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ESA Approach to the Prevention of Stress-

Corrosion Cracking in Spacecraft
Hardware

Dr Giancarlo Bussu
Material Mechanics and Processes, TEC-QMM
ESA/ESTEC
giancarlo.bussu@esa.int

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Overview
! Stress-Corrosion Cracking (SCC) as a failure
phenomenon
! Methods for the prevention of SCC failures in
spacecraft hardware
! ESA test method for the determination of
susceptibility to SCC of materials
! ESA SCC requirements and materials selection criteria
to prevent SCC
! Conclusions
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What is stress-corrosion cracking?

Stress-Corrosion Cracking (SCC) is a failure phenomenon that occurs in
SCC sensitive materials when they are subjected to sustained tensile
stress in the presence of a corrosive environment

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The relative influences of electrochemical and mechanical factors in
the corrosion and SCC damage of a susceptible material. Precise
separation of initiation and propagation stages is experimentally
difficult. Stimulation of cracking by atomic hydrogen may also become
involved in this transition region.
Effect of stress intensity on the kinetics of
SCC. Stages I and II may not always be
straight lines but may be strongly,curved,
and one or the other may be absent in
some systems. Stage III is characterised by
a rapid crack propagation as K approaches
Kc.
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Why is so important to avoid SCC failures?

! SCC affects integrity and safety of spacecraft
hardware

! SCC is one of the most important causes of structural

failures at launch sites

! Poor resistance to SCC is one of the most common

causes for rejecting a material during project reviews

! SCC failures can occur even when a structure is

unloaded (e.g. during storage)
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Factors promoting SCC

In the presence of sustained tensile stresses caused by:

! MANUFACTURING PROCESSES (e.g. forging,

rolling, cold working in general),

! ASSEMBLY (e.g mismatch, excessive clearance

between parts),

! In WELDED and BOLTED JOINTS (tensile residual

stresses up to yield)

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Factors promoting SCC

In the presence of a corrosive environment such as:

! LAUNCH SITES (typically coastal environment),

! ATMOSPHERE and INHABITED MODULES (water

condensation),

! during STORAGE and TRANSPORTION,

! in the presence of CHEMICAL SUBSTANCES (some

cleaning fluids, hydrazine etc.)
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Problems in controlling SCC

! SCC is a complex phenomenon where electrochemical, mechanical
and metallurgical factors are synergistically involved,

! Uncertainty in the determination of the environment,

! Uncertainty in the determination of stress levels,

! Lack in the understanding of the SCC initiation and propagation

mechanisms,

! Influence of additional variables such as temperature

SCC is difficult to control therefore must be prevented

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Methods to prevent SCC failures

! Selection of SCC resistant materials,

! Appropriate selection of manufacturing processes

aimed to reduce residual stresses,

! Selection of design solutions aimed to reduce tensile

stresses in the Short-Transverse (ST) direction of the
material where the resistance to SCC is least

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ESA approach to the prevention of SCC failures

! TESTING: commonly used materials are tested to

assess their level of susceptibility to SCC

! CLASSIFICATION: materials are classified with

respect to their level of susceptibility to SCC,

! SELECTION CRITERIA: only SCC resistant

materials are used in spacecraft hardware

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ESA test method to determine to susceptibility to SCC

Alternate immersion in 3.5% NaCl water solution for 30 days

- No failure
- No relevant reduction in tensile strength High resistance
- No metallographic evidence of SCC to SCC

- No failure Moderate
- No relevant reduction in tensile strength
- But there is metallographic evidence of SCC resistance to SCC

- Failures occur during testing Low resistance

- There is a reduction in tensile strength to SCC
- There is evidence of SCC from metallography

SCC specimens (S-T) under constant load (corresp. to 75%

of the material yield strength)

Control specimens (exposed unloaded) 11

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ESA test method to determine to susceptibility to SCC

! This test method has been used in Europe for more

than 30 years,

! Specimens are subjected to constant load (no problem

of stress relaxation during testing),

! Metallographic analysis allows the investigator to

distinguish between SCC and simple metal corrosion.

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ESA criteria for classification of materials

Materials (heat treated alloys) are classified in three TABLES
(high, moderate, low resistance to SCC) based on:

TESTING LITERATURE DATA

Previous
(multiple batch testing)
IN-SERVICE EXPERIENCE

CLASSIFICATION 13
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ESA SCC requirements for spacecraft hardware

! ECSS-Q-70-36
- Materials classification (Table I - high resistance,
Table II - moderate resistance, and Table III - low
resistance to SCC),
- Materials selection criteria,
- Quality assurance
! ECSS-Q-70-37
- ESA test method for the determination of
susceptibility to SCC
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ESA materials selection criteria for the prevention of SCC

! Table I (highly resistant) materials should be selected for
structural applications,

! Table II (moderately resistant) materials are allowed only

if a suitable alloy cannot be found in Table I,

! Table III (low resistant) materials should not be selected

for structural applications,

! Table II and III materials are accepted only if it can be

demonstrated that for a specific application the
probability of SCC is remote (case-by-case approach).
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Example of the case-by-case approach

A selected aluminium alloy is not classified in ECSS-Q-70-37
Bend test configuration (max stress corresp. to 75% of σ0.2), alternate exposure to 3.5%
NaCl water solution for 30 days:

Box frame

S Assembly force
T

Support reaction forces

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ESA-NASA activities on SCC standardization

! Periodical exchange and review of SCC test results

! Classification of tested materials in same Tables

! Collaboration in drafting and reviewing SCC standards

at ISO level (ISO CD 16455-1 and ISO CD 16455-2)

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Conclusions
1) SCC failures can be prevented by an appropriate
selection of materials, manufacturing processes and
design-solutions.
2) ESA constant load test method has been used for more
than 30 years in Europe. The test involves a 30-day period
of alternate exposure and it allows by metallographic
analysis to distinguish between SCC and metal corrosion.
3) Heat treated alloys are classified in Tables (high,
moderate and low resistance to SCC) based on test results,
previous in-service experience and literature data.

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Mean breaking stress versus exposure time for short-transverse 3.2-mm (0. 1 25-in.) diameter
aluminium alloy 7075 tension specimens tested according to ASTM G 44 at various exposure
stress levels. Each point represents an average of five specimens.

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Effect of temper on SCC performance of aluminium
alloy 7075 subjected to alternate immersion in 3.5%
NaCl solution at a stress of 207 MPa (30 ksi). Mean
flaw depth was calculated from the average breaking
strength of five specimens subjected to identical
conditions. Source: Ref 17
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Influence of specimen configuration on SCC test
performance (alternate immersion in 3.5% sodium
chloride per ASTM G 44). Aluminium alloy
7075-T7X51 specimens stressed 310 MPa (45 ksi);
each point represents 60 to 90 specimens. Source:
Ref 18
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SCC Table I - Steel Alloys
Alloy
Carbon steel(1000 series)
Low alloy steel(4130,4340 etc)
(E) D6AC, H-11
Music wire(ASTM 228)
HY-80 steel
HY-130 steel
HY-140 steel
1095 spring steel
300 series stainless
steel(unsensitised)2
400 series ferritic stainless steel
21-6-9 stainless steel
Carpenter 20 Cb Stainless steel
Carpenter 200 Cb-3 stainless steel
A286 stainless steel
AM350 stainless steel
AM355 stainless steel
Almar 362 stainless steel
Custom 450 stainless steel
Custom 455 stainless steel
15-5 PH stainless steel
PH 14-8 Mo stainless steel
PH 15-7 Mo stainless steel
17-7 PH stainless steel
Nitronic 33 (3)
(E) Maraging steel MARVAL X12
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Condition
Below 125 kg/mm2; (180 ksi) UTS 1) A small number of laboratory failures of
Below 125 kg/mm2; (180 ksi) UTS
specimens cut from plate more than 2
(1)
inches thick have been observed at 75%
Below 148 kg/mm2; (210 ksi) UTS
cold drawn yield, even within this ultimate strength
Quenched and tempered range. The use of thick plate should
Quenched and tempered therefore be avoided in a corrosive
Quenched and tempered environment when sustained tensile stress
Quenched and tempered in the short transverse direction is expected.
All 2) Including weldments of 304L, 316L, 321
All and 347.
All 3) Including weldments.
All
4) SCT 1000 = sub-zero cooling and
All
tempering at 538°C (1000F)
All
SCT 1000(4) and above 5) H1000 = hardened above 538C (1000F)
SCT 1000 and above 6) CH900 = cold worked and aged at 480C
H1000 (5) and above (1000;F)
H1000 and above 7) SRH950 = solution treated and tempered
H1000 and above at 510C (950F)
H1000 and above (E) ESA classification - not in NASA
CH900 and SRH950 and above (6,7) MSFC-SPEC-522A
CH900
CH900
All
All
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SCC Table I - Nickel Alloys

Alloy Condition

Hastelloy C All
Hastelloy X All
Incoloy 800 All
Incoloy 901 All
Incoloy 903 All
Inconel 600 (3) Annealed
Inconel 625 Annealed
Inconel 718 (3) All
Inconel X-750 All
Monel K-500 All
NiSpan -C 902 All
Rene 41 All
Unitemp 212 All
Waspaloy All

3) Including weldments

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SCC Table I - Aluminium Alloys

Alloy, Condition Cast (3) Condition
Wrought (1,2)
Alloy, 1000 All 355.0, C355.0 T6
series 2011 T8 356.0, A356.0 All
2024, rod bar 357.0 All
T8
B358.0 (Tens- All
2219 T6, T8 50) 359.0 All
(E) 2419 T8 380.0, A380.0 As cast
(E) 2618 T6, T8 514.0 (214) As cast (5)
3000 series All 518.0 (218) As cast (5)
5000 series 535.0 (Almag As cast (5)
All (4,5)
35) A 712.0, C As cast
6000 series All 712.0
(E)7020 T6 (6)
7049 T73
7149 T73
7050 T73
7075 T73
7475 T73

1) Mechanical stress relieved (TX5X or TX5XX) where possible

2) Including weldments of the weldable alloys.
3) The former designation in shown in parenthesis when significantly different.
4) High magnesium content alloys 5456, 5083 and 5086 should be used only in controlled tempers (H111, H112, H116, H117, H323, H343) for resistance to
stress-corrosion cracking and exfoliation
5) Alloys with magnesium content greater than 3.0% are not recommended for high temperature application, 66C (150F) and above.
6) Excluding weldments.
(E) ESA classification - not in NASA MSFC-SPEC-522A 23
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SCC Table I - Copper Alloys/ Misc. Alloys

CDA no (1) Condition (% cold rolled) (2) Alloy Condition
110 37 Beryllium, S-200C Annealed
170 HS 25 (L605) All
AT, HT (3)
HS 188 All
172 AT, HT (3) All
194 MP35N
37 All
195 Titanium 3Al-2.5V All
90
Titanium 6Al-4V All
230 40
Titanium 13V-11Cr-3Al All
422 37 (E)Titanium OMI 685, IMI All
443 10 Stabilised
829
510 37 Magnesium, M1A All
521 37 Magnesium, LA141
619 40(9% B phase) Magnesium, LAZ933
619 40(95% B phase)
688 40
706 50
725 50, annealed
280,524,606 0 1) Copper Development Association alloy number
632,655,705 0 2) Maximum per cent cold rolled for which stress-corrosion cracking
710,715 0 data are available
(E)917, (E)937 0 3) AT = annealed and precipitation hardened, HT = work hardened and
precepitation hardened

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SCC Table II - Steel Alloys/Miscellaneous alloys

Alloy Condition
Carbon steel (1000 series) 1225 to 1370 MPa UTS
Low-alloy steel (4130,4340 etc) 1225 to 1370 MPa UTS
Nitronic 32 All
Nitronic 60 All
400 series martensitic stainless steel (1)
(except 440) All
PH 13-8 Mo stainless steel Below H1000 (2)
15-5 PH stainless steel All
17-4 PH stainless steel

1) Tempering between 370 and 600C should be avoided because corrosion and stress-corrosion resistance
is lowered.
2) H1000 = hardened above 538C (1000F).

Alloy Condition
Magnesium AZ31B All
Magnesium ZK60A All
Magnesium (E) ZW3 All

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SCC Table II - Aluminium Alloys(1,2)

Alloy, wrought Condition Alloy, cast Condition
2024 rod, bar, extrusion T6, T62 319.0, A319.0 As cast
333.0, A333.0 As cast
2024 plate, extrusions T8
2124 plate T8
2048 plate T8
4032 T6
5083 All (3)
5086 All (3)
5456 All (3) 1) Mechanically stress relieved products (TX5X or TX5XX) should
7001 T75, T76 be specified where possible.
(E) 7010 T74 2) Sheet, unmachined extrusion and unmachined plate are the most
7049 T76 resistant forms.
7050 T74, T76 3) Except for controlled tempers listed in footnote 3 of Table I,
7075 T76 T74, aluminium alloys. These alloys are not recommended for high-
7175 T76 temperature applications. 66C (150F) and above.
7475 T76 (E) ESA classification - not in NASA MSFC-SPEC-522A.
7178 T76
(E) Russian Al-Li 1420, 1421 Solu. treat+age

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SCC Table III - Steel Alloys

Alloy Condition
Carbon steel(1000 series) Above 1370 MPa UTS
Low alloy steel(4130,4340 etc) Above 1370 MPa UTS
(E) D6AC, H-11steel Above 1370 MPa UTS
440C stainless steel All
18 Ni Maraging steel, 200 grade Aged at 900F
18 Ni Maraging steel, 250 grade Aged at 900F
18 Ni Maraging steel, 300 grade Aged at 900F
18 Ni Maraging steel, 350 grade Aged at 900F
AM 350 stainless steel Below SCT 1000
AM 355 stainless steel Below SCT 1000
Custom 455 stainless steel Below H1000
PH 15-7 Mo stainless steel All except CH900
17-7 PH stainless steel CH900 All except CH900
(E) Kovar All

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SCC Table III - Aluminium Alloys

Alloy, Wrought (1,2) Condition Alloy Condition
2011 T3, T4 295.0 (195) T6
All B295.0 (B195) T6
2014
520.0 (220) T4
2017 All
707.0 (607, tern-alloy 7) T6
2024 T3, T4 D712.0 (D612, 40E) As cast
2024 Forgings T6, T62, T8
2024 Plate T62
(E) Al-Li 2080 T8
(E) 2618 T3, T4
7001 T6
7005 All
(E) 7020 Weldments
7039 All
7075 T6
7175 T6
7079 T6
7178 T6 1) Mechanical stress relieved (TX5X or TX5XX) should be specified where
7475 T6 possible.<br>
(E) Al-Li 8090 All 2) Sheet, unmachined extrusion and unmachined plate are the least susceptible
(E) BS L93 T6 forms.<br>
(E) Russian Al-Li 1441, 1460 All (E) ESA classification - not in NASA MSFC-SPEC-522A.
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SCC Table III - Copper Alloys/ Magnesium

alloys
CDA no (1) Condition (% cold rolled) (2) Alloy Condition
260 50 Magnesium AZ61B All
353 50 Magnesium AZ80A All
443 40 Magnesium WE54 All
672 50, annealed
Magnesium ZCM711 All
687 10, 40
762 A, 25, 50
766 38
770 38, 50, annealed
782 50

1) Copper Development
Association alloy number
2) Rating based on listed
conditions only

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