mechanism & prevention mechanism & prevention Prepared by Prepared by Vaneshwari vankar Vaneshwari vankar Roll no Roll no- -924 924 Department of metallurgy & materials Department of metallurgy & materials Faculty of techo & Engg., Faculty of techo & Engg., M.S.university M.S.university %#&% %#&% 5ttess cottosloo ctockloq (5cc) ls tbe ooexpecteJ 5ttess cottosloo ctockloq (5cc) ls tbe ooexpecteJ soJJeo follote of ootmolly Joctlle metols sobjecteJ to soJJeo follote of ootmolly Joctlle metols sobjecteJ to o teoslle sttess lo o cottoslve eovltoomeot ot elevoteJ o teoslle sttess lo o cottoslve eovltoomeot ot elevoteJ tempetotote lo tbe cose of metols tempetotote lo tbe cose of metols 1be cbemlcol eovltoomeot tbot cooses 5cc fot o qlveo 1be cbemlcol eovltoomeot tbot cooses 5cc fot o qlveo olloy ls ofteo ooe wblcb ls ooly mllJly cottoslve to tbe olloy ls ofteo ooe wblcb ls ooly mllJly cottoslve to tbe metol neoce metol potts wltb sevete 5cc coo oppeot metol neoce metol potts wltb sevete 5cc coo oppeot btlqbt ooJ sbloy wblle beloq fllleJ wltb mlctoscoplc btlqbt ooJ sbloy wblle beloq fllleJ wltb mlctoscoplc ctocks ctocks SCC ofLen progresses rapldly and ls more common SCC ofLen progresses rapldly and ls more common among alloys Lhan pure meLals among alloys Lhan pure meLals 1he speclflc envlronmenL ls of cruclal lmporLance and 1he speclflc envlronmenL ls of cruclal lmporLance and only very small concenLraLlons of cerLaln hlghly acLlve only very small concenLraLlons of cerLaln hlghly acLlve chemlcals are needed Lo produce caLasLrophlc cracklng chemlcals are needed Lo produce caLasLrophlc cracklng ofLen leadlng Lo devasLaLlng and unexpecLed fallure ofLen leadlng Lo devasLaLlng and unexpecLed fallure 1he sLresses can be resulL of Lhe crevlce loads due Lo 1he sLresses can be resulL of Lhe crevlce loads due Lo sLress concenLraLlon or can be caused by Lhe Lype of sLress concenLraLlon or can be caused by Lhe Lype of assembly or resldual sLresses from fabrlcaLlon Lhe assembly or resldual sLresses from fabrlcaLlon Lhe resldual sLresses can be relleved by anneallng resldual sLresses can be relleved by anneallng 1he lmporLanL varlables affecLlng SCC are LemperaLure 1he lmporLanL varlables affecLlng SCC are LemperaLure soluLlon composlLlon meLal composlLlon sLress and soluLlon composlLlon meLal composlLlon sLress and meLal sLrucLure meLal sLrucLure Two main cases of stress corrosion Two main cases of stress corrosion cracking cracking Season cracklng of Season cracklng of brass brass CausLlc CausLlc embrlLLlemenL of embrlLLlemenL of sLeel sLeel en does SCC occur? en does SCC occur? SLress corroslon cracklng occur ln envlronmenLs LhaL SLress corroslon cracklng occur ln envlronmenLs LhaL are merely mlldly corroslve Lo Lhe maLerlal And also are merely mlldly corroslve Lo Lhe maLerlal And also ln Lhe presence of sLress n suscepLlble maLerlal ln Lhe presence of sLress n suscepLlble maLerlal SCC depends on Lhe sLress lnLenslLy aL any pre SCC depends on Lhe sLress lnLenslLy aL any pre exlsLlng or developed crack Llp exlsLlng or developed crack Llp 1he concenLraLlon of sLress aL Lhe Llp of a sharp crack 1he concenLraLlon of sLress aL Lhe Llp of a sharp crack or flaw can be quanLlfled ln Lerms of Lhe SLress or flaw can be quanLlfled ln Lerms of Lhe SLress lnLenslLy lacLor kc lL deLermlnes Lhe growLh raLe of lnLenslLy lacLor kc lL deLermlnes Lhe growLh raLe of SCC cracks for a speclflc alloy envlronmenL SCC cracks for a speclflc alloy envlronmenL comblnaLlon comblnaLlon CaLasLrophlc fallure of a componenL wlll occur CaLasLrophlc fallure of a componenL wlll occur when Lhls facLor reaches a crlLlcal value Lhe when Lhls facLor reaches a crlLlcal value Lhe lracLure Loughness of Lhe maLerlal kc 1hls lracLure Loughness of Lhe maLerlal kc 1hls enables Lhe deLermlnaLlon of allowable defecL enables Lhe deLermlnaLlon of allowable defecL slze ln deslgn Lo avold fallure under glven slze ln deslgn Lo avold fallure under glven loadlng condlLlons loadlng condlLlons rowt rate of SCC cracks rowt rate of SCC cracks SLage 1below Lhreshold value of SLage 1below Lhreshold value of k1 growLh of crack ls noL k1 growLh of crack ls noL expecLed expecLed SLage 2 cracklng growLh raLe ls SLage 2 cracklng growLh raLe ls lndependenL of k1 and depends lndependenL of k1 and depends lnsLead on Lhe corroslve lnsLead on Lhe corroslve envlronmenL n Lemp envlronmenL n Lemp SLage 3ln above sLage growLh SLage 3ln above sLage growLh conLlnues Lo lncrease and leads conLlnues Lo lncrease and leads Lo rapld acceleraLlon of Lhe crack Lo rapld acceleraLlon of Lhe crack and flnal fracLure when k1 and flnal fracLure when k1 reaches k1c whlch ls fracLure reaches k1c whlch ls fracLure Loughness of maLerlal Loughness of maLerlal ecanism involves in stress ecanism involves in stress corrosion corrosion AcLlve paLh dlssoluLlon AcLlve paLh dlssoluLlon Pydrogen embrlLLlemenL Pydrogen embrlLLlemenL lllm lnduced cleavage lllm lnduced cleavage ctive pat dissolution ctive pat dissolution ,osL common acLlve paLh ls graln boundry ,osL common acLlve paLh ls graln boundry ConsequenLly a form of crevlce corroslon can occur whereby ConsequenLly a form of crevlce corroslon can occur whereby Lhe graln boundary corrodes wlLh Lhe speclmen surface and Lhe graln boundary corrodes wlLh Lhe speclmen surface and Lhe crack wall remalnlng passlve 1hls process can occur ln Lhe Lhe crack wall remalnlng passlve 1hls process can occur ln Lhe absence of sLress glvlng rlse Lo lnLergranular corroslon LhaL ls absence of sLress glvlng rlse Lo lnLergranular corroslon LhaL ls unlformly dlsLrlbuLed over Lhe speclmen 1he effecL of Lhe unlformly dlsLrlbuLed over Lhe speclmen 1he effecL of Lhe applled sLress ls probably malnly Lo open up cracks Lhereby applled sLress ls probably malnly Lo open up cracks Lhereby allowlng easler dlffuslon of corroslon producLs away from Lhe allowlng easler dlffuslon of corroslon producLs away from Lhe crack Llp and allowlng Lhe crack Llp Lo corrode fasLer crack Llp and allowlng Lhe crack Llp Lo corrode fasLer AcLlve paLh corroslon processes are lnherenLly llmlLed by Lhe AcLlve paLh corroslon processes are lnherenLly llmlLed by Lhe raLe of corroslon of Lhe meLal aL Lhe crack Llp whlch llmlLs Lhe raLe of corroslon of Lhe meLal aL Lhe crack Llp whlch llmlLs Lhe maxlmum crack growLh raLe Lo around 10 maxlmum crack growLh raLe Lo around 10 2mm/s and crack 2mm/s and crack growLh raLes are ofLen much lower down Lo around 10 growLh raLes are ofLen much lower down Lo around 10 8 8 mm/s or less mm/s or less drogen embrittlement drogen embrittlement Pydrogen dlssolves ln all meLals Lo a moderaLe exLenL lL ls Pydrogen dlssolves ln all meLals Lo a moderaLe exLenL lL ls very small aLom and flLs ln beLween Lhe meLal aLoms ln Lhe very small aLom and flLs ln beLween Lhe meLal aLoms ln Lhe crysLals of Lhe meLal crysLals of Lhe meLal 1he dlffuslon coefflclenL for hydrogen ln ferrlLlc sLeel aL room 1he dlffuslon coefflclenL for hydrogen ln ferrlLlc sLeel aL room LemperaLure ls slmllar Lo dlffuslon coefflclenL for salL ln waLer LemperaLure ls slmllar Lo dlffuslon coefflclenL for salL ln waLer Pydrogen Lends Lo be aLLracLed Lo reglons of hlgh Lrlaxlal Pydrogen Lends Lo be aLLracLed Lo reglons of hlgh Lrlaxlal Lenslle sLress 1hus lL ls drawn Lo Lhe reglons ahead of cracks Lenslle sLress 1hus lL ls drawn Lo Lhe reglons ahead of cracks or noLches LhaL are under sLress 1he dlssolved hydrogen Lhen or noLches LhaL are under sLress 1he dlssolved hydrogen Lhen asslsLs ln Lhe fracLure of Lhe meLal posslbly by maklng asslsLs ln Lhe fracLure of Lhe meLal posslbly by maklng cleavage easler or posslbly by asslsLlng ln Lhe developmenL of cleavage easler or posslbly by asslsLlng ln Lhe developmenL of lnLense local plasLlc deformaLlon 1hese effecLs lead Lo lnLense local plasLlc deformaLlon 1hese effecLs lead Lo embrlLLlemenL of Lhe meLal Cracklng may be elLher lnLer or embrlLLlemenL of Lhe meLal Cracklng may be elLher lnLer or Lransgranular Crack growLh raLes are Lyplcally relaLlvely rapld Lransgranular Crack growLh raLes are Lyplcally relaLlvely rapld up Lo 1 mm/s up Lo 1 mm/s ilm induced cleavage ilm induced cleavage lf a normally ducLlle maLerlal ls coaLed wlLh a brlLLle lf a normally ducLlle maLerlal ls coaLed wlLh a brlLLle fllm Lhen a crack lnlLlaLed ln LhaL fllm can propagaLe fllm Lhen a crack lnlLlaLed ln LhaL fllm can propagaLe lnLo Lhe ducLlle maLerlal for a small dlsLance before lnLo Lhe ducLlle maLerlal for a small dlsLance before belng arresLed by ducLlle blunLlng lf Lhe brlLLle fllm belng arresLed by ducLlle blunLlng lf Lhe brlLLle fllm has been formed by a corroslon process Lhen lL can has been formed by a corroslon process Lhen lL can reform on Lhe blunLed crack Llp and Lhe process can reform on Lhe blunLed crack Llp and Lhe process can be repeaLed 1he brlLLle fllms LhaL are besL be repeaLed 1he brlLLle fllms LhaL are besL esLabllshed as causlng fllm esLabllshed as causlng fllm lnduced cleavage are de lnduced cleavage are de alloyed layers 1he fllm lnduced cleavage process alloyed layers 1he fllm lnduced cleavage process would normally be expecLed Lo glve a Lransgranular would normally be expecLed Lo glve a Lransgranular fracLure fracLure Classification of mecanism Classification of mecanism ,eLallurglcal mechanlsm ,eLallurglcal mechanlsm lslocotloo coploootlty lslocotloo coploootlty 5ttess oqloq ooJ mlctoseqteqotloo AJsotptloo 5ttess oqloq ooJ mlctoseqteqotloo AJsotptloo lssoluLlon mechanlsm lssoluLlon mechanlsm 5ttess occeletoteJ 5ttess occeletoteJ Jlssolotloo lllm fotmotloo ot ctockloq woll Jlssolotloo lllm fotmotloo ot ctockloq woll Nobel Nobel elemeot eotlcbmeot elemeot eotlcbmeot Pydrogen mechanlsm Pydrogen mechanlsmnyJtlJe fotmotloo nyJtlJe fotmotloo nyJtoqeo nyJtoqeo embtlttlemeot embtlttlemeot ,echanlcal mechanlsm ,echanlcal mechanlsm 1oooel llttloq ooJ 1eotloq 1oooel llttloq ooJ 1eotloq cottosloo ptoJoct weJqloq cottosloo ptoJoct weJqloq etods of prevention etods of prevention owetloq tbe sttess owetloq tbe sttess below Lhe Lhreshold value lf below Lhe Lhreshold value lf one exlsLs one exlsLs llmlootloq tbe ctltlcol eovltoomeot specles llmlootloq tbe ctltlcol eovltoomeot specles cbooqloq tbe olloy cbooqloq tbe olloy ls one posslble recourse lf ls one posslble recourse lf nelLher Lhe envlronmenL nor sLress can be nelLher Lhe envlronmenL nor sLress can be changed changed Applyloq cotboJlc ptotectloo Applyloq cotboJlc ptotectloo Lo Lhe sLrucLure wlLh Lo Lhe sLrucLure wlLh an exLernal power supply or consumable anodes an exLernal power supply or consumable anodes AJJloq loblbltots AJJloq loblbltots Lo Lhe sysLem lf feaslble Lo Lhe sysLem lf feaslble cootloqs cootloqs are someLlmes used and Lhey depend on are someLlmes used and Lhey depend on keeplng Lhe envlronmenL away from Lhe meLal keeplng Lhe envlronmenL away from Lhe meLal