STRESS CORROSION

Introduction
Stress corrosion is the failure of metal due to the simultaneous influence of static tensile stresses and a corrosive environment and this is specific to a particular metal.

Stress corrosion cracking is cracking due to a process involving conjoint corrosion and straining of a metal due to residual or applied stressed.

Stress corrosion is generally evidenced as cracks giving an appearance of brittleness in a material which is otherwise has normal ductile properties. The cracks may follow intergranular paths which grow at relatively slow velocities. If the load is constant during the period of crack growth the cracks will eventually reach a critical size to result in material failure

STRESS CORROSION CRACKING MECHANISMS.

: specific chemical species adsorbs on the crack surface and lowers the fracture stress. : stress ruptures the passive film locally and sets up an active-passive cell. Newly formed passive film is ruptured again under stress and the cycle continues until failure.

STRESS CORROSION CRACKING MECHANISMS.

Pre-existing path such as grain boundaries where intermetallics and compounds are formed.

Hydrogen embrittlement is a major mechanism of SCC for steels and other alloys such as titanium. Hydrogen atoms diffuse to the crack tip and embrittle the metal.

GRAIN BOUNDARIES

STRESS CORROSION CRACKING

STRESS CORROSION CRACKING FACTORS

What causes stress corrosion cracking? Stress corrosion cracking results from the conjoint action of three components:

SOME COMBINATIONS OF ENVIRONMENT AND MATERIAL

KNOWN TO CAUSE STRESS CORROSION ARE LISTED BELOW:
Material
Al alloys Cu alloys Ni alloys Ti alloys Low strength ferritic steels

Environment known to cause stress corrosion

Moist air, Sea Water, Chloride, Bromide and iodide solutions Ammonia solutions and vapours, amines, moist SO2, solutions of acetates, citrates formates, tartrates, nitrites and sodium hydroxide. Hydroxide solutions and hydrofluoric acid vapour

Solutions of chlorides, bromides, and iodides, liquid N2O4, methanolic solutions and dry salts and elevated temperatures
Solutions of hydroxides, nitrates, carbonates, phosphates, molybdates, acetates, cyanides, and liquid ammonia

High Strength ferritic steels

Stainless Steels

Moist air, water, aqueous and organic solutions. Susceptibility increases with increasing stregnth of materials
Solutions of chlorides , fluorides, iodides, bromides, sulphates , Phosphates, nitrates and polythionic acids

Prevention

Remove or reduce stress - stress relief anneal, thicker sections. Change environment - add inhibitors. Change material - look at data to find better material.

Cathodic protection will avoid the problems but remember that hydrogen embrittlement is initiated by cathodic conditions.

FACTORS INFLUENCING CORROSION

Some factors which influence metal corrosion and the rate of corrosion are the:
a) b) c) d) e) f)

g)
h) i) j)

k)

Type of metal Heat treatment and grain direction. Presence of a dissimilar, less corrodible metal (galvanic corrosion) Anode and cathode surface areas (in galvanic corrosion) Temperature. Presence of electrolytes (hard water, salt water, battery fluids, etc.) Availability of oxygen. Presence of different concentrations of the same electrolyte. Presence of biological organisms. Mechanical stress on the corroding metal. Time of exposure to a corrosive environment.

Metals have a wide range of corrosion resistance. The most active metals (those which tend to lose electrons easily), such as magnesium and aluminum, corrode easily. The most noble metals (those which do not lose electrons easily), such as gold and silver, do not corrode easily. Corrosion is accelerated by higher temperature environments which accelerate chemical reactions and allow greater moisture content at saturation in air.

Electrolytes form on surfaces when condensation. The wet surfaces, increasing the electrical conductivity of the electrolyte, thereby increasing the rate of corrosion. When some of the electrolyte on a metal surface is partially confined (such as between faying surfaces or in a deep crevice), metal in this confined area corrodes more rapidly than other metal surfaces of the same part outside this area. This type of corrosion is called an oxygen concentration cell. Slimes, molds, fungi, and other living organisms (some microscopic) can grow on damp surfaces. Once they are established, the area tends to remain damp, increasing the possibility of corrosion. corrosion can decrease with time, due to the barrier formed by corrosion products, or increase with time if a barrier to corrosion is being broken down.