Seminar no Seminar no- -33 33

Stress corrosion cracking Stress corrosion cracking

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