Search Results (25)

In recent years, significant increases in premature failures of rock bolts that are attributed to stress corrosion cracking (SCC) have been observed in underground reinforcement systems, which pose serious safety concerns for underground operations. A multitude of studies have focused on understanding the environmental factors, such as the composition of the corrosive medium, temperature, and humidity, in promoting the SCC of rock bolts, but the SCC failure mechanism associated with microstructural changes is still unclear due to the complexity of the underground environments. To understand its failure mechanism and develop effective mitigation strategies, this study evaluated different testing conditions, employing pin-loaded and bar-loaded coupon tests using representative specimens. The tests were conducted in an acidified sulfide solution. The failure characteristics and crack paths of the failed specimens were examined. It was observed that the steel with lower carbon content exhibited a reduced susceptibility to SCC. The subcritical cracks observed in the specimens were influenced by the microstructure of the material. SCC was observed not only on the original surface of rock bolts, which featured mill scale and decarburization, but also on freshly machined surfaces. Evidence for the occurrence of hydrogen-induced SCC was identified and discussed. The proposed testing methods and the obtained results contribute to a deeper understanding of SCC in rock bolts as well as promote the development of more durable materials for underground mining applications, ultimately enhancing the safety and reliability of rock bolt systems. Full article

This study explores the effects of Zn addition through micro-alloying on the microstructure and discharge performance of Mg-Al-Mn-Ca alloy anodes for magnesium-air batteries. The results show that the second-phase particles (d > 1 μm) in a Mg-Al-Mn-Ca alloy promote dynamic recrystallization (DRX) via particle-stimulated nucleation (PSN), resulting in a uniform equiaxed grain structure and fiber texture. In contrast, Zn and Ca co-segregation in a Mg-Al-Mn-Ca-Zn alloy facilitates continuous dynamic recrystallization (CDRX) and, combined with the PSN mechanism, forms a unique structure where three types of grains with different grain boundary densities coexist. The addition of Zn and Ca effectively reduces the c/a axis ratio, promoting texture homogenization. The Mg-Al-Mn-Ca alloy exhibits rough discharge surfaces due to simultaneous discharge at numerous grain boundaries and severe hydrogen evolution corrosion from micro-galvanic effects, inducing the chunk effect (CE). Conversely, the structure where three types of grains with different grain boundary densities coexist in the Mg-Al-Mn-Ca-Zn alloy promotes discharge product detachment through stress cracking, achieving uniform discharge and significantly enhancing discharge performance. The uniform texture reduces hydrogen evolution corrosion, improving anode utilization. This study demonstrates that controlling the microstructure, particularly grain boundary density and grain texture, enables the development of high-performance Mg-Al-Mn-Ca-Zn alloy anodes, especially at higher current densities, offering a new strategy for designing efficient magnesium alloy anode materials. Full article

Dry storage canisters of used nuclear fuels are fabricated using SUS 304L stainless steel. Chloride-induced stress corrosion cracking (CISCC) is one of the major failure modes of dry storage canisters. The cracked canisters can be repaired by friction stir welding (FSW), a low-heat input ‘solid-phase’ welding process. It is important to evaluate the ClSCC resistance of the friction stir welded material. Stress corrosion cracking (SCC) studies were carried out on mill-annealed base materials and friction stir welded 304L stainless U-bend specimens in 3.5% NaCl + 5 N H₂SO₄ solution at room temperature and boiling MgCl₂ solution at 155 °C. The engineering stress on the outer fiber of the FSW U-bend specimen was ~60% higher than that of the base metal (BM). In spite of the higher stress level of the FSW, both materials (FSW and BM) showed almost similar SCC failure times in the two different test solutions. The SCC occurred in the thermo-mechanically affected zone (TMAZ) of the FSW specimens in the 3.5% NaCl + 5 N H₂SO₄ solution at room temperature, while the stirred zone (SZ) was relatively crack-free. The failure occurred at the stirred zone when tested in the boiling MgCl₂ solution. Hydrogen reduction was the cathodic reaction in the boiling MgCl₂ solution, which promoted hydrogen-assisted cracking of the heavily deformed stirred zone. The emergence of the slip step followed by passive film rupture and dissolution of the slip step could be the SCC events in the 3.5% NaCl + 5 N H₂SO₄ solution at room temperature. However, the slip step height was not sufficient to cause passivity breakdown in the fine-grained SZ. Therefore, the SCC occurred in the partially recrystallized softer TMAZ. Overall, the friction-stirred 304L showed higher tolerance to ClSCC than the 304L base metal. Full article

In the oil and gas industry, the corrosion attributed to hydrogen sulfide (H₂S) is one of the most significant challenges. This review paper systematically investigates the diverse facets of H₂S corrosion, including its sources, corrosion locations, mechanisms, and resultant corrosion products. Understanding different forms of H₂S corrosion, such as stress-oriented hydrogen-induced cracking (SO-HIC), sulfide stress cracking (SSC), and hydrogen-induced cracking (HIC), provides a thorough comprehension of these phenomena. The paper discusses critical factors influencing H₂S corrosion, such as temperature, flow rate, pH, and H₂S concentration, highlighting their implications for sustainable practices in the oil and gas sector. The review emphasizes the significance of monitoring and mitigation strategies, covering continuous monitoring, applying corrosion inhibitors, selecting materials, and conducting thorough data analysis and reporting. Furthermore, the role of training in fostering a sustainable approach to H₂S corrosion management is highlighted. This exploration advances the overarching goal of sustainable development in the oil and gas industries by providing insights into understanding, monitoring, and mitigating H₂S corrosion. The findings presented here offer a foundation for developing environmentally conscious strategies and practices to guarantee the long-term viability and flexibility of refinery operations. Full article

Corrosion product films (CPFs) have significant effects on hydrogen permeation and the corrosion process at the crack tip. This paper established a two-dimensional calculation model to simulate the formation of CPFs at the crack tip and its effects on the crack tip stress status and hydrogen diffusion. The CPFs were simplified as a single-layer structure composed of Fe₂O₃, the effective CPFs boundary was modeled by the diffusion of oxygen, and the CPF-induced stress was modeled by hygroscopic expansion. The simulation was conducted with two stages; the first stage was to simulate the formation of CPFs formation and its effects on the crack tip stress status, while the second stage focused on the hydrogen diffusion with and without CPF formation under different external tensile loads. The results indicate that the highest compressive stress induced by the formation of CPFs is located at 50~60° of the crack contour and dramatically weakens the crack tip tensile stress at low-stress status. The CPFs can inhibit the hydrogen permeation into the crack tip, and the hydrostatic pressure effects on the redistribution of the permeated hydrogen are significant under larger external load conditions. Full article

Atmospheric corrosion of aluminum aircraft structures occurs due to a variety of reasons. A typical phenomenon leading to corrosion during aircraft operation is the deliquescence of salt contaminants due to changes in the ambient relative humidity (RH). Currently, the corrosion of aircraft is controlled through scheduled inspections. In contrast, the present contribution aims to continuously monitor atmospheric corrosion using the acoustic emission (AE) method, which could lead to a structural health monitoring application for aircraft. The AE method is frequently used for corrosion detection under immersion-like conditions or for corrosion where stress-induced cracking is involved. However, the applicability of the AE method to the detection of atmospheric corrosion in unloaded aluminum structures has not yet been demonstrated. To address this issue, the present investigation uses small droplets of a sodium chloride solution to induce atmospheric corrosion of uncladded aluminum alloy AA2024-T351. The operating conditions of an aircraft are simulated by controlled variations in the RH. The AE signals are measured while the corrosion site is visually observed through video recordings. A clear correlation between the formation and growth of pits, the AE and hydrogen bubble activity, and the RH is found. Thus, the findings demonstrate the applicability of the AE method to the monitoring of the atmospheric corrosion of aluminum aircraft structures using current measurement equipment. Numerous potential effects that can affect the measurable AE signals are discussed. Among these, bubble activity is considered to cause the most emissions. Full article

The effect of the secondary α phase on stress corrosion cracking of a novel metastable β titanium alloy, Ti-6Mo-5V-3Al-2Fe, in 3.5% NaCl solution was investigated by slow strain rate testing. Fine acicular secondary α phase was obtained by aging at the low temperature of 520 °C, and coarsened rod-like secondary α phase was obtained by aging at the high temperature of 680 °C. The electrochemical measurement results and slow strain rate testing results show that the microstructure contained with fine acicular secondary α phase exhibits better corrosion resistance and less stress corrosion cracking susceptibility. The fracture morphology exhibits a mixed fracture characteristic with shallow and small dimples, as well as tear ridges and flat facets with undulating surfaces. The combination of Absorption Induced Dislocation Emission and Hydrogen Enhanced Localized Plasticity is the main mechanism for stress corrosion cracking. Fine acicular secondary α phase with narrow spacing leads to less accumulated dislocations and smaller localized stress, so that has a beneficial effect on stress corrosion performance. Full article

The metastable β titanium alloys used in marine engineering applications suffered from stress-corrosion cracking in seawater. The different phase composition leads to the distinct stress-corrosion cracking behaviors of the alloy. In this work, the influence of the phase composition on the stress-corrosion cracking of a novel metastable β titanium alloy Ti-6Mo-5V-3Al-2Fe-2Zr was investigated. The alloys with different phase compositions were prepared by three types of thermal-mechanical processing, i.e., the single β phase (assigned as M_(β)), the β phase plus fine α phase (assigned as M_(β+fα)), and the β phase plus coarsened α phase (assigned as M_(β+cα)). The electrochemical tests and constant-stress loading tests were performed, and the phase composition and microstructure were analyzed by XRD and SEM. The M_(β) alloy exhibits the best corrosion resistance as well as the compact properties of oxide films, followed by the M_(β+fα) alloy and the M_(β+cα) alloy. Tear ridges and a flat facet with an undulating surface were observed on the stress-corrosion cracking fracture surface, which indicated the occurrence of high-degree dislocations movement and localized plastic deformation. Absorption-induced dislocation emission (AIDE) and hydrogen-enhanced localized plasticity (HELP) are the primary mechanisms for the stress-corrosion cracking of the alloy. The increased amount of β phase has a beneficial effect on stress-corrosion cracking resistance. For the alloy with β and α phases, the α phase with wider spacing has an adverse effect on stress corrosion performance. Full article

The radiolysis of water is a significant cause of corrosion damage in the primary heat transport systems (PHTSs) of water-cooled, fission nuclear power reactors (BWRs, PWRs, and CANDUs) and is projected to be a significant factor in the evolution of corrosion damage in future fusion reactors (e.g., the ITER that is currently under development). In Part I of this two-part series, we reviewed the proposed mechanisms for the radiolysis of water and demonstrate that radiolysis leads to the formation of a myriad of oxidizing and reducing species. In this Part II, we review the role that the radiolysis species play in establishing the electrochemical corrosion potential (ECP) and the development of corrosion damage due to intergranular stress corrosion cracking (IGSCC) in reactor PHTSs. We demonstrate, that the radiolytic oxidizing radiolysis products, such as O₂, H₂O₂, HO₂⁻, and OH, when in molar excess over reducing species (H₂, H, and O₂²⁻), some of which (H₂) are preferentially stripped from the coolant upon boiling in a BWR PHTS, for example, renders the coolant in many BWRs oxidizing, thereby shifting the ECP in the positive direction to a value that is more positive than the critical potential (E_crit = −0.23 V_she at 288 °C) for IGSCC in sensitized austenitic stainless steel (e.g., Type 304 SS). This has led to many IGSCC incidents in operating BWRs over the past five decades that has exacted a great cost on the plant operators and electricity consumers, alike. In the case of PWRs, the primary circuits are pressurized with hydrogen to give a hydrogen concentration of 10 to 50 cm³/kgH₂O (0.89 to 4.46 ppm), such that no sustained boiling occurs, and the hydrogen suppresses the radiolysis of water, thereby inhibiting the formation of oxidizing radiolysis products from water. Thus, the ECP is dominated by the hydrogen electrode reaction (HER), although important deviations from the HER equilibrium potential may occur, particularly at low [H₂]. In any event, the ECP is displaced to approximately −0.85 V_she, which is below the critical potential for IGSCC in sensitized stainless steels but is also more negative than the critical potential for the hydrogen-induced cracking (HIC) of mill-annealed Alloy 600. This has led to extensive cracking of steam generator tubing and other components (e.g., control rod drive tubes, pressurizer components) in PWRs that has also exacted a high cost on operators and power consumers. Although the ITER has yet to operate, the proposed chemistry protocol for the coolant places it close to a BWR operating on Normal Water Chemistry (NWC) without boiling or, if hydrogen is added to the IBED-PHTS, close to a BWR on Hydrogen Water Chemistry (HWC). In the current ITER technology, the concentration of H₂ in the IBED-PHTS is specified to be 80 ppb, which is the concentration that will be experienced in both the Plasma Flux Area (PFA) and in the Out of Plasma Flux Area (OPFA). That corresponds to 0.90 cc(STP) H₂/KgH₂O, compared with 20–50 cc(STP) H₂/KgH₂O employed in a PWR primary coolant circuit and 5.5 to 22 cc(STP) H₂/KgH₂O in a BWR on hydrogen water chemistry (HWC). We predict that a hydrogen concentration of 80 ppb is sufficient to reduce the ECP in the OPFA to a level (−0.324 V_she) that is sufficient to suppress the crack growth rate (CGR) below the practical, maximum level of 10⁻⁹ cm/s (0.315 mm/a) at which SCC is considered not to be a problem in a coolant circuit but, in the PFA, the ECP is predicted to be 0.380 V_she, which gives a calculated standard CGR of 2.7 × 10⁻⁶ cm/s. This is more than three orders in magnitude greater that the desired maximum value of 10⁻⁹ cm/s. We recommend that the HWC issue in ITER be revisited to develop a protocol that is effective in suppressing both the ECP and the CGR in the PFA to levels that permit the operation of the IBED-PHTS in accordance with the experience gained in fission reactor technology. Full article

This work evaluates the impact of different organic acids on the corrosion sensitivity and stress-corrosion cracking (SCC) of NiCrMoV steam turbine steel. For all organic acids, potentiodynamic measurements shows linear relationships between corrosion rate and hydrogen proton concentration between pH 2.4 and 3.9. For solutions with the same pH, i.e., similar conductivity, the corrosion rate differs depending on the type of organic acid. The anodic dissolution in formic acid is the highest, followed by acetic, propanoic and nonanoic acid. The acid dissociation reaction is identified as the rate determining step in the corrosion process. Nonanoic acid, alternatively, clearly acts as a corrosion inhibitor. In situ four-point constant-extension tests in formic acid, acetic acid and nonanoic acid, at a pH value of 3.4 were performed to evaluate their impact on the SSC sensitivity. The general degradation followed the trend of the corrosion rate, although the synergetic effect of corrosion and stress resulted in a higher degradation depth. Though nonanoic acid induced little visible corrosion, still stress-corrosion cracks were still detected. It was shown that solutions of different organic acids with the same pH do not have the same influence on stress-induced degradation. Full article

Pipelines have been installed and operated around the globe to transport oil and gas for decades. They are considered to be an effective, economic and safe means of transportation. The major concern in their operation is corrosion. Among the different forms of corrosion, stress corrosion cracking (SCC), which is caused by stresses induced by internal fluid flow or other external forces during the pipeline’s operation, in combined action with the presence of a corrosive medium, can lead to pipeline failure. In this paper, an extensive review of different factors affecting SCC of pipeline steels in various environmental conditions is carried out to understand their impact. Several factors such as temperature, presence of oxidizers (O₂, CO_2, H₂S, etc.), composition and concentration of medium, pH, applied stress, and microstructure of the metal/alloy have been established to affect the SCC of pipeline steels. SCC susceptibility of a steel at a particular temperature strongly depends on the type and composition of the corrosive medium and microstructure. It was observed that pipeline steels with water quenched and quenched and tempered heat treatments, such as those that consist of acicular ferrite or bainitic ferrite grains, are more susceptible to SCC irrespective of solution type and composition. Applied stress, stress concentration and fluctuating stress facilitates SCC initiation and propagation. In general, the mechanisms for crack initiation and propagation in near-neutral solutions are anodic dissolution and hydrogen embrittlement. Full article

High-strength aluminum alloys are exposed to more and more environmentally-induced cracking failure behaviors during service. However, due to the hard to detect nature of hydrogen, and the special working conditions, failure research has obvious hysteresis and complexity, and it is impossible to truly reflect the material failure phenomenon and mechanism. In this paper, 7085 high-strength aluminum alloy is selected as the research material to simulate and reproduce the environmental failure phenomenon of aircraft under extreme working conditions (temperature 70 °C, humidity 85%). The results proved that high-strength aluminum alloy has environmental cracking failure behavior under extreme working conditions. The failure mode that was determined was due to environment-induced hydrogen and hydrogen-induced cracking, which is the result of the combined action of hydrogen and stress. Meanwhile, we demonstrate that high-strength aluminum alloy’s environmental failure behavior in an environment of high temperature and high humidity is different from traditional stress corrosion cracking behavior. Full article

Low-alloy reactor pressure vessel steels have a rather low susceptibility to stress corrosion cracking (SCC) in a boiling water reactor (BWR) environment if the high-temperature water contains no anionic impurities. Recent investigations revealed that under oxidizing BWR normal water chemistry (NWC) conditions extremely small amounts of chloride, can cause very high SCC growth rates in these materials. Therefore, the effect of continuous and temporary chloride additions on the crack initiation behaviour was explored by a series of constant extension rate tensile (CERT) and constant load tests in high-temperature water. In an NWC environment, containing ≥2 ppb of chloride, strain-induced corrosion cracking (SICC) initiation occurred briefly after the onset of plastic yielding and at much smaller strains than in high-purity water. On the other hand, under reducing hydrogen water chemistry conditions with up to 700 ppb chloride, no SICC was detected up to very high strains. CERT experiments, with moderate short-term chloride transients before and during the loading, showed that even serious mechanical loading transients, one day after returning to high-purity water, did not result in early SICC initiation. Full article

In this paper, we analyze the potential factors affecting the hydrogen sulfide type of stress corrosion cracking in C110 casing pipes. In order to further study these cracking factors, the methods of material property testing, scanning electron microscopy, XRD, TEM, and 3D ultra-depth-of-field were applied in the experiments. Besides that, an HTHP autoclave was independently designed by the laboratory to simulate the actual corrosion environment, and the potential factors affecting the stress corrosion cracking of C110 casing pipes were determined. The test results showed that the chemical composition, metallographic structure, hardness, and non-metallic inclusions of the two types of C110 casing pipes were all qualified. In fact, there remains a risk of stress corrosion cracking when the two kinds of C110 casing pipes serve under long-term field-working conditions. It is considered in this paper that the precipitates on the material surface, stress damage, and pitting corrosion are all critical factors affecting the stress corrosion cracking of casing pipes. Full article

The effect of SRB and applied potential on the stress corrosion sensitivity of X80 pipeline steel was analyzed in high-pH soil simulated solution under different conditions using a slow strain rate tensile test, electrochemical test, and electronic microanalysis. The experimental results showed that X80 pipeline steel has a certain degree of SCC sensitivity in high-pH simulated solution, and the crack growth mode was trans-granular stress corrosion cracking. In a sterile environment, the SCC mechanism of X80 steel was a mixture mechanism of anode dissolution and hydrogen embrittlement at −850 mV potential, while X80 steel had the lowest SCC sensitivity due to the weak effect of AD and HE; after Sulfate Reducing Bacteria (SRB) were inoculated, the SCC mechanism of X80 steel was an AD–membrane rupture mechanism at −850 mV potential. The synergistic effect of Cl⁻ and SRB formed an oxygen concentration cell and an acidification microenvironment in the pitting corrosion pit, and this promoted the formation of pitting corrosion which induced crack nucleation, thus significantly improving the SCC sensitivity of X80 steel. The strong cathodic polarization promoted the local corrosion caused by SRB metabolism in the presence of bacteria, whereby the SCC sensitivity in the presence of bacteria was higher than that in sterile conditions under strong cathodic potential. Full article