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M
anufacturers and users of pipelines in the oil and
gas sectors have long believed that so-called
‘stainless steel’, is indeed stainless. The fact is
that most of these materials not only discolour
but also can corrode when they come into contact with some
endemic media. The black corrosion spots on cutlery after
passing through a dishwasher cycle are an example, but a more
dramatic illustration is salt-water corrosion in pipelines.
1
One area of production receiving little attention is during SCC
pipe and tube fabrication where welding is widely used. Unless This is characterised by cracks propagating either through or
strict welding schedules are not adhered to, however, not only along grain boundaries. It results from the combined action of
will discolouration (heat tint) take place but also corrosion tensile stresses in the material and the presence of a corrosive
resistance can be significantly reduced. medium. It can be induced in some stainless steels by adverse
heat treatments, such as those occurring in weld heat affected
The mechanism of corrosion zones.
Stainless steels owe their resistance to corrosion to the
formation of a very thin (10-5 mm), transparent surface layer MIC
of chromium oxide. This provides a passive film that acts as This type of corrosion is either promoted or caused by micro-
a barrier to penetration by an invasive environment. When organisms, typically occurring in industries related to food,
heated to a high temperature in the presence of oxygen, this beverage and chemical processing. It is usually referred to by
film increases in thickness until it becomes visible – the colour the acronym ‘MIC’ and is common in welded sections.
becomes darker with increasing film thickness. To avoid these forms of corrosion, it is essential that the
At a critical film thickness, the film becomes unstable and heat tints are properly removed before the stainless steel
begins to break down. The fractured zones created offer sites equipment or piping is exposed to aggressive or aqueous
for localised corrosion, where four principle mechanisms are environments. The alternative is to prevent heat tinting during
involved: the welding process by using an inert environment to protect
)) Crevice corrosion. the surface. during welding.
)) Pitting corrosion. Removal of heat tint
Bright annealing or acid pickling can remove light
)) Stress corrosion cracking.
discolouration, but heavier deposits may require machining
)) Microbiologically induced corrosion (MIC). such as grinding and polishing. Removal clearly requires access
to the area in question, not only for treatment, but also for
Crevice corrosion debris removal. Even when access is available, none of these
This is a localised corrosion of a metal surface, which is treatments are easy and most can be very expensive.
attributable to proximity of another metal such as a weld. It is Whilst it is not too difficult to protect the outside
a locally accelerated type of corrosion and is one of the major surface of a weld by using an inert gas as coverage, preventing
corrosion hazards in stainless steels. oxidation and loss of corrosion resistance on the inside is
often overlooked. The technique of inside protection is known
Pitting corrosion as ‘weld purging’ and uses inert gas to flush out air and thus
This produces attacks in the form of spots or pits, and takes oxygen before and during welding.
place at points where the passive layer might be weakened:
it occurs in stainless steels where oxidation has reduced the Weld purging techniques
passivity. Once the attack has started, the material can be Equipment has been developed over the past decade to make
completely penetrated within a short time. purging much easier. Currently available systems are robust
and suitable for multi-use applications. They can be supplied
to cover the size range between 25 - 2400 mm dia.
Figure 2. Extensive penetration following pitting corrosion in Figure 3. Example of PurgElite range of fully integrated
stainless steel pipe. systems covering the 25 - 250 mm pipe range.
References
1. Eastwood et al. 1993, welding stainless steel to meet hygienic
requirements, document 9, European Hygienic Engineering
Design Group (EHEDG).