tensile tests of the eight materials. It can be seen from Table 7 that the stress corrosion cracking sensitivity coefficients of the eight materials are all lower than 25%, indicating that their stress corrosion cracking sensitivity is low under simulated working conditions. According to the test results, the stress corrosion sensitivity coefficients of the 825 composite plate and the 625 weld material are the lowest, and the stress corrosion sensitivities of the 904L composite plate, weld, and surfacing material are comparable to that of the 2205 plate.
4. Discussion
The 904L alloy is a super austenitic stainless steel with good corrosion resistance which is mainly used in harsh corrosion conditions. Currently, the production technology is mature, and many steel mills at home and abroad have the production capacity. According to the performance information provided by a composite plate pressure vessel manufacturer, 904L composite plate pressure vessels have been applied in pressure vessels such as the acetic anhydride hydration reactors of some petrochemical enterprises, and the application situation is good. However, there are no reports on the application of 904L composite plate pressure vessels in upstream oil and gas field treatment stations. Through the following, combined with the results of the corrosion resistance evaluation test from the three aspects of pitting resistance, uniform corrosion resistance, and stress corrosion cracking resistance, the applicability of the 904L composite plate pressure vessels under the working conditions of high-temperature and high-pressure gas fields is analyzed.
(1) Pitting resistance.
When stainless steel is in a chlorine-containing environment, pitting corrosion will occur at a certain temperature [19,20,21,22,23,24,25]. As we all know, the improvement of chromium and molybdenum content helps to enhance the ability of stainless steel to resist localized corrosion. The comprehensive effect of chromium, molybdenum, and nitrogen on the resistance to localized corrosion is often expressed by the pitting resistance equivalent PREN [26], and the commonly used formula is as follows:
PREN = % chromium + 3.3× % molybdenum + 16× % nitrogen
Table 8 shows the pitting resistance equivalent comparison between 904L and several commonly used stainless steels in oil fields. As can be seen from Table 3, the PREN value of 904L super austenitic stainless steel is significantly higher than that of 316L stainless steel, which is also higher than that of 2205 duplex stainless steel, but lower than 825 high-alloy stainless steel.
According to the electrochemical test results, the pitting corrosion resistance of the 904L pure material and the 904L composite plate material is stronger than that of the 2205 pure material and lower than that of the 825 composite plate and the 625 welding material. The pitting resistance of the 904L composite plate weld and surfacing welding (both E385 welding materials) is lower than that of the 904L pure material and the 904L composite plate and close to that of the 2205 pure material. The chemical composition difference between the E385 welding material and 904L material is not significant, but the corrosion resistance of the E385 weld is lower than that of the 904L pure material and the 904L composite plate, which may be due to the uneven distribution of the weld chemical composition. This is because element segregation and dilution may occur during the welding process, which may form some alloy element depletion zones that are not conducive to corrosion resistance. The composition of the weld seam is usually not as uniform as that of the 904L pure material, resulting in a slightly lower corrosion resistance than the pure material. The austenite structure of 904L is very stable, but during the welding process, the heat-affected zone and weld metal may form some phases that are not conducive to corrosion resistance (such as δ ferrite, carbide precipitation, etc.) due to the cooling rate, element segregation, etc., thereby reducing the corrosion resistance of the weld.
The results of the ferric trichloride pitting test showed that the corrosion rate of the 904L pure material and the 904L composite plate was lower than that of the 2205 pure material and the 2205 composite plate, but the corrosion rate of the E385 weld and the surfacing welding of the 904L composite plate was higher than that of the 2205 pure material and the 2205 composite plate.
The 825 stainless steel is a nickel-based alloy containing 38~46% nickel, 20~23.5% chromium, 2.5~3.5% molybdenum, 0.6~1.2% titanium, and a small amount of copper. These elements, especially the high nickel, high molybdenum, and titanium content, enhance the corrosion resistance of the 825 alloy. The 904L stainless steel is a high alloy austenitic stainless steel containing 25% nickel, 19~23% chromium, 4.5% molybdenum, and 1.5% copper. Although these elements also provide a good corrosion resistance, the 904L alloy has lower nickel and molybdenum contents compared to the 825 alloy. Therefore, the corrosion resistance of the 825 materials is higher than that of the 904L pure materials and the 904L composite plates, but its price is also higher than for 904L materials. Replacing 825 composite plate with 904L composite plate will save significant investment for gas field development.
(2) Uniform corrosion resistance.
According to the weight loss test results of the high-temperature autoclave, the eight materials including the 904L pure material, 904L composite plate, E385 weld, E385 surfacing, 625 weld, 2205 composite plate, 2205 pure material, and 825 composite plate all have a low corrosion rate under simulated high-temperature, high-pressure, and high-chlorine environments. According to the NACE RP0775 standard, the corrosion rates are all classified as slight corrosion levels.
(3) Resistance to chloride stress corrosion cracking.
According to the slow strain rate tensile test results of the eight materials under simulated working conditions, the stress corrosion cracking sensitivity coefficients of the 904L composite plate, weld, and surfacing materials are all lower than 25%, indicating that their stress corrosion cracking sensitivity is low under simulated working conditions. In addition, the stress corrosion cracking sensitivity coefficient of the 904L plate is not much different from that of the 2205 plate. According to the field application of the 2205 material pressure vessels in a high-temperature and high-pressure gas field for nearly 20 years, the maintenance defects of the 2205 composite plate pressure vessels over the years are mainly pitting corrosion at the weld. The occurrence of chloride stress corrosion cracking is extremely rare, and the main reason is that the material of the 2205 composite plate is unqualified, which contains precipitated phases. Therefore, it is determined that the possibility of chloride stress corrosion cracking of the 904L composite plate under the working conditions of high-temperature and high-pressure gas field is low.
5. Conclusions
(1) The results of the electrochemical and ferric chloride pitting tests showed that the pitting resistance of the 904L composite plate was not significantly lower than that of the 904L pure plate. The pitting resistance of the 904L composite plate was lower than that of the 825 composite plate and higher than that of the solid-solution 2205 pure plate and the 2205 composite plate. The pitting resistance of the E385 weld and surfacing welding was lower than that of the solid-solution 2205 pure plate and the 2205 composite plate. The pitting resistance of the 625 weld was higher than that of the solid-solution 2205 pure material and the 2205 composite plate.
(2) The weight loss test results of the high-temperature autoclave showed that the corrosion rate of the 904L composite plate body, weld, and surfacing welding were all at a slight corrosion level under the corrosion environment simulating a high-temperature and high-pressure gas field.
(3) The results of the slow strain rate tensile tests showed that under the simulated high-temperature and high-pressure gas field corrosion environment, the chloride stress corrosion cracking sensitivity of the 904L composite plate body, weld, and surfacing welding was low.
(4) The 904L composite plate meets the requirements of pressure vessel materials’ corrosion resistance in high-temperature and high-pressure gas field environments, and has a good application prospect in processing equipment in oil and gas field stations. Field tests can be carried out from small pressure vessels.
Author Contributions
Methodology, S.W. and P.M.; validation, L.C. and C.W.; investigation, S.C.; writing—original draft preparation, Q.C.; writing—review and editing, G.L. All authors have read and agreed to the published version of the manuscript.
Funding
This research was funded by China’s national key R&D plan “Research on Safety Assessment and Risk Assessment and Early Warning of Crude Oil and Natural Gas Storage Tanks, Auxiliary Pipelines and Auxiliary Facilities” (2017YFC0805804).
Data Availability Statement
The data used to support the findings of this study are available from the corresponding author upon request.
Acknowledgments
The authors extend their thanks to the Tubular Goods Research Institute, China National Petroleum Corporation, from Xi’an, China and Tarim Oilfield Company, petrochina, from Korla, China, for their cooperation and enabling the experimental equipment and technical guidance for the implementation of our research.
Conflicts of Interest
Authors Shuai Wang and Guangshan Li were employed by the company Tubular Goods Research Institute, China National Petroleum Corporation. Author Lijing Chang was employed by the company Changqing Oilfield Company, PetroChina. Authors Chao Wu, Shaoyun Chen and Qingguo Chen were employed by the company Tarim Oilfield Company, PetroChina. The remaining authors declare that the research was conducted in the absence of any commercial or financial relationships that could be construed as a potential conflict of interest.
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Figure 1.
Size of the slow strain rate tensile sample (in).
Figure 2.
Potentiodynamic polarization curve of the samples.
Figure 3.
Macroscopic morphology of samples before and after iron trichloride pitting test.
Figure 4.
(a) The macro morphology of the 904L composite plate before and after corrosion products’ removal; (b) The macro morphology of the 904L composite plate after corrosion products’ removal.
Figure 4.
(a) The macro morphology of the 904L composite plate before and after corrosion products’ removal; (b) The macro morphology of the 904L composite plate after corrosion products’ removal.
Figure 5.
The micro morphology of the 904L composite plate before and after corrosion products’ removal (100×).
Figure 5.
The micro morphology of the 904L composite plate before and after corrosion products’ removal (100×).
Table 1.
Heat treatment parameters of composite plates and welds.
| Composite Plate Material | Heat Treatment Parameters After Explosive Composite | Heat Treatment Parameters After Welding |
|---|---|---|
| 904L + Q345R | 1010 °C/10~20 min, air cooling to ≤400 °C after air cooling | 580 °C/2 h, furnace cooling to ≤400 °C after air cooling |
| 825 + Q345R | 940 °C/20~30 min, air cooling to ≤400 °C after air cooling | 580 °C/2 h, furnace cooling to ≤400 °C after air cooling |
| 2205 + Q345R | 1050 °C/10~20 min air cooling to ≤400 °C after air cooling | 580 °C/2 h, furnace cooling to ≤400 °C after air cooling |
Table 2.
Classification of corrosion rates.
| Degree of Corrosion | Uniform Corrosion Rate (mm/a) | Maximum Pitting Rate (mm/a) |
|---|---|---|
| Light | <0.025 | <0.13 |
| moderate | 0.025–0.12 | 0.13–0.20 |
| Severe | 0.12–0.25 | 0.21–0.38 |
| Extremely severe | >0.25 | >0.38 |
Table 3.
General evaluation methods for stress corrosion cracking sensitivity.
| Stress Corrosion Sensitivity Coefficient | Stress Corrosion Sensitivity |
|---|---|
| >35% | Have a significant tendency to stress corrosion |
| 25~35% | Some tendency to stress corrosion |
| Less than 25% | No significant tendency to stress corrosion |
Table 4.
Electrochemical test results.
| No. | Material | Pitting Potential Eb (V) | Critical Current Density ip (μA/cm2) |
|---|---|---|---|
| (a) | Pure 904L | 0.111 | 7.08 |
| (b) | Pure 2205 | 0.098 | 16.00 |
| (c) | 904L composite plate | 0.029 | 5.29 |
| (d) | E385 weld | 0.102 | 5.65 |
| (e) | E385 surfacing | 0.112 | 6.72 |
| (f) | 625 weld | 0.259 | 3.70 |
| (g) | 2205 composite plate | 0.072 | 9.09 |
| (h) | 825 composite plate | 0.044 | 0.86 |
Table 5.
Results of ferric trichloride pitting test.
| No. | Material | Weight Before Test (g) | Weight After Test (g) | Weight Loss (g) | Area (cm2) | Mass Loss (g/cm2) |
|---|---|---|---|---|---|---|
| (a) | Pure 904L | 15.9671 | 15.8196 | 0.1475 | 14.9688 | 9.85 × 10−3 |
| (b) | Pure 2205 | 14.3944 | 14.1123 | 0.2821 | 15.0859 | 1.87 × 10−2 |
| (c) | 904L composite plate | 12.9069 | 12.6761 | 0.2308 | 14.8641 | 1.55 × 10−2 |
| (d) | E385 weld | 11.9554 | 11.3134 | 0.642 | 14.5075 | 4.43 × 10−2 |
| (e) | E385 surfacing | 11.1224 | 10.2061 | 0.9163 | 14.2994 | 6.41 × 10−2 |
| (f) | 625 weld | 14.6628 | 14.6323 | 0.0305 | 14.8054 | 2.06 × 10−3 |
| (g) | 2205 composite plate | 14.0658 | 13.5457 | 0.5201 | 14.7791 | 3.52 × 10−2 |
| (h) | 825 composite plate | 13.4271 | 13.4089 | 0.0182 | 14.8457 | 1.23 × 10−3 |
Table 6.
Corrosion test results.
| Material | Sample Number | Weight Before Test (g) | Length (mm) | Width (mm) | Thickness (mm) | Weight After Test (g) | Weight Loss (g) | Uniform Corrosion Rate (mm/a) | Average (mm/a) |
|---|---|---|---|---|---|---|---|---|---|
| Pure 904L | 11 | 8.5951 | 39.9 | 9.83 | 3.02 | 8.5949 | 0.0002 | 0.0006 | 0.0006 |
| 12 | 8.3942 | 39.94 | 9.89 | 2.94 | 8.3939 | 0.0003 | 0.0009 | ||
| 13 | 8.415 | 39.94 | 9.9 | 2.92 | 8.4149 | 0.0001 | 0.0003 | ||
| Pure 2205 | 21 | 8.3305 | 39.84 | 9.91 | 2.97 | 8.3303 | 0.0002 | 0.0006 | 0.0008 |
| 22 | 8.3211 | 39.84 | 9.82 | 2.99 | 8.3208 | 0.0003 | 0.0009 | ||
| 23 | 8.1886 | 39.9 | 9.91 | 2.92 | 8.1883 | 0.0003 | 0.0009 | ||
| 904L composite plate | 31 | 8.6541 | 39.69 | 9.97 | 3.00 | 8.654 | 0.0001 | 0.0003 | 0.0003 |
| 32 | 8.6359 | 39.7 | 9.95 | 2.98 | 8.6358 | 0.0001 | 0.0003 | ||
| 33 | 8.6296 | 39.64 | 9.98 | 3.02 | 8.6295 | 0.0001 | 0.0003 | ||
| E385 weld | 3A | 7.9332 | 39.76 | 9.88 | 2.79 | 7.933 | 0.0002 | 0.0006 | 0.0009 |
| 3B | 8.0547 | 39.75 | 9.88 | 2.82 | 8.0541 | 0.0006 | 0.0018 | ||
| 3C | 8.2399 | 39.74 | 9.92 | 2.88 | 8.2398 | 0.0001 | 0.0003 | ||
| E385 surfacing | 3D | 8.531 | 40.15 | 9.99 | 2.94 | 8.5309 | 0.0001 | 0.0003 | 0.0002 |
| 3E | 8.1471 | 40.21 | 10.05 | 2.77 | 8.147 | 0.0001 | 0.0003 | ||
| 3F | 7.9005 | 40.12 | 10.08 | 2.72 | 7.9005 | 0 | 0 | ||
| 625 weld | 4A | 8.804 | 39.64 | 10 | 2.96 | 8.8036 | 0.0004 | 0.0011 | 0.0015 |
| 4B | 8.7926 | 39.73 | 9.99 | 2.97 | 8.7923 | 0.0003 | 0.0009 | ||
| 4C | 8.9265 | 39.72 | 9.98 | 2.98 | 8.9256 | 0.0009 | 0.0026 | ||
| 2205 composite plate | 51 | 8.2491 | 39.88 | 9.92 | 2.92 | 8.2483 | 0.0008 | 0.0025 | 0.0012 |
| 52 | 7.9776 | 39.87 | 9.83 | 2.90 | 7.9775 | 0.0001 | 0.0003 | ||
| 53 | 8.1173 | 39.85 | 9.89 | 2.89 | 8.117 | 0.0003 | 0.0009 | ||
| 825 composite plate | 61 | 8.6737 | 39.71 | 9.96 | 2.98 | 8.6731 | 0.0006 | 0.0018 | 0.0008 |
| 62 | 8.5877 | 39.68 | 9.95 | 2.93 | 8.5876 | 0.0001 | 0.0003 | ||
| 63 | 8.3706 | 39.72 | 9.95 | 2.87 | 8.3705 | 0.0001 | 0.0003 |
Table 7.
Results of the slow strain rate tensile test.
| No. | Material | Tensile Strength | Elongation | ||||
|---|---|---|---|---|---|---|---|
| Corrosion Sample (MPa) | Blank Sample (MPa) | Change Rate (%) | Corrosion Sample (%) | Blank Sample (%) | Change Rate (%) | ||
| (a) | Pure 904L | 524 | 622 | 15.76 | 42.33 | 52.04 | 18.66 |
| (b) | Pure 2205 | 671 | 782 | 14.19 | 28.49 | 35.35 | 19.41 |
| (c) | 904L composite plate | 645 | 756 | 14.68 | 38.00 | 46.93 | 19.03 |
| (d) | E385 weld | 487 | 559 | 12.88 | / | / | / |
| (e) | E385 surfacing | 489 | 561 | 12.83 | / | / | / |
| (f) | 625 weld | 699 | 775 | 9.81 | / | / | / |
| (g) | 2205 composite plate | 695 | 827 | 15.96 | 34.65 | 42.16 | 17.81 |
| (h) | 825 composite plate | 628 | 718 | 12.53 | 31.68 | 38.02 | 16.68 |
Table 8.
Comparison of pitting resistance equivalent of several stainless steels.
| Types of Stainless Steels | ASTM | PREN |
|---|---|---|
| 316L | S31603 | 26 |
| 2205 | S31803 | 33 |
| 904L | N08904 | 34 |
| 825 | N08825 | 35 |
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MDPI and ACS Style
Wang, S.; Mei, P.; Chang, L.; Wu, C.; Chen, S.; Chen, Q.; Li, G. Evaluation of the Corrosion Resistance of 904L Composite Plate in a High-Temperature and High-Pressure Gas Field Environment. Processes 2024, 12, 2372. https://doi.org/10.3390/pr12112372
AMA Style
Wang S, Mei P, Chang L, Wu C, Chen S, Chen Q, Li G. Evaluation of the Corrosion Resistance of 904L Composite Plate in a High-Temperature and High-Pressure Gas Field Environment. Processes. 2024; 12(11):2372. https://doi.org/10.3390/pr12112372
Chicago/Turabian StyleWang, Shuai, Ping Mei, Lijing Chang, Chao Wu, Shaoyun Chen, Qingguo Chen, and Guangshan Li. 2024. "Evaluation of the Corrosion Resistance of 904L Composite Plate in a High-Temperature and High-Pressure Gas Field Environment" Processes 12, no. 11: 2372. https://doi.org/10.3390/pr12112372
APA StyleWang, S., Mei, P., Chang, L., Wu, C., Chen, S., Chen, Q., & Li, G. (2024). Evaluation of the Corrosion Resistance of 904L Composite Plate in a High-Temperature and High-Pressure Gas Field Environment. Processes, 12(11), 2372. https://doi.org/10.3390/pr12112372
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