Corrosion of steel structures in sea-bed sediment

Seabed sediment (SBS) is a special soil that is covered by seawater. With the developments in marine oil exploitation and engineering, more and more steel structures have been buried in SBS. SBS corrosion has now become a serious problem in marine environment and an important issue in corrosion science. In this paper, approach in the field of SBS corrosion is reviewed. Electrochemical and microbial corrosion factors, corrosion mechanism, measurement of metal corrosion rate, corrosion evaluation and prediction of corrosion are also discussed here.

Corrosion behaviour of steel in beach soil along Bohai Bay

Research on corrosion of steel structures in various marine environments is essential to assure the safety of structures and can effectively prolong their service life. In order to provide data for anticorrosion design of oil exploitation structures in the Bohai Bay, the corrosion behaviour and properties of steel in beach soil, using typical steel samples (Q235A carbon steel and API 5Lx52 pipeline steel) buried 0.5, 1.0 and 1.5 m deep under typical beach soils in Tanggu, Yangjiaogou, Xingcheng, Yingkou and Chengdao for 1-2 years were studied. The carbon steel and pipeline steel were both corroded severely in the beach soil, with the form of corrosion being mainly uniform with some localised attack (pitting corrosion). The corrosion rate of the carbon steel was up to 0.16 mm/year with a maximum penetration depth of 0.76 mm and that of the pipeline steel was up to 0.14 mm/year, with a maximum penetration depth of 0.53 mm. Compared with carbon steel, the pipeline steel generally had better corrosion resistance in most test beach soils. The corrosion rates and the maximum corrosion depths of carbon steel and pipeline steel were in the order: Tanggu>Xingcheng>Chengdao>Yingkou>Yangjiaogou with corrosion altering with depth of burial. The corrosion of steel in the beach soil involves a mixed mechanism with different degrees of soil aeration and microbial activity present. It is concluded that long term in situ plate laying experiments must be carried out to obtain data on steel corrosion in this beach soil environment so that the effective protection measures can be implemented.

Study on steel corrosion in different seabed sediments

A series of simulation experiments on carbon steel (A(3) steel) and low alloy steel (16 Mn steel) in marine atmosphere (MA), seawater (SW) and seabed sediment (SBS) including rough sea sand, fine sea sand and seabed mud were carried out indoors for a year or so by means of individually hanging plates (IHP) and electrically connected hanging plates (ECHP). The corrosion of steels in SBS was mainly due to the macrogalvanic cell effect. The steel plates at the bottom of SBS, as the anode of a macrogalvanic cell, showed the heaviest corrosion with a corrosion rate of up to 0.12 mm/a, approximately equal to that of steel plates in marine atmosphere. The test results showed that the corrosion rates of A(3) and 16 Mn steel in marine environment were in the order: MA > SW > SBS by the IHP method; and MA > SBS > SW by the ECHP method. The corrosion rates of steels in the water/sediment interface were directly proportional to the grain size of the SBS by the ECHP method, but those of steels in the water/sediment interface did not vary with the grain size of SBS by the IHP method. The corrosion rate of low-alloy steel was a little higher than that of carbon steel. The results of this study have important applications for design of offshore steel structures such as oil platform, pier, and port.

Corrosion resistance of steel with hot-dipped galvanized zinc and zinc alloy coatings in seawater

Hot-dipped galvanized zinc and zinc alloy coatings were used as the hot-dipped low alloy zinc coatings (aluminum content less than protective metallic coatings for steel structures in seawater in Chi- or equal to 10 wt%) is equal to or even lower than that of the pure na. Corrosion of the two coatings immersed in sea water in Qingdao zinc sheet, while the performance of the hot-dipped high alloy zinc and Xiamen for 6 years were introduced and analyzed, which pro-coatings is higher than that of the pure zinc sheet. The hot-dipped vides a basis for further development and applications of these coat- high alloy zinc coatings can be further developed for optimal tings in China. Tests proved that the anti-corrosion performance of formance in the future.

Ice induced low temperature fatigue crack propagation in offshore structural steel A131

To investigate the low temperature fatigue crack propagation behavior of offshore structural steel A131 under random ice loading, three ice failure modes that are commonly present in the Bohai Gulf are simulated according to the vibration stress responses induced by real ice loading. The test data are processed by a universal software FCPUSL developed on the basis of the theory of fatigue crack propagation and statistics. The fundamental parameter controlling the fatigue crack propagation induced by random ice loading is determined to be the amplitude root mean square stress intensity factor K-arm. The test results are presented on the crack propagation diagram where the crack growth rate da/dN is described as the function of K-arm. It is evident that the ice failure modes have great influence on the fatigue crack propagation behavior of the steel in ice-induced vibration. However, some of the experimental phenomena and test results are hard to be physically explained at present. The work in this paper is an initial attempt to investigate the cause of collapse of offshore structures due to ice loading.

Fractography and Crack Initiation of Very-High-Cycle Fatigue for a High Carbon Low Alloy Steel

Very-High-Cycle Fatigue (VHCF) is the phenomenon of fatigue damage and failure of metallic materials or structures subjected to 108 cycles of fatigue loading and beyond. This paper attempts to investigate the VHCF behavior and mechanism of a high strength low alloy steel (main composition: C-1% and Cr-1.5%; quenched at 1108K and tempered at 453K). The fractography of fatigue failure was observed by optical microscopy and scanning electron microscopy. The observations reveal that, for the number of cycles to fatigue failure between 106 and 4108 cycles, fatigue cracks almost initiated in the interior of specimen and originated at non-metallic inclusions. An “optical dark area” (ODA) around initiation site is observed when fatigue initiation from interior. ODA size increases with the decrease of fatigue stress, and becomes more roundness. Fracture mechanics analysis gives the stress intensity factor of ODA, which is nearly equivalent to the corresponding fatigue threshold of the test material. The results indicate that the fatigue life of specimens with crack origin at the interior of specimen is longer than that with crack origin at specimen surface. The experimental results and the fatigue mechanism were further analyzed in terms of fracture mechanics and fracture physics, suggesting that the primary propagation of fatigue crack within the fish-eye local region is the main characteristics of VHCF.

Mixed-mode fracture mechanisms near the fatigue threshold of aisi-316 stainless-steel

Near threshold, mixed mode (I and II), fatigue crack growth occurs mainly by two mechanisms, coplanar (or shear) mode and branch (or tensile) mode. For a constant ratio of ΔK_I/ΔK_II the shear mode growth shows a self-arrest character and it would only start again when ΔK_I and ΔK_II are increased. Both shear crack growth and the early stages of tensile crack growth, are of a crystallographic nature; the fatigue crack proceeds along slip planes or grain boundaries. The appearance of the fracture surfaces suggest that the mechanism of crack extension is by developing slip band microcracks which join up to form a macrocrack. This process is thought to be assisted by the nature of the plastic deformation within the reversed plastic zone where high back stresses are set up by dislocation pile-ups against grain boundaries. The interaction of the crack tip stress field with that of the dislocation pile-ups leads to the formation of slip band microcracks and subsequent crack extension. The change from shear mode to tensile mode growth probably occurs when the maximum tensile stress and the microcrack density in the maximum tensile plane direction attain critical values.

Corrosion failure of marine steel in sea-mud containing sulfate reducing bacteria

The corrosion failure behavior of marine steel is affected by stress, which exists in offshore structures at sea-mud region. The sulfate reducing bacteria (SRB) in the sea-mud made the steel more sensitive to stress corrosion cracking (SCC) and weaken the corrosion fatigue endurance. In this paper, a kind of natural sea-mud containing SRB was collected. Both SCC tests by slow strain rate technique and corrosion fatigue tests were performed on a kind of selected steel in sea-mud with and without SRB at corrosion and cathodic potentials. After this, the electrochemical response of static and cyclic stress of the specimen with and without cracks in sea-mud was analyzed in order to explain the failure mechanism. Hydrogen permeation tests were also performed in the sea-mud at corrosion and cathodic potentials. It is concluded that the effect of SRB on environment sensitive fracture maybe explained as the consequences of the acceleration of SRB on corrosion rate and hydrogen entry into the metal.

Electrochemical and quantum chemical study of purines as corrosion inhibitors for mild steel in 1 M HCl solution

The purines and its derivatives, such as, guanine, adenine, 2,6-diaminopurine, 6-thioguanine and 2,6-dithiopurine, were investigated as corrosion inhibitors for mild steel in 1 M HCl solution by weight loss measurements, electrochemical tests and quantum chemical calculations. The polarization curves of mild steel in the hydrochloric acid solutions of the purines showed that both cathodic and anodic processes of steel corrosion were suppressed. The Nyquist plots of impedance expressed mainly as a depressed capacitive loop with different compounds and concentrations. For all these purines, the inhibition efficiency increased by increasing the inhibitor concentration, and the inhibition efficiency orders are 2,6-dithiopurine > 6-thioguanine > 2,6-diaminopurine > adenine > guanine with the highest inhibiting efficiency of 88.0% for 10(-3) M 2,6-dithiopurine. The optimized structures of purines, the Mulliken charges, molecular orbital densities and relevant parameters were calculated by quantum chemical calculations. The quantum chemical calculation results inferred that the adsorption belong to physical adsorption, which might arise from the pi stacking between the pi electron of the purines and the metal surface. (C) 2008 Elsevier Ltd. All rights reserved.