egesee ee eee eccerene BRC-CORP 37-74.F 167 Section 31. METAL DUSTING Definition of Metal dusting corrosion is a process whereby metal is removed by the Teaction of hot process gas with the metal surface to form carbides, which may Subsequently be oxidized and swept away in the process stream. ‘Carburization is a pre-requisite for metal dusting corrosion, and is distinguished from it by the deterioration it produces (see Section 6 on Carburization). Such a di tinction has questionable merit, however, but has found common usage throughout the industry. Metal dusting corrosion produces a wear appearance or distinct pit formation. Figure 31-1 shows a localized wear pattern occurring adjacent to a weld, in an Incoloy alloy 800 tube. Figure 31-2 shovs s general wall thinning occurring in a tube of the same alloy where pitting is also observed. Discussion of the Problem Metal dusting corrosion can occur simply by formation of brittle carbides at grain boundaries. These carbides can fracture, when subjected to pesvice stresses (mechanical and thermal) or volume stresses, associated with increased carbon concentration at the process stream surface. The process stream can then sweep avay particles of metal, which have been loosened from the tube wall by these fracture processes. The deterioration pattern is related to localized carburization, susceptibility of the metal surface, and flow characteristics of the process stream. The metal dusting corrosion example shown in Figure 31-1 is somewhat more compley than eimpla carhurization, as indicated by the micrograph of the tube wall shown in Figure 31-3. In this case, the intergranular carbides initially formed (layer D) were oxidized ayer C). Oxides have very low mechanical strength, and fracture quite easily, permitting rapid metal particle removal in a high velocity strean. The surface of Figure 31-3 consists of an iron-nickel solid solution (layer A) where chromium has been removed to form carbides, and an oxide layer (layer 3). These pheses are alov canily reuuved from the tube wall during service. Metal dusting corrosion usually occurs at temperatures above 649°C (2200°F), although it hax been reported in piping exposed to temperaturee ac low as 427°C (800°F). Efforts have been made to minimize carburization, by sulfur and steam additions to the process stream. The subsequent effects are not well documented. Methods of Checking for the Problem Metal dusting corrosion can be identified visually by the wear pattern or pitted appearance it produces, along with metallographic examination. Often, the finding of magnetic particles in adhering coke material is an indicieion of metal dusting. Methods of Eliminating the Problem Metal dusting corrosion is characteristic of specific process streams. Factors reducing carburization, such as increasing chromium, nickel or silicon content, in austenitic alloys, can be helpful in reducing the rate of metal dusting. ‘In general, the susceptibility to metal dusting will be reduced when (ZCr) + 2x(%Si) > 24x, in iron-based alloys. Steam in the Process stream also promotes a stable oxide film and reduces metal dusting suscepesbilicy.168 BRC-CORP 37-74. Employment of austenitic stainless alloys where the silicon content is in excess of 2.5 percent can promote formation of the detrimental eigna~ Phase (see Section 35). Because the conditions causing metal dusting are only poorly defined, solutions will not be the same for each occurrence. Each problen must be carefully studied to determine the most effective and economical moat that will be compatible vith the process stream. Figure 31-4 Localized metal Dusting Aajecent to te Weld In an Incoloy 800 Tube Magnification: 4X. Po cccccccccccccceBRC-CORP 37.74. ie Figure 31.2 ‘Metal Dusting Corrosion of Incoloy 800 Tube [Note general wall tninning ang prting ‘Magnification: 1X. eo ©0000 OCOEEOOBRC-CORP 37-745 eoeee socscceest Figure 31.3 Photomicrograph of # Cross Section Through the Wall of an Incoloy Alloy 800 Tube Attacked by Metal Dusting Note that four distinct layers may be seen, Magnification: 40X. ccePoccccccccccccccest