Stress Corrosion Cracking: Theory and Practice

808 Pages·2011·49.21 MB·English

by  V S Raja

Stress corrosion cracking
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Stress corrosion
cracking
Theory and practice
Edited by
V. S. Raja and Tetsuo Shoji
Oxford Cambridge Philadelphia New Delhi
© Woodhead Publishing Limited, 2011
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First published 2011, Woodhead Publishing Limited
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Library of Congress Control Number: 2011934934
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Contents
Contributor contact details xiii
List of reviewers xix
Foreword xxi
Preface xxiii
Part I Fundamental aspects of stress corrosion cracking
(SCC) and hydrogen embrittlement 1
1 Mechanistic and fractographic aspects of
stress-corrosion cracking (SCC) 3
S. P. Lynch, Defence Science and Technology Organisation
(DSTO), Australia
1.1 Introduction 3
1.2 Quantitative measures of stress-corrosion cracking (SCC) 5
1.3 Basic phenomenology of stress-corrosion cracking (SCC) 6
1.4 Metallurgical variables affecting stress-corrosion cracking
(SCC) 11
1.5 Environmental variables affecting stress-corrosion
cracking (SCC) 14
1.6 Surface-science observations 14
1.7 Proposed mechanisms of stress-corrosion cracking (SCC) 18
1.8 Determining the viability and applicability of stress-
corrosion cracking (SCC) mechanisms 28
1.9 Transgranular stress-corrosion cracking (T-SCC) in model
systems 29
1.10 Intergranular stress-corrosion cracking (I-SCC) in model
systems 54
1.11 Stress-corrosion cracking (SCC) in some commercial
alloys 58
1.12 General discussion of stress-corrosion cracking (SCC)
mechanisms 66
1.13 Conclusions 76
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vi Contents
1.14 Acknowledgements 78
1.15 References 78
2 Hydrogen embrittlement (HE) phenomena and
mechanisms 90
S. P. Lynch, Defence Science and Technology Organisation
(DSTO), Australia
2.1 Introduction 90
2.2 Proposed mechanisms of hydrogen embrittlement (HE)
and supporting evidence 100
2.3 Relative contributions of various mechanisms for
different fracture modes 113
2.4 General comments 123
2.5 Conclusions 125
2.6 References 126
Part II Test methods for determining stress corrosion
cracking (SCC) susceptibilities 131
3 Testing and evaluation methods for stress corrosion
cracking (SCC) in metals 133
W. Dietzel and P. Bala Srinivasan, Helmholtz-Zentrum Geesthacht,
Germany and A. Atrens, The University of Queensland, Australia
3.1 Introduction 133
3.2 General aspects of stress corrosion cracking (SCC) testing 134
3.3 Smooth specimens 136
3.4 Pre-cracked specimens – the fracture mechanics approach
to stress corrosion cracking (SCC) 143
3.5 The elastic-plastic fracture mechanics approach to stress
corrosion cracking (SCC) 155
3.6 The use of stress corrosion cracking (SCC) data 158
3.7 Standards and procedures for stress corrosion cracking
(SCC) testing 159
3.8 Future trends 163
3.9 References 164
Part III Stress corrosion cracking (SCC) in specifi c materials 167
4 Stress corrosion cracking (SCC) in low and medium
strength carbon steels 169
U. K. Chatterjee, Indian Institute of Technology Kharagpur, India
and R. K. Singh Raman, Monash University, Australia
4.1 Introduction 169
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Contents vii
4.2 Dissolution-dominated stress corrosion cracking (SCC) 170
4.3 Hydrogen embrittlement-dominated stress corrosion
cracking (SCC) 187
4.4 Conclusions 191
4.5 References 192
5 Stress corrosion cracking (SCC) in stainless steels 199
V. Kain, Bhabha Atomic Research Centre, India
5.1 Introduction to stainless steels 199
5.2 Introduction to stress corrosion cracking (SCC) of
stainless steels 202
5.3 Environments causing stress corrosion cracking (SCC) 203
5.4 Effect of chemical composition on stress corrosion
cracking (SCC) 215
5.5 Microstructure and stress corrosion cracking (SCC) 218
5.6 Nature of the grain boundary and stress corrosion
cracking (SCC) 221
5.7 Residual stress and stress corrosion cracking (SCC) 223
5.8 Surface fi nishing and stress corrosion cracking (SCC) 225
5.9 Other fabrication techniques and stress corrosion
cracking (SCC) 229
5.10 Controlling stress corrosion cracking (SCC) 231
5.11 Sources of further information 233
5.12 Conclusions 233
5.13 References 234
6 Factors affecting stress corrosion cracking (SCC)
and fundamental mechanistic understanding of
stainless steels 245
T. Shoji, Z. Lu and Q. Peng, Tohoku University, Japan
6.1 Introduction 245
6.2 Metallurgical/material factors 245
6.3 Environmental factors 254
6.4 Mechanical factors 261
6.5 Elemental mechanism and synergistic effects for complex
stress corrosion cracking (SCC) systems 263
6.6 Typical components and materials used in pressurized
water reactors (PWR) and boiling water reactors (BWR) 265
6.7 References 269
7 Stress corrosion cracking (SCC) of nickel-based alloys 273
R. B. Rebak, GE Global Research, USA
7.1 Introduction 273
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viii Contents
7.2 The family of nickel alloys 274
7.3 Environmental cracking behavior of nickel alloys 279
7.4 Resistance to stress corrosion cracking (SCC) by
application 285
7.5 Conclusions 301
7.6 References 301
8 Stress corrosion cracking (SCC) of aluminium alloys 307
M. Bobby Kannan, James Cook University, Australia, P. Bala
Srinivasan, Helmholtz-Zentrum Geesthacht, Germany and V. S.
Raja, Indian Institute of Technology Mumbai, India
8.1 Introduction 307
8.2 Stress corrosion cracking (SCC) mechanisms 308
8.3 Factors affecting stress corrosion cracking (SCC) 313
8.4 Stress corrosion cracking (SCC) of weldments 325
8.5 Stress corrosion cracking (SCC) of aluminium composites 331
8.6 Conclusions 334
8.7 References 334
9 Stress corrosion cracking (SCC) of magnesium
alloys 341
A. Atrens, The University of Queensland, Australia, W. Dietzel
and P. Bala Srinivasan, Helmholtz-Zentrum Geesthacht, Germany,
N. Winzer, Fraunhofer Institute for Mechanics of Materials IWM,
Germany and M. Bobby Kannan, James Cook University, Australia
9.1 Introduction 341
9.2 Alloy infl uences 345
9.3 Infl uence of loading 354
9.4 Environmental infl uences 360
9.5 Mechanisms 363
9.6 Recommendations to avoid stress corrosion cracking
(SCC) 370
9.7 Conclusions 371
9.8 Acknowledgements 373
9.9 References 373
10 Stress corrosion cracking (SCC) and hydrogen-
assisted cracking in titanium alloys 381
I. Chattoraj, Council of Scientifi c and Industrial Research (CSIR),
India
10.1 Introduction 381
10.2 Corrosion resistance of titanium alloys 385
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Contents ix
10.3 Stress corrosion cracking (SCC) of titanium alloys 386
10.4 Hydrogen degradation of titanium alloys 388
10.5 Conclusions 404
10.6 Acknowledgements 405
10.7 References 405
11 Stress corrosion cracking (SCC) of copper and
copper-based alloys 409
M. Bobby Kannan, James Cook University, Australia and
P. K. Shukla, Southwest Research Institute, USA
11.1 Introduction 409
11.2 Stress corrosion cracking (SCC) mechanisms 410
11.3 Stress corrosion cracking (SCC) of copper and
copper-based alloys 411
11.4 Role of secondary phase particles 419
11.5 Stress corrosion cracking (SCC) mitigation strategies 419
11.6 Conclusions 422
11.7 References 424
12 Stress corrosion cracking (SCC) of austenitic
stainless and ferritic steel weldments 427
H. Shaikh, T. Anita, A. Poonguzhali, R. K. Dayal and B. Raj,
Indira Gandhi Centre for Atomic Research, India
12.1 Introduction 427
12.2 Effect of welding defects on weld metal corrosion 429
12.3 Stress corrosion cracking (SCC) of austentic stainless
steel weld metal 431
12.4 Welding issues in ferritic steels 462
12.5 Conclusions 478
12.6 References 478
13 Stress corrosion cracking (SCC) in polymer
composites 485
J. K. Lim, Chonbuk National University, South Korea
13.1 Introduction 485
13.2 Stress corrosion cracking (SCC) of short fi ber reinforced
polymer injection moldings 487
13.3 Stress corrosion cracking (SCC) evaluation of glass fi ber
reinforced plastics (GFRPs) in synthetic sea water 505
13.4 Fatigue crack propagation mechanism of glass fi ber
reinforced plastics (GFRP) in synthetic sea water 511
13.5 Aging crack propagation mechanisms of natural fi ber
reinforced polymer composites 519
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x Contents
13.6 Aging of biodegradable composites based on natural fi ber
and polylactic acid (PLA) 526
13.7 References 535
Part IV Environmentally assisted cracking problems in
various industries 537
14 Stress corrosion cracking (SCC) in boilers and
cooling water systems 539
M. J. Esmacher, GE Water & Process Technologies, USA
14.1 Overview of stress corrosion cracking (SCC) in water
systems 539
14.2 Stress corrosion cracking (SCC) in boiler water systems 540
14.3 Stress corrosion cracking (SCC) in cooling water systems 552
14.4 Stress corrosion cracking (SCC) monitoring strategies 566
14.5 References 567
15 Environmentally assisted cracking (EAC) in oil and
gas production 570
M. Iannuzzi, Det Norske Veritas, Norway
15.1 Introduction 570
15.2 Overview of oil and gas production 571
15.3 Environmentally assisted cracking (EAC) mechanisms
common to oil and gas production 580
15.4 Materials for casing, tubing and other well components 584
15.5 Corrosivity of sour high pressure/high temperature
(HPHT) reservoirs 592
15.6 Environmentally assisted cracking (EAC) performance of
typical alloys for tubing and casing 594
15.7 Qualifi cation of materials for oil- and gas-fi eld
applications 599
15.8 The future of materials selection for oil and gas
production 603
15.9 References 604
16 Stress corrosion cracking (SCC) in aerospace
vehicles 608
R. J. H. Wanhill, National Aerospace Laboratory NLR,
The Netherlands and R. T. Byrnes and C. L. Smith, Defence
Science and Technology Organisation (DSTO), Australia
16.1 Introduction 608
16.2 Structures, materials and environments 610
16.3 Material–environment compatibility guidelines 615
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