Stress Corrosion Cracking Crack Research Articles

Nano-micrometer scale characterization of PWSCC crack tips in the transition zone of 52M overlay and the implication to intergranular cracking

This study examines the microstructural characteristics of the primary water stress corrosion cracking (PWSCC) crack tip in the transition zone (TZ) of the 52 M overlay and its implications for intergranular cracking. In the TZ, the Cr content at grain boundaries near the fusion boundary (FB) is lower than those farther from the FB. Additionally, residual strain at grain boundaries near the FB is higher than that farther away, with the fine-grained zone around the FB showing higher local deformation than the surrounding columnar grains. Stress corrosion cracking (SCC) crack growth rate (CGR) test results indicate that the TZ showed certain SCC sensitivity, and the closer to the FB, the lower the SCC resistance. Analysis of the SCC crack tip found that the distinctive composition distribution of the 52 M overlay TZ, characterized by low Cr and high Fe near the FB, is prone to intergranular oxidation, thereby reducing SCC resistance. Conversely, higher Cr and lower Fe content at grain boundaries in the TZ farther from the FB form dense, Cr-rich oxides ahead of the crack tip that slow SCC crack growth, resulting in the diffusion of oxidation along the dislocation structure into the grains and forming a fibrous oxidation zone.

Ameliorating dilution of Cr and Ni and improving PWSCC resistance of 52 M overlay by hot wire plasma arc cladding

The multi-scale chemical composition distribution and microstructure of Alloy 52 M overlay on low alloy steel by hot wire plasma arc cladding (HWPC) were characterized. Stress corrosion cracking (SCC) growth rates were quantified in the dilution zone (DZ) near the fusion boundary and in the bulk of Alloy 52 M using compact tension samples with a thickened cladding overlay. The DZ of the Alloy 52 M side exhibited a single macroscopic dilution zone containing approximately 27–28 wt% Cr and 50 wt% Ni, in contrast to the multiple dilution zones observed in the DZ of Alloy 52 M overlays or joints prepared using other welding technologies such as submerged arc welding (SMAW). The DZ of the HWPC overlay exhibited less dilution of Cr and Ni compared to SMAW weldment. This resulted in a shorter average SCC band and fewer local intergranular cracks in the DZ of HWPC, as observed from SCC crack growth rate specimens tested in simulated PWR primary water at 325 °C and 350 °C. These findings highlight the advantages of utilizing HWPC to enhance SCC resistance in the DZ of Alloy 52 M overlays over conventional cladding technologies.

The effect of inhomogeneous microstructures on strength and stress corrosion cracking of 7085 aluminum alloy thick plate

Inhomogeneous microstructures and alloy chemistry along the thickness direction can greatly affect the mechanical and corrosion properties of new generation 7xxx aluminum alloy thick plates. The inhomogeneous microstructure, stress corrosion cracking (SCC) resistance and strength of AA7085 thick plate (160 mm) at T/2, T/4, and surface position using mechanical tests, double cantilever beam (DCB) crack extension tests and electron microscopy experiments. The results show that the ultimate tensile strength, yield strength and elongation of the T/2 position are slightly lower than those of the surface position, but the SCC resistance of the T/2 position is significantly higher than that of the surface position. The reason is that larger discontinuously quench-induced grain boundary precipitates (Q-GBPs), and lower Zn and Mg elemental content of GBPs (including Q-GBPs and age-induced GBPs (A-GBPs)) and grain boundaries (GBs). Furthermore, it is newly found that the mechanical effects of larger-sized low aspect ratio unrecrystallized grains contribute significantly to the excellent SCC resistance of the T/2 position. The large size grain structure makes short-range SCC cracks along the large-angle GB more tortuous at T/2, improving the stress intensity required for sustained crack extension. In addition, the high GB triple junction deflection angle resulting from a low aspect ratio grain structure at T/2 improves the average driving force required for crack extension and drive force reduction after localized crack growth.

Inhibiting stress corrosion cracking of a prefabricated surface‐defective magnesium alloy thanks to biological organic components

AbstractBiomedical magnesium (Mg) alloys remain a challenge for their mainstream application, because the combination of bio‐mechanical stress and corrosive physiological environment leading to stress corrosion cracking (SCC). It is crucial to avoid the sudden brittle fracture of Mg alloys in vivo for predicting their service duration. However, the key factors, such as surface or physiological environment features, determining the origination or propagation of SCC behavior are still unclear. In the present study, a prefabricated surface defects coating was prepared by the phytic acid (PA, C6H18O24P6) conversion treatment. Four mimicking physiological media were used, ranging from simple to equivalent (Dulbecco's Modified Eagle Medium and Protein [DMEM+Pro]). The results showed that the PA film with numerous micro‐cracks provided limited protective ability in synthetic biological media. A striking finding was determined that although initial high corrosion rate of samples in DMEM+Pro led to an increased SCC nucleation, significant ductile fracture with elongation to failure (14.86%) was observed. Combined with the fracture features, the adsorption or deposition of biological composition into the tunnel of SCC cracks significantly inhibited the hydrogen embrittlement (HE) behavior. These results indicate that preventing the propagation of SCC crack by biological composition, rather than nucleation, plays a key role in avoiding the sudden fracture of Mg alloys. It provides a novel perspective to determine the non‐brittle fracture of Mg alloys for biomedical applications.

Influences of microstructures and macrozones on the stress corrosion cracking sensitivity of a near alpha titanium alloy

In this study, we investigated stress corrosion cracking (SCC) behaviors in a near alpha titanium alloy (Ti-6Al-3Nb-2Zr-1Mo) with distinct microstructures and microtextures. By analyzing fracture surfaces, crack growth paths, and grain orientations, we found that the SCC crack growth rate increased with an increase in the volume fraction of the primary αp phase, due to elevated crack initiation density and concentrated grain orientations. Additionally, SCC cracks exhibited a preference for propagating along boundaries between neighboring soft macrozones (easy for slip) and hard macrozones (relatively hard for slip), as well as through macrozones favorable for slip.

Effect of the triangular prism dent on stress corrosion cracking behavior of alloy 690TT heat transfer tube in a lead-containing alkaline solution

In this paper, the microstructural changes and mechanical characteristics of alloy 690TT heat transfer tube with a triangular prism dent are investigated by combining experimental and simulation methods, and subsequently examines their influence on stress corrosion cracking (SCC) behavior. The results indicate that the deformation mechanism caused by impact dent is slip and twinning. The structural transformation of high-density dislocations, as well as Copper and Brass deformation textures, are formed at dent bottom, resulting in stress concentration through work hardening, which greatly increases SCC sensitivity. Oxidation preferentially occurs along grain boundaries and dislocations, and the corrosion products are formed, which exhibit a semi-coherent orientation relationship with the matrix. Oxidation is essentially a de-alloying process in which oxygen diffuses inward and Cr migrates towards the oxidation zone. The wedge force generated by corrosion products provides another driving force for initiation and propagation of SCC cracks, in addition to external loads and residual stress. SCC cracks propagate in the form of intergranular stress corrosion cracking and transgranular stress corrosion cracking in a high temperature lead-containing alkaline solution.

Prediction of stress corrosion crack growth rate of cold worked stainless steels in BWR conditions by the slip oxidation model

Stress corrosion cracking (SCC) is a critical issue for boiling water reactor (BWR) components, and their cold working is considered to be an accelerating factor for SCC crack growth rates (CGRs). However, no method has been proposed to quantitatively evaluate the SCC CGRs of cold worked stainless steels. In this study, the changes in material properties due to cold working were reflected in the input parameters of the Hashimoto-Koshiishi model, a mechanistic model of SCC growth based on the slip oxidation mechanism, to enable a quantitative evaluation of the SCC crack growth rate (CGR) of cold worked SSs. In addition, a simplified equation as a function of the yield strength of cold worked 316LSSs was developed for ease of practical use in the integrity assessment of components. The CGRs calculated by the model and/or the simplified equation were in good agreement with the experimentally obtained CGRs for cold worked SSs and the heat affected zone (HAZ) of Type 316L SSs.

Effect of surface hemispherical dent depth on the microstructure evolution and stress corrosion cracking of heat transfer tubes in steam generator

The deformation mechanism and SCC behavior of alloy 690TT with dents are investigated. Dents lead to stress concentration and microstructure changes, increasing stress corrosion cracking (SCC) sensitivity. The deformation mechanism at dents is slip and twinning. The dent shoulder zone experiences oxidation due to the residual tensile stress, whereas the dent bottom zone induces SCC due to the stress concentration, exhibiting a symmetrical distribution of “splayed character”. There is a critical threshold exists for dent depth that induces SCC, and the length of SCC cracks is positively correlated with dent depth in a power function.

Effect of material chemical composition on oxidation and stress corrosion cracking of the submerged arc welding Alloy 52M overlay in a simulated PWR primary water

Compact tension (CT) specimens from submerged arc welding Alloy 52 M overlay are used to determine the stress corrosion cracking (SCC) resistance of the dilution zones and bulk overlay metal on the 52 M side in a simulated pressurized water reactor (PWR) primary water. SEM-EDS and X-ray fluorescence spectroscopy (XRF) results show three dilution zones (DZs) on the 52 M side. Oxidation test results show that the thickness of the compact oxide layer and maximum local oxidation penetration depth decrease for 1st DZ, 2nd DZ, and bulk 52 M, which are consistent with the average SCC growth rate and the number of local intergranular SCC cracks in these regions. The dilution zones with low Cr but high Fe content possess lower oxidation and SCC resistance than the bulk 52 M.

Analysis of Crack Propagation Behaviors in RPV Dissimilar Metal Welded Joints Affected by Residual Stress.

In severe service environments, the presence of high local residual stress, significant organizational gradient, and nonlinear changes in material properties often leads to stress corrosion cracking (SCC) in dissimilar metal welded (DMW) joints. To accurately predict the crack growth rate, researching the initiation and propagation behavior of SCC cracks in DMW joints under residual stress (RS) is one of the most important methods to ensure the safe operation of nuclear power plants. Using the extended finite element method (XFEM), the crack propagation behaviors in DMW joints under different RS states are predicted and compared. The effects of RS, crack location, and initial crack length on crack propagation behavior are investigated. The crack in a DMW joint without RS deflects to the material of low yield strength. High residual stress urges the crack growing direction to deflect toward the material of high yield strength. Young's modulus has little impact on the crack deflection paths. The distance between the specimen symmetric line and the boundary line has little effect on the crack initiation and propagation within the RS field. A long initial crack is more likely to initiate and propagate than a short crack. To a long crack and the crack that is far from the interface of two materials, the impact of residual stress on the crack propagation path is significant when it is located in a material with high yield strength, while when the initial crack is located in the material with low yield strength, RS has a great influence on the deflection of a short crack growth direction on the condition that the crack is adjacent to the interface.

Study on the wear resistance and corrosion behaviour of self-sealed MAO/ZrO2 coatings prepared on 7075 aluminium alloy

Self-sealed microarc oxidation (MAO) coatings were prepared on 7075 aluminium alloy by incorporating different concentrations of ZrO2 particles. The wear resistance and corrosion behaviour of MAO- and MAO/ZrO2-coated alloys were investigated. The results show that the tribological behaviour of the coatings was controlled by an abrasive mechanism. The coefficient of friction (COF) for the MAO/ZrO2-coated samples decreased to 0.82, indicating that the wear resistance was significantly improved due to the incorporation of hard ZrO2 particles and the enhanced compactness and surface roughness of the coatings. The sealed pores effectively prevented the permeation of the corrosion solution, thus increasing the electrochemical corrosion resistance. Pores and microcracks would be enlarged and preferentially fractured during slow strain rate testing (SSRT) and thus were the initial sites for corrosion pitting and SCC crack propagation. The interlocking mechanism between the pores (microcracks) and ZrO2 particles enhanced the strength of the pores (microcracks); therefore, the stress corrosion cracking (SCC) susceptibility of the MAO/ZrO2-coated samples was also reduced. Moreover, the MAO/ZrO2 coatings formed with the addition of 4 g/L ZrO2 particles had the best corrosion resistance, and the SCC susceptibility was reduced by 8.1% compared with that of the Al matrix.

Insights into the stress corrosion cracking propagation behavior of Alloy 690 and 316 L stainless steel in KOH versus LiOH oxygenated water

The stress corrosion cracking (SCC) propagation behavior of 20% cold worked 316 L stainless steel (SS) and Alloy 690 was investigated in high-temperature oxygenated water. No discernable effect was observed at the same pH level for LiOH or KOH. Increasing pH could dramatically enhance the crack growth rates (CGRs) due to the dissolution of Cr-rich oxide film and the weakening of passivity in high pH regimes. The similarities in SCC behavior and cracking characteristics indicate that the cracking mechanism of both austenite alloys occurs by a slip-dissolution model.

Effect of Anodic Polarization on the Susceptibility of AA6111 Automotive Sheet to Stress Corrosion Cracking

AA6xxx Al-Mg-Si-Cu alloys are increasingly used to meet lightweight objectives in automotive applications given their high strength-to-weight ratio. However, their use in conjunction with steels and carbon fiber-reinforced polymers in these applications will result in galvanic coupling that may be deleterious to the Al alloy. As such, the ability of anodic polarization to induce stress corrosion cracking (SCC) in AA6xxx, an alloy typically considered SCC-resistant, is explored. In this study, fracture mechanics-based testing under full immersion in 0.6 M NaCl was used to quantify the threshold stress intensity above which SCC can occur (KTH) and stage II SCC crack growth rate (da/dtII) as a function of applied potential at and above the freely corroding potential. Under freely corroding conditions and potentials applied within the range observed for the freely corroding potential, no SCC was observed as results matched those gathered in the air (i.e., KTH was equivalent to the measured fracture toughness). When applying potentials anodic to the freely corroding potential (greater than −706 mVSCE), a decrease in KTH and an increase in da/dtII was observed. Crack growth rates measured under anodic polarizations were slowed through the reapplication of the freely corroding potential. These data imply that galvanic coupling may have the capacity to induce severe SCC in AA6111.

Stress-corrosion cracking of polypropylene in harsh oxidizing environments

Thermoplastic pipes are widely used in the semiconductor industry, where they are used to drain highly corrosive liquid waste. When exposed to oxidizing environments, thermoplastic pipes can undergo stress-corrosion cracking (SCC), potentially causing them to fail prematurely in the absence of appropriate design and maintenance guidelines. Here, the stress-corrosion cracking behavior of polypropylene, commonly used in waste drainage pipes for dilute sulfuric acid/hydrogen peroxide mixtures (Piranha solutions), is investigated as a function of applied energy release rate. Sub-critical crack growth experiments are performed with compact tension specimens in sulfuric acid/hydrogen peroxide mixtures using a custom constant-force loading system to evaluate the effects of temperature and chemical composition on SCC crack growth. The activation energy for the SCC process is 99.7 ± 15.3 kJ/mol, and the crack growth rate depends sensitively on the concentrations of sulfuric acid and hydrogen peroxide in the mixture. We propose a practical guideline to calculate the service life of polypropylene pipes in Piranha solutions using crack velocity curves and show that accidental exposure to a concentrated Piranha solution can significantly reduce service life.

Correlation between machining-induced surface alterations and stress corrosion cracking susceptibility of au stenitic stainless steels

Correlation between machined surface alterations and stress corrosion cracking (SCC) susceptibility of austenitic stainless steels is investigated. The machining-induced residual stress, roughness, micro-hardness and dislocation density were characterized and the surface/subsurface cracks were examined after SCC tests in boiling magnesium chloride solution. The results showed SCC crack initiation and early propagation were highly related to the machining-induced alterations. By establishing a quantitative relationship between the surface characteristics and surface crack density, the comprehensive impact of the residual stress, surface roughness as well as the dislocation density on SCC susceptibility is revealed. The predicted crack density is in good agreement with the measured data. As a result, the SCC susceptibility of the machined surface is described by the surface integrity properties.

X80 U-bend stress corrosion cracking (SCC) crack tip dissolution by fast corroding Desulfovibrio ferrophilus IS5 biofilm

Stress corrosion cracking (SCC) is a serious problem threatening structural integrity and safety. Metal corrosion pits can develop into more harmful cracks under mechanical stress. It is known in abiotic corrosion that fast corrosion does not necessarily cause more severe SCC. This is because fast corrosion can prevent or dissolve crack tips and convert them into less harmful pits if the uniform corrosion rate is fast enough. This work experimentally proved the hypothesis that the same phenomenon occurs in biotic corrosion. It was found that a highly corrosive SRB (sulfate reducing bacterium) strain, namely Desulfovibrio ferrophilus (strain IS5), caused fast uniform corrosion and dull pits, but no SCC cracks against X80 carbon steel U-bend coupons (stressed). In comparison, Desulfovibrio vulgaris, a far less corrosive SRB strain caused less corrosion, but generated sharp pits and SCC cracks in a 3-month lab test. This work also revealed that the X80 U-bend had a 44% higher sessile cell count and 34% higher weight loss after a 14-d D. ferrophilus incubation in deoxygenated enriched artificial seawater culture medium at 28 °C when compared with the (flat) square coupons (no stress). This weight loss trend was corroborated by transient electrochemical measurements.

Stress corrosion cracking under extreme near-neutral GCC conditions, parametric and comparative study using phase field modeling

Stress Corrosion Cracking (SCC) is a failure mechanism that occurs when certain materials are subjected to both external or residual stresses and corrosion. This combined effect leads to the development of cracks in the susceptible materials. Submerged steel pipelines in the petroleum sector are built of low-alloy steels having a ferrite-cementite composition, including API 5L X70. Such materials are sensitive to SCC damage in aqueous systems. The film rupture dissolution repassivation (FRDR) process is used in this study to evaluate the cracks and pits growth in oil and gas pipelines in the Gulf area under diverse SCC environmental conditions. The SCC crack propagation and pit growth under near-neutral environmental conditions were analyzed using phase field modelling. X70 steel under NS4 the solution was used for the analysis to represent the anodic dissolution film rupture mechanism. A parametric study was done to study the impact of different electrochemistry and phase field parameters on crack growth behaviour. The study assess the susceptibility to SCC caused by an pit by employing diverse settings to evaluate the impact of corrosion parameters and the interaction among the FRDR mechanism. The corrosion rates are influenced by the interface kinetics coefficient (L), which exhibits an accelerated effect as L increases. This transition from fracture-controlled to dissolution-controlled SCC growth occurs until the system reaches the diffusion limit, beyond which further increases in L do not significantly impact corrosion rates. Moreover, higher values of the kinetic coefficient (k) advance the creation of SCC cracks at the crack front, resulting from corrosion originating from pitting at the crack mouth. This process leads to the refinement of the pit and its transformation into a crack. A comparison analysis was utilized to validate our simulation under a near-neutral NS4 solution for X70 steel by correlating the findings with other numerical methods for crack growth utilizing the same material and environmental parameters. The results show decent agreement with the comparative study.

Analysis of Longitudinal Cracks of Casing in Heavy Oil Thermal Recovery Well

This paper investigates cracking failure of the casing tube. There were longitudinal cracks in the heavy oil thermal recovery well occurred in an oil field. The fracture cause of casing was analyzed by macrographic observation, chemical composition analysis, mechanical property test, metallographic analysis, scanning electron microscope (SEM) and residual stress calculation. The results showed that the crack of the failed casing originates from the external surface of the pipe and has the characteristic of intergranular propagation. The fracture characteristics are brittle fracture. The conclusion showed that stress corrosion cracking(SCC) is the main cause of longitudinal crack of casing in the heavy oil thermal recovery well. Under the combined action of external corrosive media and internal stress, SCC cracks are generated on the surface of casing, and the cracks propagate along grain boundaries and finally lead to cracking and failure of casing. Some recommendations were proposed to avoid similar failures.

Effects of Multi-Pass Turning on Stress Corrosion Cracking of AISI 304 Austenitic Stainless Steel

Austenitic stainless steels are extensively used in mechanical engineering. The machined surface integrity has an essential influence on the stress corrosion cracking (SCC) performance of stainless steels. In this paper, the effects of multi-pass turning on the SCC susceptibility of AISI 304 austenitic stainless steel were investigated by correlating the SCC crack density to the machining-induced surface characteristics in terms of roughness, micro-hardness, and residual stress. In the multi-pass turning, the surface roughness and residual stress were the least after the double pass turning, and the surface micro-hardness was the maximum after the triple-pass turning. The SCC susceptibility was evaluated after SCC tests in boiling MgCl2 solution. The results showed that the weakest SCC sensitivity was observed in double-pass turning 304 stainless steel, while the most susceptible SCC was found in triple-pass turning. Compared with the double-pass turning, the increase in SCC sensitivity of triple-pass turning was attributed to the larger roughness, higher micro-hardness and greater residual tensile stresses.

Synchronous improvement of mechanical properties and stress corrosion resistance by stress-aging coupled with natural aging pre-treatment in an Al-Zn-Mg alloy with high recrystallization fraction

Enhancing the strength of Al-Zn-Mg alloys is critical to the weight-lightening of structural components in the application of high-speed trains and aerospace industries, while high stress corrosion cracking (SCC) susceptibility of Al-Zn-Mg alloys (especially the alloy with high recrystallization fraction) with high strength makes it difficult. In this study, the influence of tensile stress-aging coupled with natural aging pre-treatment on the mechanical properties and SCC resistance of Al-Zn-Mg alloy with high recrystallization fraction has been investigated. The results show that tensile stress-aging at 160 ℃ can inhibit the dissolution of clusters/Guinier-Preston (GP) zones formed during long-term natural aging pre-treatment, which increases the number density of matrix precipitates (MPts), narrow the width of precipitate free zone (PFZ), and dramatically improve the mechanical properties of the experimental Al-Zn-Mg alloy. Meanwhile, the precipitation of the high density of MPts within the matrix will assume a large number of solute atoms during artificial aging, which will reduce the supplement of solute atoms to grain boundaries. As a result, the volume of anodic active grain boundary precipitates (GBPs) and the content of free solute atoms at grain boundaries are reduced, which reduces the possibility of initial nucleation and propagation of SCC crack. The coupled treatment method proposed in this study proves efficient in resolving the contradiction between the strength and SCC resistance in Al-Zn-Mg alloy.