Corrosion Mechanism Description Temp.

Range Affected Prevention Inspection Methods

metallurgy
General Corrosion Mechanisms-Mechanical and Metallurgical Failure Mechanisms
Graphitization Loss in strength, ductility, creep resistance 800-1100 CS & .5Mo steel Adding Cr +.7 Metallographic test *
Spheroidization Loss in strength, creep resistance- large 850-1400 CS, Cr-Mo Temperature control MG, Tensile and hardness tests.
Softning agglomerated arbides in 5-9% Cr
Temper Embrit. Reduction in toughness- limited P to 25% of 650-1100 2.25Cr-1Mo New -Limit Charpy Impact
max design P for temp’s below MPT(350 oF for impurities* )Si, Mn, P,
older steel and 150oF for newer steels) Sn, Sb, As)
Strain Aging Increase in hardness and strength with a - CS & C-.5 Mo Adding aluminum and No*
reduction in ductility and toughness. PWHT
885oF Embrittlement Loss in toughness due to a metallurgical 600-1000 400SS series, duplex Use of low ferrite or Impact or bend test
change caused by high temp. SS, wrought and non-ferritic alloys* Hardness *
cast 300 series SS Use of PWHT followed
by rapid cooling
Sigma Phase Loss of fracture toughness 1000-1750 Duplex, Ferritic & use alloys that are Physical Testing*
Embrittlement martensitic, with resistant to sigma
Cr> 17%,300 SS formations
wrought ,cast ,weld *Desigmatized by
solution
annealing@1950/4 hrs
Brittle Fracture Cracks are straight, non-branching with no -- CS, LAS, 400 SS Design for low temp N/A
plastic deformation operation *
Creep & Stress Increase of 25 F or 15% stress can cut the -- All PWHT UT,RT,ET,VT,WFMT,SWUT,
Rupture remaining life in half, Deformation/cracking PT
Thermal Fatigue Thermal fatigue is the result of cyclic stresses Temp. swing All Design & operation to VT,PT,MT *
caused by variations in temperature. of 200F minimize thermal
Transgranular cracks filled with oxides. stress & cycling *
Short Term Permanent deformation occurring at relatively All Burner management, VT,IR, Heat indicating paint
Overheating – Stress low stress levels as a result of localized Minimize localized
Rupture overheating. “fish mouth” failures. temperature excursions.
Steam blanketing Departure from nucleate boiling (DNB) - near -- CS, LAS Design VT, IR scans
knife edge with elongation of grains.
DMW Cracking Occurs on ferrtic side of weld@ high temp. >510 Ferrtic & austenitic Use nickel base filler VT,PT,MT
between austenitic and ferrtic
Thermal Shock Thermal fatigue cracking, when high and non- - All Prevent interruption in PT/MT, difficult to locate
uniform thermal stress develop over a short flow of high temp line.
time due to differential expansion or Minimize severe
contraction. Usually occurs when a colder restraint.
liquid contacts a warmer metal surface. Craze Install thermal sleeves
cracks Review hot/cold
injection points
Erosion/Corrosion Pits, groves, waves, rounded holes and - All More corrosion VT,UT,RT
valleys(directional pattern) resistant alloy *
Cavitation Sharp-edge pitting damage - All Design VT,UT,RT
--
Mechanical Fatigue CS, titanium exhibit an endurance limit- 300 ss, All Design to minimize MT, PT
400 ss, aluminum & non-ferrous alloys, don’t stress concentrations
exhibit an endurance limit- “calm shell” *
fingerprint with “ beach marks”- cracks initiate
Vibration-Induced A form of mechanical fatigue --- All Design MT, PT*
Fatigue
Refractory Damage due to oxidation, sulfidation and other -- All Refractories Design VT, IR scan
Degradation high temp mechanisms
Reheat Cracking Due to stress relaxation during PWHT @ high --- LAS, 300SS, NI- Design UT, MT, PT
temp’s- heavy wall sections- intergranular. alloys
General Corrosion mechanisms-Uniform or Localized Loss of Thickness
Galvanic Corrosion 1) Electrolyte, 2) anode-cathode, 3) electrical -- All VT & UT*
connection- depends on cathode area- coat Design*
cathode rather than anode.
Atmospheric corrosion Marine (20 mpy), humid (1-3) mpy, dry(<1 <250 CS, LAS, Copper Design VT, UT
mpy) alloyed Aluminum
CUI Pitting damage, loss in thickness-loose flaky More severe CS, LAS, 300 SS, Appropriate paint VT, UT, X-Ray profile, neutron
scale- carbuncle type pitting 212-250,>250 400 SS, DUPLEX coatings, Maintain backscatter.
for marine SS insulation barriers *
env.
Cooling Water Fresh water> 140F, brackish water> 115f, -- All Design Lab samples, velocity, U-factor
corrosion cause scaling- titanium hydrides >180f
Boiler Water Oxygen scavenging (catalyzed sodium sulfite --- CS, LAS, 300 SS, Fe3O4 (magnetite) Water analysis *
Condensate or hydrazine)- amine inhibitor for CO2 Copper based alloys
corrosion
CO2 Corrosion occurs when effluent stream temp <300F CS, LAS 300ss, 400ss, VT, UT, RT
drops below dew points (300F) >12%Cr
Flue-Gas Dew-Point Sulfuric & forms @ 280F, hydrochloric acid -- CS, LAS, 300 ss Design VT, UT, PT, (300 SS to locate
forms @ 130F SCC)
Microbiologically Occurs where water is present, stagnant flow- -- All Biocides, Tank Stream analysis
Induced Corrosion cup shaped pit within pits in CS or subsurface internal-coating ,
pits in SS U/G-CP
Soil Soil resistivity is used to determine corrosivety --- CS, cast iron, ductile CP, Coating Measuring Potential *
-external thinning with localized pitting iron
Caustic Localized grooves >175F, >200f CS, LAS, 300 SS Design* UT, RT
(very high)
Dealloying Brass become reddish when dealloyed, while <200F Copper alloys, Cast CP, coating Acoustic techniques, Ultrasonic
cast iron becomes charcoal gray iron,Alloy400 attenuation,MG, UT is N/A
Graphitic Graphite is cathodic-damage occurs in the <200F Cast iron Coating Acoustic techniques, MG, UT is
presence of moisture or aqueous phase N/A
 High Temperature Corrosion [400 oF]
Oxidation General thinning with an oxide layer covering >1000f - CS Iron-based alloys Upgrading more UT
the surface >1500 - resistant alloy*
300SS
Sulfidation Hydrogen accelerates corrosion- Uniform >500, <500 Iron, nickel and Add Cr UT
thinning ( localized sometimes) for copper copper based alloys
alloys
Carburization Requires high carbon-activity gas, low oxygen >1100F Iron-based alloys Lower temp, higher MG, hardness testing
potential O2&S partial pressure
Decarburization Requires low carbon-activity gas, CS will be --- CS, LAS Add Cr, Mo FMR, MG, hardness test
pure iron.
Metal Dusting Preceded by carburization-pits filled with 900-1500 All No metal is immune- VT* ,Heater tubes-
crumbly residue of oxides and carbides in LAS H2S forms protective Compression wave UT*
Deep round pits in SS sulfide layer
Fuel Ash Contaminants are S, Na,K,V- Molten dissolves All Injecting VT
oxide layer & 50 Cr-50 Ni more resistant special additives
Nitriding It’s rare- Nitrogen diffuses into surface forming Starts>600, CS, LAS, 300SS, 30-80% Ni Mg, hardness test, VT,
needle-like particles of Fe3N and Fe4N hard severe >900 400SS magnetism (300SS)
brittle surface layer – dull gray dry

Environment- Assisted Cracking

Chloride SSC, Surface initiated cracks under the combined >140 F SS300 Use low chloride water PT, Phase analysis EC
action of tensile stress, temperature and an techniques *
aqueous chloride environment.
Corrosion Fatigue Initiate @ pits, notches, surface defect. brittle ---- All Design UT, MTWFMT
fracture ,Transgranular, ,not branched.
Caustic SCC Surface cracks adjacent to non-PWHT- welds- ----- CS, LAS,300 SS PWHT, Ni alloys are WFMT,EC,RT /ACFM,*
( Embrittlement) Integranular spider web and filled w/oxides- resistant PT Not Good
Transgranular in 300ss-50 to 100 ppm is
sufficient for cracking
Ammonia SCC Copper alloys: aqueous, 8.5 pH, O2, Any range Copper alloys CS PWHT CS-300SS, Ni EC- Copper Alloys,
zinc>15%, bluish corrosion product, alloys, 90-10/70-30 CS-WFMT,SWUT & AET
trans/intergranular cracks—CS- anhydrous CuNi are immune-
ammonium, <.2% water, Air/O2, non PWHT process control
weld or HAZ
Liquid Metal Liquid Metal Embrittlement (LME) is a form ---300 SS - All Prevented by protecting MT,PT
Embrittlement (LME) of cracking that results when certain molten Zinc metal substrates from
metals come in Cu Alloys - coming into contact
contact with specific alloys. Cracking can be Mercury with the low melting
very sudden and brittle in nature. Alloy 400 - metal.
 Intergranular cracking Mercury
Al. Alloys -
Mercury
HS S-Cd,
Lead
Hydrogen Loss in ductility-thick walls are more Ambient to CS. LAS, 400SS, Use lower strength PT, MT,WFMT,
Embrittlement vulnerable as it takes hydrogen more time to 300F; not PH SS, HS Ni alloys alloys, PWHT RT- Not Good
diffuse out- cracks are subsurface or surface likely above
160-180F
initiating-intergranular, brittle cracking.

General – Uniform or Localized Loss in Thickness Phenomena

Amine corrosion Amine itself is not corrosive, contaminates are >220F CS Proper Op’s, 300ss, VT&UT- Internal
(CO2, H2S, degradation products, HSAS)-CS avoid O2 leakage, Profile RT- External
is suitable for most units- MED, DGA, ADIP, Avoid HSAS.
DEA, MDEA-3 TO 6 FPS (rich amine)20 FPS
(lean amine)- general thinning (low velocity),
localized (high)
Ammonium Bisulfide 2% corrosive, 8% highly corrosive- low 120-150 CS, Cu alloys Velocity 10-20fps, UT, RT
( Alkaline Sour Water) velocities cause under deposit brasses resistant alloys(duplex ,
corrosion,NH4HS salts formed . 825) @ higher
velocities
Ammonium Chloride Occurs in absence of free water @ temp’s >300 All Ni alloy, Titanium
above Jew pint- Localized pitting-salt have alloys, water wash UT,RT ,Corrosion Probes
whitish, greenish, brownish appearance
Hydrochloric Acid Associated with dew point corrosion- PH<4.5- --- All Proper Op’s, Ni alloy, UT,RT, Monitoring
(HCL) oxygen increase corrosion Titanium alloy Ph ,Corrosion probes
High Temp H2/H2S Hydrogen increase corrosion rate compared to >500F All Add Cr VT,UT ,RT
high temp Sulfidation-uniform corrosion
Hydrofluoric (HF) LAS, 300,400ss aren’t suitable-CS forms >150F CS, Cu & Ni alloys Proper Op’s, UT ,RT
Acid protective fluoride scale-water concentration design, alloy C-276
>3% is corrosive- In CS limit RE=%Cu+
%Ni+%Cr=.2 max- Uniform loss for alloy
400 and cracking for non-stress relieved alloy
400
Naphthenic Acid TAN as low as 0.1 could cause problems- >425, severe CS, LAS, 300SS, Add Mo UT,RT, Hydrogen probes
Corrosion corrosion is severe in mixed flow stream- >750 400SS,Ni alloy
Localized, pitting
Phenol (Carbolic It’s solvent to remove aromatics from lube oil <250F CS, 304ss 316SS, C-276 (High UT,RT ,ER Probes
Acid) -5 to 15% phenol(dilute) is very corrosive- minimal, >450 velocities)- Ovhe temp
general or localized corrosion. Best CS & 304SS >30F above dew point
prevented through proper material
selection & control of ph solvent chemistry.
Phosphoric Acid Catalyst in polymerization units- solid <120 CS,304SS,316SS, Upgrade metallurgy UT,RT,ER Probes
phosphoric acid is not corrosive- may (300ss@100%) Alloy 20
penetrate 0.25” steel in 8 hrs- general or , <225f (316ss,
alloy
localized
 20@85%)
Sour Water (Acidic) H2S decreases pH to 4.5- general, localized --- CS SS,Cu alloys, Ni alloys UT,RT ,Corrosion Probes
pitting-SCC may occur in 300SS.

Sulfuric Acid Affect CS-HAZ- Severe corrosion in ---- All Ni alloys RT,UT, ER probes
CS@>3FPS and/or >65% concentration-
General corrosion

General- Environment-Assisted Cracking

Polythionic acid Stress Occurs during shutdowns, startups, when 750-150 for Sensitize austenitic Use PT
CC (PASCC) exposed to air& moisture-HAZ “L grade SS is sensitization steels chemically stable steel
less susceptible to sensitization- Intergranular (321ss, 347, alloy 825
cracks.” and alloy625)

Amine Stress CC Occurs in lean amines- MEA, DEA mainly- >ambient PWHT, Resistant ACFM/WFMT, PT(not good)*
concentration is not a factor- initiate ID on alloys
welds ( transverse or longitudinal) or adjacent
to HAZ- Intergranular and filled with oxides
Wet H2S Damage Caused by atomic hydrogen. H 2 is formed due <180f CS, LAS Process (pH, H2S Focus on weld seam and
(Blistering/HIC/SOHI to corrosion. below 50, wash water, nozzles-VT WFMT, EC,
C/SSC) ammonia &cyanides RT/ACFM*
concentrations- PWHT SWUT- Volumetric inspection
& crack sizing *
Hydrogen Stress Results by exposure to aqueous HF acid --- PWHT, Resistant WFMT, Hardness testing
Cracking- HF environment- HAZ-Interganular- use CS with alloys
Carbon equivalent (CE) <0.43
Carbonate Stress Susceptibility increases with pH and carbonate >200F PWHT, Resistant alloy WFMT, SWUT
Corrosion Cracking concentration- Propagate parallel to welds,
weld deposits, HAZ- Intergranular and filled
with oxides
General- Other Mechanisms
HTHA Exposure to hydrogen at elevated temperatures --- CS, C-Mo, Cr-Mo Add Cr&Mo UT techniques
and pressures- H reacts with carbides to form
methane-300ss and >5Cr are not susceptible to
HTHA- may cause decarburization-
Intergranular with blistering sometimes.
Titanium hydriding Hydrogen diffuses into titanium to form >165f, Titanium alloys Avoid titanium alloys EC Techniques
hydride (brittle)- PH<3, PH>8 > 350 in in hydriding services
hydrogen
atmosphere.