INTERGRNULAR CORROSION OF AUSTENITIC STAINLESS STEEL

Prepared by: Anil N. VAGHAMSHI Roll No: 923(BE-IV) Metallurgical & Material Science Department The M.S. University of Baroda.

CONTENTS
INTRODUCTION REASONS FOR IGC OCCURANCE MECHANISM OF GRAIN BOUNDARY IGC BY SENSITIZATION OF AUSTENITIC S.S REAL CASE OF IGC IGC IN WELD HOW TO CONTROL IGC REFRENCES

INTERGRANULAR CORROSION
Intergranular corrsion occurs at grain boundries.Rate of corrosion of grain boundary is higher than grains. In some cases, grain boundaries are more susceptible to localize attack than rest of the material. It is most often observed in stainless steel.

REASONS
Phase precipitation at grain boundries and deplete the matrix that decreases the corrosion resistance. Grain boundary phase may be more reactive than matrix . Segration of various solute atoms at the grain. Some working conditions in which given metal do not have resistaance to IGC.

MECHANISM
Metals are made up of polycrystalline grains,These grains are separated by grain boundary. These grain boundaries have higher disorder than grains thats why their energy is higher than grains. These grain boundaries are of two types: Low Angle Grain Boundary High Angle Grain Boundry

The order of grain boundaries according to their energy is given below: High angle grain boundary > Incoherent > Twin boundary > Coherent grain boundary.

SENSITIZATION OF AUSTENITIC S.S

The main effect that causes IGC is sensitization and depletion. High angle grain boundaries are more prone to sensitization and depletion of element.

FIG:Electron photomicrograph of carbides isolated from sensitized S.S.

It is a process of precipitation of new phase at grain boundaries. Whenever stainless steel is heated to 450 to 850C. the carbon present diffuses to the grain boundary. This gives precipitation of carbide by combination with Cr. Such as precipitation of Cr23C6 which shows IGC when exposed to atmosphere.

FIG: Sensitization of austenitic stainless steel

C content in austenitic s.s usually is 0.06 to 0.08% so excess carbon is available to combine with Cr.Thus region forms with very low Cr shows very less resistance to corrosion and disolves in any corroding atmosphere such as HCL,HNO3 etc.
Another mechanism of IGC is segregation of elements at grain boundary. Such as Cr in S.S, This Chromium carbide precipitation depends on many factors such as temperature, exposure time, %of carbon. Temp. and carbon content are diectly proportional to sensitiztion.

REAL CASE OF IGC

FAILURE OF PREHEATING TUBE

FIG: FAILURE OF PREHEATING TUBE

FIG: MICROSTRUCTURE OF FAILURE PART

A cracked 316Ti stainless steel Preheater tube was analyzed to determine the failure mechanism. A second non-cracked tube section from a different elevation was also analyzed to determine the condition of the tube material. The interior of the tube carries process gas that reportedly contains hydrogen, carbon dioxide and monoxide, water and water vapor, methane, nitrogen and traces of hydrogen sulfide. The tube exterior is heated with flue gas. Uniform intergranular corrosion was observed on the ID surface. The intergranular corrosion was attributed to a sensitized microstructure (chromium carbide precipitation along grain boundaries when held at 9321562o F or 500 to 850o C) resulting from the high flue gas temperatures.

Failure of a Stainless steel Tank Used for Storage of Heavy Water/Helium

The dished ends of a heavy water/helium storage tank manufactured from 8 mm (0.3 in.) thick type 304 stainless plate leaked during hydro testing. Repeated attempts at repair welding did not alleviate the problem. Examination of samples from one dished end

the cracking was confined to the heat affected zone (HAZ) surrounding circumferential welds and, to a lesser extent, radial welds that were part of the original construction. Most of the cracks initiated and propagated from the inside surface of the dished ends.
Microstructures of the base metal, HAZ, and weld metal indicated severe sensitization in the HAZ due to high heat input during welding. An intergranular corrosion test confirmed the observations.
FIG: Macrograph of the specimen after intergranular corrosion testing

FIG: Macrograph of the etched cross section on the weld metal.

The severe sensitization was coupled with residual stresses and exposure of the assembly to a coastal atmosphere during storage prior to installation. This combination of factors resulted in failure by stresscorrosion cracking.

IGC IN WELD
In weld of austenetic s.s sensitization observed in Heat Affected Zone.In HAZ area shoes combination of temperature and composition that result in formation of chromium depleted zone at grain boundary. Welded structures and materials attacked intergranularly are called Weld Decay. It is usually a band in the parent plate somewhat removed from the weld.

WELD INTERGRANULAR CORROSION

Microstructure also effects the IGC of austenitic s.s. Large size grain shows high susceptibility to intergranular corrosion. It is bacause small grain gives large grain boundary area and less continous network of carbide.

CONTROL OF IGC IN AUSTENITIC S.S.

Employing high temperature solution heat treatment commonly termed as Quench temperin or solution annealing. Adding elements that are strong carbide former (called stabilizers). Lowering the carbon content to below 0.03%.

REFRENCES:
Corrosion Engg. By M G Fontana. Introduction to Physical Metallurgy By Sidney H. Avenor. Corrosion Engg. By Philip A. Schweitzer. Internet Research.