ASSIGNMENT CMT 555

Material Selection and Design

1. Material Selection

There are two types for selection of proper material for a particular corrosive services.
Metallics (metals and alloys)
Non-metallic (rubber-natural and synthetic, plastics, ceramics, carbon and graphite and
wood)

Metal and alloys

Environment Proper Material
Nitric acid Stainless steels
Caustic Nickel and nickel alloys
Hydrofluoric acid Monel(Ni-Cu)
Hot hydrochloric acid Hastelloys (Ni-Cr-Mo)(Chlorimets)
Dilute sulfuric acid Lead
Nonstaining atmospheric exposure Aluminum
Distilled water Tin
Hot strong oxidizing solution Titanium
Ultimate resistance Tantalum
Concentrated sulfuric acid Steel

Stainless steels
Stainless steels are iron base alloys that contain a minimum of approximately 11% of chromium
(Cr), the amount needed to prevent the formation of rust in unpolluted atmosphere. The main
alloying elements in stainless steel are chromium, nickel and carbon. Other than Ni, Cr and C the
following alloying elements may also present in stainless steel : molybdenum (Mo), nitrogen
(N), silicon (Si), manganese (Mn), copper (Cu), titanium (Ti), niobium (Nb), tantalum (Ta)
and/or tungsten (W).

Major alloying elements

Chromium

Minimum concentration of Cr in a stainless steel is 12 14 wt. %. Structure : BCC
(ferrite forming element).

Nickel

Structure : FCC (austenite forming element/stabilize austenitic structure). Added to
produce austenitic or duplex stainless steels. These materials possess excellent ductility,
formability and toughness as well as weld-ability. Nickel improves mechanical properties
of stainless steels servicing at high temperatures. Nickel increases aqueous corrosion
resistance of materials.

Carbon

Very strong austenite forming element (30x more effective than Ni). i.e. if austenitic
stainless steel 18Cr 8Ni contains 0.007 %C, its structure will convert to ferritic
structure. However the concentration of carbon is usually limited to 0.08 %C (normal
stainless steels) and 0.03 %C (low carbon stainless steels to avoid sensitization during
welding).

Minor alloying elements

Manganese

Austenitic forming element. When necessary can be used to substitute Ni. Concentration
of Mn in stainless steel is usually 2-3%.

Molybdenum

Ferritic forming element. Added to increase pitting corrosion resistance of stainless steel
(2-4 %). Molybdenum addition has to be followed by decreasing chromium concentration
(i.e. in 18-8SS has to be decreased down to 16-18%) and increasing nickel concentration
(i.e. has to be increased up to 10-14%). Improves mechanical properties of stainless steel
at high temperature. Increase aqueous corrosion resistance of material exposed in
reducing acid.

Tungsten

Is added to increase the strength and toughness of martensitic stainless steel.

Nitrogen

Stabilize austenitic structure. Increases strength and corrosion resistance. Increases weld
ability of duplex SS.

Titanium, Niobium and Tantalum

To stabilize stainless steel by reducing susceptibility of the material to intergranular
corrosion. Ti addition >5x% C. Ta+Nb addition >10x% C.

Copper

Is added to increase corrosion resistance of stailess steel exposed in environment
containing sulfuric acid.

Silicon

Reduce susceptibility of SS to pitting and crevice corrosion as well as SCC.

Five basics types of stainless steels

Austenitic

Susceptible to SCC. Can be hardened by only by cold working. Good toughness and
formability, easily to be welded and high corrosion resistance. Non-magnetic except after
excess cold working due to martenstic formation.

Martensitic

Application : when high mechanical strength and wear resistance combined with some
degree of corrosion resistance are required. Typical application include steam turbine
blades, valves body and seats, bolts and screws, springs, knives, surgical instruments and
chemical engineering equipment.

Ferritic

Higher resistance to SCC than austenitic SS. Tend to be notch sensitive and are
susceptible to embrittlement during welding. Not recommended for service above 300C
because they will loss their room temperature ductility.