Beruflich Dokumente
Kultur Dokumente
Cracking
(CorrosionEngineering)
EnvironmentallyAssistedCracking
LectureOutline
Stresscorrosioncracking
CrackInitiation
CrackGrowth
MetallurgicalEffects
ElectrochemicalEffects
TypicalSCCMaterials
HydrogenInducedCracking
SourcesofHydrogen
CorrosionFatigue
TestMethodstoexamineEAC
FractureMechanics
MechanismsforEAC
TypesofCorrosion
Uniform
Galvaniccorrosion
Crevicecorrosion
Pittingcorrosion
Intergranularcorrosion
Selectiveleaching
Erosioncorrosionandfretting
Environmentallyinducedcracking
Hydrogendamage
EnvironmentallyInducedCracking
Definition
Brittlemechanicalfailuresthatresultsfrom
thesynergismbetweentensilestressanda
corrosiveenvironment
Stresscorrosioncracking(SCC)
CorrosionFatigue
Hydrogeninducedcracking
MetalInducedEmbrittlement
StressCorrosionCracking
Stresscorrosion
crackingistypically
definedasafailurethat
occurswhenyouhavea
susceptiblematerial
thatissimultaneously
exposedtoarelatively
lowconstanttensile
stressinanaggressive
environment
ExampleofSCC
Surfacecracksonstainless
steelexposedtoseawater
Intergranularand
transgranularcrackson
stainlesssteelexposedto
seawater
SCCTextbook
BasicSCCphenomenology
(CrackInitiation)
Crackinitiationdoesnot
necessaryoccurallthe
timefromsmoothsurface
Machiningmarks
Fatiguecracks
Crackscaninitiatefrom
corrosionpitsorcrevice
corrosion,or
intergranularcorrosion
Thetransitiondepends
upontheoriginaldefect
shape
BasicSCCphenomenology
(CrackGrowth)
Typicallythereisalackof
macroscopicdeformation
andabsenceofgeneral
corrosion
Crackbranchingand
secondarycracksare
typical
Intergranularfracture
surfacesproducedbySCC
aresmooth
Transgranularexhibit
numerousfinescale
featuredsuchasserrated
steps
SCC MetallurgicalEffects
Puremetalstendtobeless
susceptibletoSCCthan
alloys,butcanstillundergo
cracking
Copperinammonia
Alloycompositionand
microstructurehavealarge
effectonSCCresistance
Especiallyaroundgrain
boundaries
Generaltrendisthat
increasingSCCsusceptibility
withincreasingstrength
SCC MetallurgicalEffects
Grainboundary
morphology(andsize)
canhaveamajoreffect
onSCCsusceptibility
Elongatedgrain
boundarycanleadto
reducedSCCresistance
Coldworkcanalso
affectthesusceptibility
ofmaterials
SCCElectrochemicalEffects
SCCElectrochemicalEffectsExamples
P.MScott.2000
TypicalSCCMaterialEnvironment
Combinations(StainlessSteel)
Proseketal.
2009
TypicalSCCMaterialEnvironment
Combinations(StainlessSteel)
TypicalSCCMaterialEnvironment
Combinations(StainlessSteel)
Ferricstainlesssteelsare
generallymoreresistantto
SCCthanausteniticSS,
howeverwhensmall
amountsofnickelisadded
theycanbecome
susceptible
Duplexstainlesssteelare
generallyalsomore
resistanttoSCCcompared
totheausteniticstainless
steels.However,theyare
nottotallyimmune
AlShamarietal.2009
TypicalSCCMaterialEnvironment
Combinations(CarbonSteel)
TypicalSCCMaterialEnvironment
Combinations(NickelAlloys)
TypicalSCCMaterialEnvironment
Combinations(CopperAlloys)
Wetaerated
environmentscontaining
smallquantitiesof
ammonium,nitrites,and
nitratesledtoSCCin
copper
SCCinitiatedatshallow
pitswherethepassive
layerofCuOhadbeen
destroyed
Brasscartridgecasesin
1920crackedfromhigh
residualstressesand
traceamountsof
ammonia
TypicalSCCMaterialEnvironment
Combinations(Aluminum)
Extensivelyusedin
aircraft
Mostcommonalloysto
crackare2xxx,7xxx,and
5xxxseries
Susceptibletohumid
air,seawater,and
potablewater
TypicalSCCMaterialEnvironment
Combinations(Titanium)
Titanium(Ti)isvery
corrosionresistant
Tiusuallysuffersfrom
environmentally
inducedcrackingfrom
hydrogen
embrittlement
Formationofhydrides
embrittlethematerial
HydrogenInducedCracking
Damagingeffectsfromhydrogenisaphenomena
knownashydrogenembrittlementorhydrogen
inducedcracking
HICisrelevanttoSCCashydrogenisgeneratedat
cracktipsinaqueousenvironments
Numeroustypesofhydrogenembrittlement
processes
Concentrationofhydrogeninregionsofthemetal
Hydrideformation
SourcesofHydrogen
Solutionsusedtocleanandapplyprotective
coatings
Weldinginmoistatmospheres
Heattreatmentinhydrogenbearing
atmospheres
Cathodicprotection
Aqueoushydrogensulfide(OilandGas
Industry)
Corrosionprocess
Highpressuregaseoushydrogen(fuel)
HydrogenInducedCracking
CorrosionFatigueCracking
Corrosionfatigueis
similartoSCCinthat
theenvironment
enhancesthecrack
growth
Crackscangrowby
cyclingofcrackfront
ASMEcodeisbasedon
fatiguecrackgrowthin
air needtoapply
someenvironmental
factor
Argonne.2011
CorrosionFatigueCracking
Crackgrowthrateper
cycletypicallyincreases
withlowerfrequency
Increasingtheratio,R,
ofminimumtothe
maximumstresstends
todecreasethecrack
growthpercycle
TestingMethods
ConstantDeformationTests
SustainedLoadTests
SlowStrainRateTesting
CorrosionFatigueTesting
ConstantDeformationTests
Ubendtestsareusedto
measurecrackinitiation
susceptibility
Largestressandstrainmuch
greaterthanyieldstress
CRingandbentbeamareused
tomeasurecrackinitiation
susceptibility
Canapplymuchlessstressand
measuredappliedstressstrain
(straingauges)
Techniqueusedependsupon
formofmaterial(i.e.plateor
pipe)
Tensilespecimensallowgreatest
controlofappliedstressstrain
becauseoftheknowngeometry
Mainproblemisthatwhen
cracksgrow,appliedloaddrops
ConstantLoadTests
SustainedLoadTestsalso
examinecrackinitiation
CanusespringloadedCring
ProvingRingsaretypically
usedwithtensilesamples
Deadweightloadshavebeen
usedbutmuchmorebulkso
difficulttouseexceptfor
simplesolutiontests.
Differencebetween
ConstantLoadvs.Constant
Deformationisthatduring
ConstantLoadtests,stress
increaseswithcrackgrowth
SlowStrainRateTests
SlowStrainRate(SSR)testingor
constantelongationratetensile
(CERT)testingisusedtoexamine
SCCsusceptibilitybetweenalloysor
environments
Strainrateusedwillprovide
differentresultssoneedtochoose
strainratecarefully
Minimizetimefortestandprovide
accuratesusceptibility
characterization
Typicallyexamineparametersin
environmentdividedbyparameters
inair
Closerthevalueisto1,less
susceptibletoSCC
TimetoFailure
Ductility
Reductioninarea
Yieldstrength
%SCConfracturesurface
TestingMethods
FatiguePrecracksample
inairandthenexposeto
environmentofinterest
Applycyclicload
R=Smin/Smax
Rcangofrom1to1
Comparecrackgrowth
rateinenvironmenttoin
air
Examinefracturesurface
forenvironmentaleffects
WhatwouldanRof1mean?
WhatwouldanRof1mean?
WhatwouldanRof0mean?
FractureMechanicsTesting
Typicaltestingis
conductedusingmodeI
KIc isthevaluetypically
consideredbecauseitis
lowerthanothermodes
Crackswillgrowbelow
KIC whenitis
susceptibletoSCC
MechanismsofSCC
HydrogenEmbrittlement
AdsorptionInducedCleavage
FilmRupture
FilmInducedCleavage
HydrogenEmbrittlement
Hydrogenweakens
interatomicbondsand
facilitatesdecohesion
Hydrogenfacilitates
dislocationactivityin
theplasticzoneahead
ofcrackpromoting
crackgrowthbyslip
microvoidcoalescence
AdsorptionInducedCleavage
Similartohydrogen
inductedcrackingthisis
speculatedfor
aggressiveions
Aggressiveionsweaken
bondingbetween
adjacentatomsatcrack
tip.
FilmruptureorSlipDissolution
Mostwidelycited
mechanism
Basedonruptureof
protectivefilmbyslip
bandsthatintersectcrack
tip
Dissolutionalonggrain
boundariesorlowindex
crystalplanes
Filmmayreformand
processstartsagainor
surfacemaycontinueto
befilmfree
FilminducedCleavage
Filminducedcleavage
includesrepeated
sequencesof:
formationofan
environmentallyinduced
brittlefilmatcracktip
Rapidbrittlefractureofthe
film
Continuationofthe
fractureintothe
underlyingsubstrate/metal
Crackarrestandblunting
LectureReview
Stresscorrosioncrackingisthefailuremodethatoccurswhen
youhaveasusceptiblematerial,inanaggressiveenvironment,
withlowconstanttensileload
Crackinitiationcanoccuratmachinemarks,fatiguecracks,pits,or
intergranularcorrosion
Crackgrowthcanoccurinvariousformsincludingintergranularfracture
andtransgranularfracture
Metallurgicaleffectscanincreasesusceptibility(weldedregionstendto
beweakpoints)
Materialstendtobesusceptibleinvariouselectrochemicalpotential
ranges(outsiderangenocrackingmayoccur)
HydrogenInducedCrackingoccurswhenhydrogenembrittle
materialthatleadstofailureatlowerstresses
Environmentleadstoanenhancedeffectoncorrosionfatigue
crackgrowthrate
LectureReview
VarioustestmethodstoexamineEACincludingconstant
deformation,sustainedloads,slowstrainrate,and
corrosionfatigue
Environmenttypicallydecreasesthestressintensityvalue
wherecrackswillbegintopropagate
MechanismsforEACincludehydrogenembrittlement,
adsorptioninducedcleavage,filmrupture,andfilm
inducedcleavage