Stress Corrosion Research Articles

STUDY OF THE EFFECT OF HEAT TREATMENT ON THE RESISTANCE OF 20GL STEEL TO SSCC

In the modern world much attention is paid to the problems of oil and gas industry. In the process of operation of oil production equipment, the material from which it is made, is in direct contact with the environment containing corrosive-active substances (including H2S), the impact of which leads to the loss of mechanical properties of the material and often its destruction. The observed trend of increasing number of failures of equipment used in oil production aggravates the problem of corrosion testing by the mechanism of sulfide stress corrosion cracking (SSCC). Analysis of the current literature has shown that the damage and subsequent costs of eliminating the consequences of equipment failures amount to about 5 % of the GDP of the Russian Federation. Oil companies operating in the Russian Federation are interested in reducing the above mentioned costs, in this connection it becomes relevant to conduct a study of corrosion resistance of steels in H2S-containing medium and reveal the rate of corrosion damage of the material depending on the concentration of H2S in the reaction solution and the pH-value of the medium, as well as the influence of heat treatment modes of steels on the course of this process. The purpose of this scientific work is to study the effect of different heat treatment modes on the stress corrosion resistance of 20GL steel in reactive H2S-containing media. The methods of evaluating the material resistance to corrosion-active H2S-containing medium were chosen as the methods of evaluating the degradation of plastic properties of steel. The paper presents the results of laboratory corrosion tests of samples from 20GL steel. In order to analyze the resistance of this steel to corrosion damage, the samples after different heat treatment regimes were subjected to SSCC-A tests, while during the experiments the concentration of hydrogen sulfide in the reaction medium was varied in combination with the acidity index. The obtained experimental results showed that all the samples in the course of the tests show resistance to SSCC, however, it should be noted that increasing the concentration of H2S in the reaction medium up to 2800±200 mg/l has no effect on the change in the relative elongation from pH-medium, while the decrease in the concentration of H2S to the value of 300±100 mg/l leads to a change in elongation from pH on all tested samples. The greatest influence in this case is exerted by the heat treatment mode and based on the results obtained, in view of economic efficiency, normalization can be considered as the optimal mode.

Morphological evolution and mechanical property degradation of Q355NH weathering steel and Q355 steel under stress corrosion

Morphological evolution and mechanical property degradation of Q355NH weathering steel and Q355 steel under stress corrosion

Determining the controlling factor of the stress corrosion cracking of 2024 aluminum alloy with different heat treatments in thin electrolyte layer environment

Determining the controlling factor of the stress corrosion cracking of 2024 aluminum alloy with different heat treatments in thin electrolyte layer environment

Dynamic behavior of duplex stainless steel with improved chloride-induced stress corrosion cracking resistance in drop scenarios for dry storage containers

Dynamic behavior of duplex stainless steel with improved chloride-induced stress corrosion cracking resistance in drop scenarios for dry storage containers

Bridging static corrosion behavior and stress corrosion cracking susceptibility in dilute Mg-Zn-Ca alloys

Bridging static corrosion behavior and stress corrosion cracking susceptibility in dilute Mg-Zn-Ca alloys

Effect of vanadium on stress corrosion cracking for high-strength railway steel in simulated SO2-polluted environment

Effect of vanadium on stress corrosion cracking for high-strength railway steel in simulated SO2-polluted environment

Stress corrosion cracking behavior of T91 steel in low oxygen concentration liquid lead-bismuth eutectic at 450°C

Stress corrosion cracking behavior of T91 steel in low oxygen concentration liquid lead-bismuth eutectic at 450°C

General corrosion and stress corrosion cracking behaviors of Alloy 825 in high-temperature supercritical water

General corrosion and stress corrosion cracking behaviors of Alloy 825 in high-temperature supercritical water

The relationship between microstructural characteristics and galvanic effect, SCC behavior of friction stir welded joint in as-welded and heat-treated conditions

The relationship between microstructural characteristics and galvanic effect, SCC behavior of friction stir welded joint in as-welded and heat-treated conditions

Анализ на аварията на мост с предварително напрегната стоманобетонна конструкция

The analysis of the causes of damages or accidents in structures is essential and directly related to the development of the regulations and the improvement of construction and design practices. This paper presents the possible causes of the failure of a prestressed concrete bridge. The analysis is based on a literature review of the information available to the author. The focus is on the phenomenon associated with the development of cracks in certain types of prestressing steels mainly used between 1960 and 1980 – stress corrosion cracking (SCC). The main goal is to highlight the importance of maintenance and the assessment of the condition of existing bridges. Additionally, the potential for applying innovative methods for the inspection of prestressed structures, similar to the studied bridge, is discussed.

Stress Corrosion Cracking of Aluminum in Chloride-Containing Solution

This study investigates the stress corrosion cracking (SCC) behavior of Aluminum in chloride solutions, focusing on varying bending angles (0°, 90°, and 180°), temperatures (25°C, 35°C, and 45°C), and NaCl concentrations (1%, 2%, and 3.5%). Bending tests using a universal testing machine and corrosion tests employing the open circuit potential (OCP) method and anodic polarization Tafel method were conducted. Results revealed that the highest balanced potential (-0.33684 V) occurred at a 0° bend angle in distilled water, while the lowest (-1.02513 V) was at a 180° bend angle in 3.5 wt% NaCl solution. The lowest corrosion rate (0.002403953 mmpy) was observed at a 0° bend angle in distilled water at 25°C, and the highest (2.18789227 mmpy) at a 180° bend angle in 3.5 wt% NaCl solution at 45°C. Surface characterization indicated significant pitting corrosion in NaCl solutions, particularly at a 180° bend angle, while no pitting was seen in distilled water. These findings highlight the substantial impact of bending angle and chloride concentration on the SCC behavior of Aluminum, providing valuable insights for its application in corrosive environments.

Effect of the Grain Boundary Microstructure on SCC Resistance of High Strength Al-Zn-Mg Alloy Extruded Materials

It is known while Al-Zn-Mg alloys extruded materials have high strength, those materials are characteristically occurred to Stress Corrosion Cracking (SCC). Our group have systematically controlled Mg and Zn composition and clarified the relationship between strength and precipitates. The purpose of this study is to clarify the relationship between the mechanical properties and SCC resistance and the microstructure. Therefore, our group controlled the mechanical properties and SCC resistance by adjusting the chemical composition and the quenching conditions of our Al-Zn-Mg alloy extruded materials, and the following two findings were obtained by using SCC test, tensile test, and transmission electron microscope (TEM) observation. The number density of η' phase on Al-Zn-Mg alloy extruded materials affected the improvement of mechanical properties, and the precipitation free zone (PFZ), which is the grain boundary microstructure affected SCC resistance.

ANN-Based Prediction of Corrosion Behavior of Alloy 600: Implications for an Anti-Corrosion Coating Design in PWSCC Environments

The modeling of the corrosion rate of Alloy 600 in primary water stress corrosion cracking conditions (PWSCC) is a challenging task for existing as well as new structures due to the wide deviation of its composition across the worldwide PWSCC environment. The major parameters influencing the rate are temperature, stress intensity factor, pH, conductivity, ECP, Yield strength, B3(OH)3, and LiOH. The individual effects of these parameters on corrosion are known to some extent; however, the combined effect of these parameters together is complex, nonlinear, and unpredictable. Herein, we developed an Artificial Neural Network to predict the corrosion crack growth rate for any combination of the above five parameters and to better understand the effects of these parameters jointly on corrosion behavior. Three-dimensional mappings clearly reveal the complex interrelationship between the temperature and stress intensity factor at different variables, and the effect of the variables rather than a single variable on the corrosion rate of Inconel alloy 600 in PWSCC conditions. Moreover, the index of relative importance for these variables has also been presented providing deep insights for anti-corrosion coating designs in PWSCC environments.

Grain refinement and plasma electrolytic oxidation of a Mg–Zn–Zr–Ce alloy: a synergistic approach to enhancing mechanical properties and stress-corrosion cracking resistance

Grain refinement and plasma electrolytic oxidation of a Mg–Zn–Zr–Ce alloy: a synergistic approach to enhancing mechanical properties and stress-corrosion cracking resistance

Evaluating dealloying as a precursor to stress corrosion cracking: a micro-mechanical testing approach

Dealloying (selective dissolution) results in the formation of a (nano)porous film which has been proposed to act as a precursor to stress corrosion cracking (SCC) by a cleavage mechanism. The geometry of this film (e.g., ligament size and thickness) influences its ability to act as a precursor. This study investigates the micro-scale mechanical response of a dealloyed layer formed on Alloy 800 when exposed to boiling 50 wt% NaOH solution. Post-exposure in-SEM tensile and micro-cantilever bending tests were conducted on porous films of different geometries, formed after 2, 18 and 24 h of exposure. Results indicate that a porous dealloyed layer is more brittle compared to the base material and SCC can be induced, even with the corrosive environment removed. Increasing the time of exposure coarsened ligaments resulting in increased ductility of the porous film. In contrast, increasing the strain rate resulted in the porous film shifting towards brittle failure.

Session 27. Oral Presentation for: CarbonNet project: carbon capture and storage case study – subsea system design challenges and opportunities

Presented on 29 May 2025: Session 27 The CarbonNet project represents a pioneering and strategic intiative in the realm of carbon capture and storage (CCS) within the Gippsland region of Victoria, Australia. It is specifically designed to facilitate the state’s ambitious net zero emissions target by receiving carbon dioxide (CO2) emissions from industrial sources and securely store them in geological formations offshore. This paper presents an overview of CarbonNet’s development stages, focusing on its transition into a multi-user CCS hub. Key aspects include the project’s objectives, infrastructure, technical challenges, and innovative solutions. Initially conceptualised in 2009, CarbonNet has evolved through rigorous stages: concept and regional screening, feasibility and site selection, and in 2024, the project development and commercial establishment. The proposed pipeline network consists of an 80 km onshore pipeline and a 17 km offshore subsea pipeline, designed to transport CO2 to the Pelican Reservoir storage site, a saline reservoir under Bass Strait. Critical to the system’s design is adherence to Australian/New Zealand Standards AS/NZS 2885.1 for pipeline construction, ensuring durability and safety. During the front-end engineering design (FEED) phase, challenges were encountered, particularly in flow assurance and material selection. Steady-state and transient analyses were conducted to optimise pipeline sizing, assess operating conditions, and ensure integrity under varying scenarios. The project also addresses potential risks like stress corrosion cracking and hydrate formation, implementing rigorous testing and monitoring to mitigate these issues. The findings provide valuable insights into CO2 impurity levels, pipeline material resilience, and the integration of advanced technologies within CCS infrastructure. Ultimately, CarbonNet contributes to global efforts to reduce carbon emissions. To access the Oral Presentation click the link on the right. To read the full paper click here

Prediction of degradation in 90° elbow joints of ba35 brass used in potable water pipes through computational fluid dynamics (CFD) simulation

Failure of 90° elbows in water pipes due to corrosion is a critical issue in water supply and distribution systems. Therefore, understanding the behavior of pipelines under corrosion is essential to increase their durability. This original study aims to specifically analyze the failure of 90° elbows due to the erosion-corrosion phenomenon. The behavior of water flow, in terms of velocity profile, pressure gradient, and turbulence zones at these elbows, is numerically simulated using the computational fluid dynamics (CFD) method. The simulations, performed with FLUENT software, identify the areas most susceptible to erosion and corrosion, thus contributing to a better understanding of processes such as stress corrosion cracking and cavitation. This work also highlights the importance of designing elbows with suitable characteristics and adopting adequate maintenance practices to prevent failures. These results can serve as a basis for future experimental validations and for the design of more robust pipeline systems.

Revolutionizing Resilience: A Comprehensive Review of Technological, AI-Driven Innovations in Anchorage Zone Design and Maintenance

Anchorage zones, the critical junctures transferring immense prestressing forces in concrete and steel structures, remain persistent vulnerability hot spots. Susceptible to stress concentrations, corrosion propagation, and fatigue-induced degradation, their premature failure jeopardizes structural integrity despite conservative design codes and labor-intensive inspections. Traditional approaches often fail to capture the dynamic interplay of environmental stressors (chloride ingress, humidity fluctuations, thermal cycling) and evolving operational loads (increasing traffic volumes, extreme weather events). This review synthesizes groundbreaking advancements in artificial intelligence (AI) that are fundamentally transforming anchorage zone engineering, moving beyond static safety factors towards dynamic, predictive, and optimized management. We detail innovations including: high-accuracy convolutional neural networks (CNNs) achieving 92% crack detection in real-time; hybrid physics-informed neural networks (PINNs) slashing finite element analysis (FEA) computational overhead by 60%; integrated digital twin frameworks fusing LiDAR and fiber optic sensing for millimeter-level displacement tracking; and reinforcement learning (RL) algorithms dynamically modulating prestress levels in response to forecasted loads, demonstrably reducing critical stress peaks by 25%. Robust case studies, notably on the Hong Kong-Zhuhai-Macao Bridge and Japan’s Akashi Kaikyō Bridge, evidence up to 40% life cycle cost savings through AI-prioritized interventions. While challenges persist notably data scarcity for rare failure modes and computational demands of real-time digital twins emerging solutions like generative AI for synthetic data augmentation, edge computing deployments, probabilistic Bayesian updating, and multi-agent RL coordination chart a clear road map. This review establishes AI not merely as a tool, but as an indispensable paradigm for realizing resilient, adaptive, and economically sustainable anchorage systems in next-generation infrastructure.

Synergistic Corrosion Mechanisms of Alloys in High‐Temperature and High‐Pressure Water Environments: A Review

ABSTRACTHigh‐temperature and high‐pressure (HTHP) water serves as a critical heat‐exchange and reaction medium in numerous industrial applications. Under these extreme conditions, water exhibits distinct physicochemical properties that significantly elevate the corrosion susceptibility of alloys. This study investigates the mechanisms of oxidative corrosion, electrochemical corrosion, and stress corrosion cracking (SCC) in alloys exposed to HTHP water. From a synergistic perspective, it elucidates how interconnected phenomena—namely, accelerated oxide layer rupture, enhanced ion diffusion, and localized stress concentration—markedly accelerate alloy degradation. The findings reveal that reduced intermolecular hydrogen bonding, increased electrical conductivity, and heightened activity of corrosive ions in HTHP water are critical drivers of corrosion. By analyzing molecular structures and dynamics, it clarifies the complex interplay among HTHP water properties, corrosive ions, electrochemical reactions, and mechanical stress, thereby enhancing the understanding of alloy failure mechanisms. These insights provide a theoretical basis for designing corrosion‐resistant materials and equipment.

Cooperative Jahn-Teller effect and engineered long-range strain in manganese oxide/graphene superlattice for aqueous zinc-ion batteries

The Jahn-Teller and cooperative Jahn-Teller effects are phenomena that induce asymmetry in individual ions and solid-state lattices and are commonly observed in structures containing specific transition metals, such as copper and manganese. Although the Jahn-Teller effect causes lattice distortions that stress electrode materials in rechargeable batteries, strategically utilising the strain generated by cooperative Jahn-Teller distortions can enhance structural stability. Here we introduce the cooperative Jahn-Teller effect on MnO2 by constructing a two-dimensional superlattice structure with graphene crated in the bulk MnO2/graphene composite material. The strong interaction between MnO2 and graphene increases the concentration of high-spin Mn3+ ions, creating orderly long-range biaxial strains that are compressive in the out-of-plane direction and tensile in the in-plane direction. These strains mitigate Zn2+ intercalation stress and proton corrosion, enabling over 5000 cycles with 165 mAh g−1 capacity retention at 5 C (1 C = 308 mA g−1) in aqueous zinc-ion batteries. Our approach offers an effective strategy to significantly enhance the lifetime of rechargeable batteries by introducing the cooperative Jahn-Teller effect that overcomes the stress of ion insertion in electrode materials.