Why Subsea Equipment is Often Fabricated from More

Exotic Materials
With the increasing use of Subsea developments worldwide in more demanding climates,
more corrosive resistant, stronger, durable materials are needed. Deeper, harsh environments
for subsea applications demand the need for careful material selection. Such demand reflects
why more exotic materials are being used for subsea equipment. Exotic materials produce
greater corrosive resistance which alone is a main reason to the popular use, better resistance
to corrosion leads to many benefits including prolonged life of the material as well as reduced
costs in maintenance and inspection. Corrosion is not the only parameter to be considered
during the material selection stage; materials used in subsea applications need to have strong
mechanical properties to minimise the chance of failure as economically possible. As the
lifespan of both oil and gas fields increase it is imperative that a sustainable material is
selected when designing components for subsea applications.
With regard to subsea applications the toughness of the material is an important parameter.
Modern day uses of exotic materials are often alloyed with other elements to increase
strength. High toughness of materials for the applications of pipelines will help reduce to risk
of failure through other risks that are not corrosion. Other problems include dropped objects,
a material with a higher toughness has a greater chance of not rupturing from the impact than
that of a material with a lower toughness. A property that needs great consideration in
locations where a busy shipping area is operating above, or in a location susceptible to
earthquakes or landslides.Alloys are predominantly used more regularly than pure metals as
in relation to conducting electricity or thermal transfers pure metals achieve this better than
that of alloys. However regarding strength (stiffness) of heat transfer, alloys perform better
than pure metals [1].
Table 1(Chemical Composition [2])
Properties
%
Nickel
58.0 min
Chromium
20.0-23.0
Iron
5.0 max
Molybdenum
8.0-10.0
Niobium (& Tantalum)
3.15-415
Carbon
0.10 max
Manganese
0.5 max
Silicon
0.5 max
Phosphorus
0.015 max
Sulfer
0.015 max
Aluminium
0.40 max
Titanium
0.40 max
Cobalt
0.1 max
Exotic materials are strengthened through processes such as alloying, where various metals or
chemicals are used to determine the required parameters for individual environments. Inconel
625 is a nickel-chromium alloy that is used in subsea applications because of the high
strength and corrosion resistance [2]. Table 1 reveals that in the instance of Inconel 625 the
extent of how many properties an exotic material can be comprised of. This amalgamation of

properties results in a material that reduces corrosion from pitting, crevice as well as
chloride-ion-stress-corrosion cracking. The high corrosion-fatigue strength produced from the
material makes it ideal for subsea applications such as seals, cable connectors and fasteners;
given the before mentioned risks depending on the proposed environment. In comparison to
pure metals such as carbon steel exotic materials for example, titanium produces high
strength whilst being 45% lighter than steel [3]. Not considering the cost implications of
exotic materials, regarding purpose and function solely are reasons why such materials as
titanium and Inconel 625 are being used over pure metals. Pure metals cannot rival the
figures produced from exotic materials given their enhanced properties, despite high initial
costs exotic materials over time will produce saving on time and cost regarding inspection,
maintenance and repair in comparison to pure metals.
In subsea applications corrosion of components is an important parameter that has to be
carefully reviewed, which should be reflected in the material selection for said components.
The implications failure due to corrosion can have devastating consequences for the operator,
if a pipeline were to fail releasing its contents into the water would result in severe
repercussions. Not only would there be a serious loss in resources, cost, time and detrimental
environmental impact but the reputation of the operator would also be damaged, in turn
jeopardising future contracts.
As shown in table 1, exotic materials have a broad mixture of properties each of these
properties contributes to the material regarding corrosion resistance, strength and toughness.
High nickel contents in alloy increase the toughness and ductility of a material whilst also
lowering the corrosion rate which increases resistance to corrosion [4]. The addition of
chromium can see resistance to corrosion increased at higher temperatures; the use of
molybdenum within the alloy helps improve the corrosion resistance against galvanic
corrosion. In comparison to exotic materials carbon steel is incredibly popular in various
engineering situations despite having a limited resistance to corrosion. It is often understood
that carbon steel cannot contain alloy elements, however alloy elements can be used there are
restrictions. By nature carbon steels have a limited alloy content, approximately less than 2%
of its weight [5]. Without the addition of surface protection carbon steels should not be
considered, particularly against that of chemical elements because such attacking corrosion
occurs so quickly.
In conclusion as subsea operations seek oil and gas resources in increasingly harsh
environments accompanied with the extended lifespan of oil and gas field the need for a more
efficient material is sought. This requirement is regularly met by the use of exotic materials
such as Inconel, stainless steels and various other alloys. The high strength, toughness and
corrosion resistance is achieved in exotic materials through alloying, a process where various
properties are combined. It was noted that if cost was not an implication that materials such
as carbon steel would rarely be used given the enhanced values achievable from exotic
materials. More basic metals such as carbon steel cant rival such values given the
amalgamation of properties in alloys. Much like the increased strength characteristics exotic
materials also produce high resistive corrosion functions. Through the use of nickel and
chromium, resistance at higher temperatures and the corrosion rate is reduced. It was deemed
that in comparison, carbon steel unless applied with surface protection should not be
considered for similar applications because corrosion can attack the material in quick
succession. It was determined that the reasons for the use of exotic materials in the
fabrication of subsea equipment are because of the superior material properties that can be

achieved, regardless of cost. Despite the increase in the initial cost, improved overall purpose
of the material accompanied with high resistance to corrosion makes it the more desirable
material to use regarding maintenance, inspection and repair.

References
[1] Heidersbach, R., 2011. Metallurgy and Corrosion Control in Oil and Gas Production. [ebook] New Jersey: John Wiley & Sons, Inc. Available at: Google
Books<http://books.google.co.uk/books?
hl=en&lr=&id=XD8ynYRTQ8oC&oi=fnd&pg=PR13&dq=Subsea+corrosion+exotic&ots=m
3nVCm2olB&sig=3rU5GrrwiFPIj6zfmWGoeoQQd1g#v=onepage&q&f=false> [Accessed 5
November 2014]
[2] Special Metals, 2006. Inconel Alloy 625. [pdf] Special Metals Corporation. Available at: <
http://www.cablejoints.co.uk/upload/Inconel_625___Material_Metals_Specification.pdf>
[Accessed 7 November 2014]
[3] Oregon Institute of Technology, 2009. Corrosion Considerations When Designing with
Exotic Metals and Advanced Composites. [pdf] Oregon Institute of Technology. Available at:
<https://www.atimetals.com/news/corrosion-conference/Documents/CSC09pdfs/PAPER_4B2_STUART.pdf> [Accessed 7 November 2014]
[4] Norwegian Univeristy of Science and Technology, 2012. Pitting and Crevice Corrosion of
Stainless Steel under Offshore Conditions. [pdf] Norwegian Univeristy of Science and
Technology.
Available
at:
<
http://www.divaportal.org/smash/get/diva2:566900/FULLTEXT01.pdf> [Accessed 8 November 2014]
[5] Bruce, D, C. and David, S., 1995. Handbook of Corrosion Data. [e-book] United States
of
America:
ASM
international.
Available
at:
Google
Books
<http://books.google.co.uk/books?
id=KXwgAZJBWb0C&pg=PA2&lpg=PA2&dq=pure+metal+corrosion&source=bl&ots=Rg
GWBrFv_n&sig=YNdXSzxXnBaG5aUiU7WcYIpOvUg&hl=en&sa=X&ei=oBFhVP7ECrL
dsAT8k4CoAg&ved=0CDYQ6AEwAw#v=onepage&q=pure%20metal
%20corrosion&f=false> [Accessed 9 November 2014]