Corrosion-fatigue

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Corrosion fatigue crack in carbon steel St. 33

150 m

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SEM fracture surface (with striations) of fatigue crack in copper

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SEM fracture surface of fatigue crack in AISI 310 labyrint of gas turbine

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The three models of loading

II

III

MODE I Opening MODE

MODE II Sliding MODE

MODE III Tearing MODE

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Approaches of (corrosion-) fatigue

- Classical approach: Woehler / Smith curves

- Fracture mechanics approach: Paris law: da/dN = C.Kn
C and n are constants for a given material and stress ratios The stress intensity factor K is determined by: K = f. . .a N/mm3/2 f = geometry factor = nominal stress a = crack length
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S-N curves of X6CrNiMoTi17-12-2 in air and acetic acid (Woehler / Smith curves)

Cyclic stress range S ( c kg/mm2)

smooth test specimen

Environment:
air 25C notched test specimen acetic acid 12%

105

106 Frequency N

107

108

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SNcurve; area of low cycle fatigue (LCF) and high cycle fatigue (HCF)

yield strength

LCF
determined by

HCF
determined by 106

10 3

104

104

107

108

Nf
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Paris law

da/dN = C.Kn
KIC A log da/dN B C

Kth log K
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Corrosion fatigue crack propagation rate as a function of the cycle crack tip stress intensity factor
Region I
Slow crack growth

Region II
Power law behaviour

Region III
Fracture instability

da /dN = C.(K) n
Aggressive environment Perturbations due to SCC, hydrogen embrittlement etc.

Log (da/dN)

Inert environment

Kth KICFC

KISCC Log (K)

KIC

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Compact Tension (CT) test piece

P

K=f(a,W,B,P) KIC
V a

PC

B W P NTT Consultancy

Schematic lay-out of corrosion fatigue test arrangement

Power cell Signal amplifier

crack
Signal amplifier

BFS

Cylinder

Servo controller

Process computer Background terminal

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Parameters influencing corrosion fatigue Surface conditions

surface roughness properties of surface metal like hardness and strength residual stress condition of surface

Stress/load/cycle frequency parameters

stress intensity range load frequency

stress ratio
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Parameters influencing corrosion fatigue (continued) Environmental aspects composition of aggressive environment (pH, temperature) electrode potential
Alloy properties chemical composition microstructure yield strength

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Woods model for initation of a micro crack in sliding zone

free surface fresh surface

1e cycle

2e cycle

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Different stages of fatigue process

initiation period (stage I)

propagation period (stage II)

(stage III)

cyclic sliding

initiation of micro crack

propagation of micro crack

propagation of macro crack

final fracture

initial fracture

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Model of wood for initiation of a microcrack in sliding zone

initation period
cyclic sliding initiation of crack propagation of micro crack initial fracture Different stadia of fatigue process

propagation period
propagation of macro crack final fracture

free surface

fresh surface

1e cycle

2e cycle NTT Consultancy

Stage I and stage II of fatigue crack propagation

load direction

free surface Stage I Stage II

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Preventive measures to eliminate or reduce corrosion fatigue Improvement of design: reduce the stress and number of stress cycles; avoid abrupt changes in diameter and sharp angles; use (full penetration) butt welds instead of fillet welds; avoid internal stresses; enlarge the dimensions, mass or strength of critical components; ensure a sufficiently flexible construction in order to absorb excessive stresses due to thermal expansion, vibrations, shocks, and load and pressure variations.
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Preventive measures to eliminate or reduce corrosion fatigue (continued 1) Using more resistant materials:

with improved corrosion resistance; with improved ductility and impact strength.
Duplex stainless steel are generally speaking more corrosion fatigue resistant then austenitic stainless steels. Copper and copper alloys are better than carbon steel and aluminium.

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Preventive measures to eliminate or reduce corrosion fatigue (continued 2)

Improvement of surface condition:

by removing tensile stresses and/or creating compressive stresses by stress relief annealing or shot peening, hammering, rolling; by decrease in surface roughness: as forged hot rolled machined ground; by autofrettage (e.g. high pressure piping in HDPE plants) by nitriding or carburizing; by application of coating and/or cathodic protection; (be careful with (cracked) chrome plating).
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Stress distribution in a shot-peened item

Tension

Peened surface compression

tension

compression

A. Distribution of residual stress in a shot peened beam having no external load

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Preventive measures to eliminate or reduce corrosion fatigue (continued 3)

Changing corrosivity:

by means of inhibitors.

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Corrosion fatigue in traverse beam of vibration dryer

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Ammonium sulfate vibration dryer

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Fatigue fracture surface of shaft of extruder

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Corrosion fatigue in AISI 316L heat exchanger tube material

200 m

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Erosion - Corrosion

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Forms of erosion-corrosion
Failure mode
turbulence without solids medium
liquid liquid erosion cavitation erosion Impingement attack

vapor gas

with solids

liquid abrasion
gas erosion

Single-face erosion-corrosion medium gas (unilateral)

medium electrons

without solids with solids solid liquid arc liquid and/or gas vacuum irradiation with
electron beams

gas abrasion drop erosion spark erosion electron beam erosion

Single-face erosion
Two-face erosion-corrosion (bilateral)

medium solids

erosion (wear)

fretting corrosion baffle hammering NTT Consultancy

Forms of erosion-corrosion
Failure mode
turbulence without solids medium
liquid liquid erosion cavitation erosion Impingement attack

vapor gas

with solids

liquid abrasion
gas erosion

Single-face erosion-corrosion medium gas (unilateral)

medium electrons

without solids with solids solid liquid arc liquid and/or gas vacuum irradiation with
electron beams

gas abrasion drop erosion spark erosion electron beam erosion

Single-face erosion
Two-face erosion-corrosion (bilateral)

medium solids

erosion (wear)

fretting corrosion baffle hammering NTT Consultancy

Liquid erosion in (small diameter) carbon steel sulphuric acid line

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Liquid erosion in (small diameter) carbon steel sulphuric acid line

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Liquid erosion in outer bend of carbon steel line in sulphuric acid service

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Liquid erosion in 304L sulphuric acid line

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Liquid erosion in sulphuric acid line

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Liquid erosion in carbon steel pipeline

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Forms of erosion-corrosion
Failure mode
turbulence without solids medium
liquid liquid erosion cavitation erosion Impingement attack

vapor gas

with solids

liquid abrasion
gas erosion

Single-face erosion-corrosion medium gas (unilateral)

medium electrons

without solids with solids solid liquid arc liquid and/or gas vacuum irradiation with
electron beams

gas abrasion drop erosion spark erosion electron beam erosion

Single-face erosion
Two-face Erosion-corrosion (bilateral)

medium solids

erosion (wear)

fretting corrosion baffle hammering NTT Consultancy

Schematic representation of steps in cavitation

(R.W. Henke)

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Mechanism of cavitation

A cavitation bubble forms on the protective film

The bubble collapses and destroys the film The newly exposed metal surface corrodes and the film is reformed A new cavitation bubble forms at the same spot

The bubble collapses and destroys the film

The exposed area corrodes and the film reforms

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Cavitation in cast iron pump impeller

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Cavitation in plug and valve seat of DN50 Stainless steel (Globe) control valve

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Cavitation in 316L control valve

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Cavitation in 316L control valve

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Cavitation in 316L urea grade valve

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Forms of erosion-corrosion
Failure mode
turbulence without solids medium
liquid liquid erosion cavitation erosion Impingement attack

vapor gas

with solids

liquid abrasion
gas erosion

Single-face erosion-corrosion medium gas (unilateral)

medium electrons

without solids with solids solid liquid arc liquid and/or gas vacuum irradiation with
electron beams

gas abrasion drop erosion spark erosion electron beam erosion

Single-face erosion
Two-face erosion-corrosion (bilateral)

medium solids

erosion (wear)

fretting corrosion baffle hammering NTT Consultancy

Impingement attack of tube wall

Water flow

Impingement corrosion pits

Corrosion film

Original metal surface

Metal tube wall

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Impingement attack in copper heat exchanger tube

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Impingement attack in (finned) copper heat exchanger tube

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Impingement attack in carbon steel body of water ring compressor

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Impingement attack in carbon steel body of water ring compressor

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Preventive measures to minimize or avoid impingement attack Avoid bubbles of gas and solids Use more impingements resistant materials like f.i. cupro-nickel alloys Install impingement plates Install inserts at entrance side of heat exchangers

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Forms of erosion-corrosion
Failure mode
turbulence without solids medium
liquid liquid erosion cavitation erosion Impingement attack

vapor gas

with solids

liquid abrasion
gas erosion

Single-face erosion-corrosion medium gas (unilateral)

medium electrons

without solids with solids solid liquid arc liquid and/or gas vacuum irradiation with
electron beams

gas abrasion drop erosion spark erosion electron beam erosion

Single-face erosion
Two-face erosion-corrosion (bilateral)

medium solids

erosion (wear)

fretting corrosion baffle hammering NTT Consultancy

Parameters influencing liquid abrasion Process side: form and magnitude of particles velocity of particles hardness of particles corrosivity of liquid (or particles) Material of construction: hardness alloy composition microstructure corrosion resistance Interaction between environment and material of construction: angle of incidence
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Liquid abrasion of a 304 cast impeller of pump in fertilizer plant

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Liquid abrasion in C30E wear partition wall of pump

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Liquid abrasion in 316L pipeline in urea slurry

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Liquid abrasion in outlet gutter of (NH4)2SO4 (Krauss-Maffei) centrifuge

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Liquid abrasion at carbon steel stirrer blade

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Liquid abrasion at Guronit V35 (GX250Cr25) wear tips of granulating screw

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Granulating screw with wear tips

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Granulating screw with wear tips

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Locations with erosion-corrosion in fertilizer plant

Straat 2 Trilgoot 1B goed stof Zeef 1B Zeef 1A Trilgoot 1A stof goed grof

Dak
Vulmergel van NF2 VULMERGEL 50m3

grof

Grofbreker 1B

Grofbreker 1A

4
Verlaad + corr.stof STOF BUNKER Doseer inrichting Stofdoseerschroef Stofafzuiging filter W.R. condens Mengschroef Recycle band Granuleerschroef Fijnbreker Filters Droogstraat 1 Zeefbrekerprod. Trilgoot

3
A.N.v. NF2 Straat 2

stoom Product koeler

W.R.

Lucht 100C 5000 m3/h

Band B2114 Band B2108 Via band B2108 en/of B2114 naar Corr. Zeven en Coating NF2 Kooi

1
Luchtverhitter
Buiten

Peil

Geluidsdemper

Emmerladder

Plaatsen met erosie

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Morphology of marl; CaCO3

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Morphology of dolomite, CaMg(CO3)2

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Forms of erosion-corrosion
Failure mode
turbulence without solids medium
liquid liquid erosion cavitation erosion Impingement attack

vapor gas

with solids

liquid abrasion
gas erosion

Single-face erosion-corrosion medium gas (unilateral)

medium electrons

without solids with solids solid liquid arc liquid and/or gas vacuum irradiation with
electron beams

gas abrasion drop erosion spark erosion electron beam erosion

Single-face erosion
Two-face erosion-corrosion (bilateral)

medium solids

erosion (wear)

fretting corrosion baffle hammering NTT Consultancy

Gas abrasion in cyclone of acrylonitrile reactor

-x Gas outlet Gas inlet 657 168 NTT Consultancy

Top view
Area with serious gas abrasion Dipleg

Dip-leg of cyclone in ACN reactor

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Gas abrasion in carbon steel dipleg of catalyst cyclone

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Repair of dip-leg of cyclone by means of metal spraying

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Cyclone in reactor melamine plant

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Gas abrasion in cyclone of reactor melamine plant

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Gas abrasion in cyclone of reactor melamine plant

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Melamine Reactor R-2101 MELAF 2

A2

A5

A4 A3

A1

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Morphology of spent catalyst, round shape

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Morphology of new catalyst, rocky shape

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Forms of erosion-corrosion
Failure mode
turbulence without solids medium
liquid liquid erosion cavitation erosion Impingement attack

vapor gas

with solids

liquid abrasion
gas erosion

Single-face erosion-corrosion medium gas (unilateral)

medium electrons

without solids with solids solid liquid arc liquid and/or gas vacuum irradiation with
electron beams

gas abrasion drop erosion spark erosion electron beam erosion

Single-face erosion
Two-face erosion-corrosion (bilateral)

medium solids

erosion (wear)

fretting corrosion baffle hammering NTT Consultancy

Drop erosion in carbon steel (saturated LP steam) line

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Drop erosion in carbon steel U-bend of steam line

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Forms of erosion-corrosion
Failure mode
turbulence without solids medium
liquid liquid erosion cavitation erosion Impingement attack

vapor gas

with solids

liquid abrasion
gas erosion

Single-face erosion-corrosion medium gas (unilateral)

medium electrons

without solids with solids solid liquid arc liquid and/or gas vacuum irradiation with
electron beams

gas abrasion drop erosion spark erosion electron beam erosion

Single-face erosion
Two-face erosion-corrosion (bilateral)

medium solids

erosion (wear)

fretting corrosion baffle hammering NTT Consultancy

Parameters influencing erosion Process side: form and magnitude of particles velocity of particles hardness of particles

Material of construction: hardness alloy composition microstructure

Interaction between environment and material of construction: angle of incidence
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Angle of incidence of erosive particle on material

v cos

v sin small angle of incidence

v cos

v sin large angle of incidence

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Survey of angles of incidence applicable for erosion resistant materials

75 applicable 60

90

doubtful applicability
45 not applicable

30

15

Angle of incidence

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Angle of incidence 10 30 20 50 60 70 80

40

90

C-steel
X22CrNi17-2

X2CrNiMoN
22-5-3

Verbund stahl Castolin 6710 Metcoloy 2 RCH 1000 Epoxy sand Rhino Hyde polyurethane Polyprop. Skega rubber Linatex Basalt Alum oxide Armed glass NTT Consultancy

Applicabilty of several materials of construction

Erosion resistant

Erosion in dolomite transport line

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Survey of design solutions to minimize erosion(-corrosion)

1. Pipe with dead end instead of elbow

2. Use of U-beams under pipes

erosion corrosion

filled with product

erosion corrosion at the bottom Old situation New situation

Old situation

New situation

U-beam filled with cement mortar

3. Welding of ribs in bunkers and funnels

erosion-corrosion

Old situation

New situation NTT Consultancy

Design solutions to minimize erosion (-corrosion) in product pipelines

O 200 pipeline

O 200 pipeline erosion-corrosion at bottom side

Gutter at bottom and side walls (partially) coated with Al2O3 tiles O 200 pipeline

Old situation

New situation NTT Consultancy

Survey of application of erosion-corrosion resistant materials Cast alloys:

C: 2.9; Si: 0.3 0.8; Cr: 1.5 2.5; Ni: 4.15 4.75; Mn: 0.4 0.6. Application: fine crushers. Ni-hard:
GX260CrMoNi20-2-1. Application: fine crushers.

Guronit V35; GX250Cr25. Application: tips of granulation screws.

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Survey of application of erosion-corrosion resistant materials (continued 1)

Hardening steels
Verbundstahl SPM 2304, a hardening steel (composition C: 0.9; Cr: 1.9; Mn: 0.4; Mo: 0.35) cladded on a non hardening steel e.g. steel St. 33. Hv after hardening about 800. Application: spin buckets, funnels, hoppers, distribution plates.

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Survey of application of erosion-corrosion resistant materials (continued 2) Overlay welds: Covered electrodes: Castolin 6710: C: 5.5; Cr: 43. Abrassadur 43: C: 6.5; Cr: 24; Nb: 7. Application: overlay welding of granulation screws and cage mills.

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Survey of application of erosion-corrosion resistant materials (continued 3) Metallic, ceramic spray layers (wire, powder or plasma spray:

Metcoloy 2: Co: 3; Cr: 13; balans: Fe. Application: troughs, granulation screws (applied with wire gun). Al2O3, Cr2O3, SiO2 ceramic spray layers. Application: valve seats and plugs.

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Survey of application of erosion-corrosion resistant materials (continued 4) Electroplating Hard chromium plating. Application: Tuflin valves.

Diffusion layers:
Cr-diffusion. Application: control valves, dust extraction system Nitriding. Application: axles, stirrers, agitators.

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Survey of application of erosion-corrosion resistant materials (continued 5) Ceramic materials: Aluminium oxide. Application: tiles in gutters, funnels. Sillicon carbide. Application: wear rings in pumps. Silicon nitride. Application: spray nozzles. Cementation (trowel and spray layers):

Epoxy-sand. Application: gutters. Cement mortar. Application: filler material for U-profiles at bottom side of lines. Plastic types:
RCH 1000; Polyurethane; Linatex; Skegarubber. Application: as a liner in hoppers, funnels, gutters.
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Forms of erosion-corrosion
Failure mode
turbulence without solids medium
liquid liquid erosion cavitation erosion Impingement attack

vapor gas

with solids

liquid abrasion
gas erosion

Single-face erosion-corrosion medium gas (unilateral)

medium electrons

without solids with solids solid liquid arc liquid and/or gas vacuum irradiation with
electron beams

gas abrasion drop erosion spark erosion electron beam erosion

Single-face erosion
Two-face erosion-corrosion (bilateral)

medium solids

erosion (wear)

fretting corrosion baffle hammering NTT Consultancy

Fretting corrosion Basic requirements for the occurrence of fretting corrosion are: The interface must be under load. Vibration or repeated relative motion between the two surfaces must occur. The load and the relative motion of the interface must be sufficient to produce slip or deformation of the surfaces.

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Example of typical location of fretting corrosion

(press-fitted ball-bearing race on a shaft)

Fretting at tight fits subject to vibration

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Schematic illustration of the wear-oxidation theory of fretting corrosion

Before

After

Cold weld

Contact point Oxidized particles

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Schematic illustration of the oxidation- wear theory of fretting corrosion

Before

After

Oxide layers

Exposed metal Oxide particles

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Preventive measures to minimize or avoid fretting corrosion

Lubrication with oil or grease; preferably in conjunction with phosphate coatings (Parkerizing). Molybdenum sulfide is effective as a solid lubricant. Combination of a soft metal with a hard metal. Increasing the surface hardness by shot peening or cold working. Use elastomer gaskets to absorb vibration. Decreasing the load or on the other hand increasing the load to avoid slip completely (by hydrolic fit).

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Shaft of syngas compressor

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Fretting corrosion in axle of compressor

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Rotor of syngas compressor with key-fit of axial thrust disc

Key-fit

fretting

Coupling at the part of steam edge Coupling at the part of MP casing edge

Shaft of syngasscompressorAFA 2/3 NTT Consultancy

Rotor of syngas compressor with hydrolic-fit of axial thrust disc

Hydrolic fit

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Forms of erosion-corrosion
Failure mode
turbulence without solids medium
liquid liquid erosion cavitation erosion Impingement attack

vapor gas

with solids

liquid abrasion
gas erosion

Single-face erosion-corrosion medium gas (unilateral)

medium electrons

without solids with solids solid liquid arc liquid and/or gas vacuum irradiation with
electron beams

gas abrasion drop erosion spark erosion electron beam erosion

Single-face erosion
Two-face erosion-corrosion (bilateral)

medium solids

erosion (wear)

fretting corrosion baffle hammering NTT Consultancy

Baffle hammering in heat exchanger tube

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General measures to combat erosion - corrosion

Aspect Specific for 1 aspect
decrease of temperature inhibitor dosing cathodic protection deaeration filtration decrease of velocity - Tees - 90 elbows - elbows with small radius - impingement plates - replaceable wear plates

Valid for both aspects

(electro-) chemical

material of construction

mechanical

surface protection - organic layers - inorganic layers - metallic layers

avoid design use

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