Influence of grinding operations on surface integrity and chloride induced stress corrosion cracking of stainless steels

Stainless steels were developed in the early 20th century and are used where both the mechanical properties of steels and corrosion resistance are required. There is continuous research to allow stainless steel components to be produced in a more economical way and be used in more harsh environments. A necessary component in this effort is to correlate the service performance with the production processes. The central theme of this thesis is the mechanical grinding process.  This is commonly used for producing stainless steel components, and results in varied surface properties that will strongly affect their service life. The influence of grinding parameters including abrasive grit size, machine power and grinding lubricant were studied for 304L austenitic stainless steel (Paper II) and 2304 duplex stainless steel (Paper I). Surface integrity was proved to vary significantly with different grinding parameters. Abrasive grit size was found to have the largest influence. Surface defects (deep grooves, smearing, adhesive/cold welding chips and indentations), a highly deformed surface layer up to a few microns in thickness and the generation of high level tensile residual stresses in the surface layer along the grinding direction were observed as the main types of damage when grinding stainless steels. A large degree of residual stress anisotropy is interpreted as being due to mechanical effects dominating over thermal effects. The effect of grinding on stress corrosion cracking behaviour of 304L austenitic stainless steel in a chloride environment was also investigated (Paper III). Depending on the surface conditions, the actual loading by four-point bend was found to deviate from the calculated value using the formula according to ASTM G39 by different amounts. Grinding-induced surface tensile residual stress was suggested as the main factor to cause micro-cracks initiation on the ground surfaces. Grinding along the loading direction was proved to increase the susceptibility to chloride-induced SCC, while grinding perpendicular to the loading direction improved SCC resistance. The knowledge obtained from this work can provide a reference for choosing appropriate grinding parameters when fabricating stainless steel components; and can also be used to help understanding the failure mechanism of ground stainless steel components during service.

Nitriding in cathodic cage of stainless steel AISI 316: influence of sample position

R.R.M. de Sousa et al. Nitriding in cathodic cage of stainless steel AISI 316: Influence of sample position. Vacuum, [s.l.], n.83, 2009. Disponivel em: . Acesso em: 04 out.2010.

Corrosion of stainless steel components in seawater reverse osmosis desalination plants-investigations on adapted internal cathodic protection

Stainless steel is widely used in seawater reverse osmosis units (SWRO) for both good mechanical and corrosion resistance properties. However, many corrosion failures of stainless steel in SWRO desalination units have been reported. These failures may often be attributed to un-adapted stainless steel grade selection and/or to the particular aggressive seawater conditions in "warm" regions (high ambient temperature, severe biofouling, etc.). Cathodic protection (CP) is a well-known efficient system to prevent corrosion of metallic materials in seawater. It is successfully used in the oil and gas industry to protect carbon steel structures exposed in open-sea. However, the specific service conditions of SWRO units may seriously affect the efficiency of such anti-corrosion system (high flow rates, large stainless steel surfaces affected by biofouling, confinement limiting protective cathodic current flow, etc.). Hence, CP in SWRO units should be considered with special care and modeling appears as useful tool to assess an appropriate CP design. However, there is a clear lack of CP data that could be transposed to SWRO service conditions (i.e. stainless steel, effect of biofouling, high flow rate, etc.). From this background a Join Industry Program was initiated including laboratory exposures, field measurements in a full scale SWRO desalination plant, and modeling work using PROCOR software. The present paper reviews the main parameters affecting corrosion of stainless steel alloys in seawater reverse osmosis units. CP on specific stainless steel devices was investigated in order to assess its actual efficiency for SWRO units. Severe environmental conditions were intentionally used to promote corrosion on the tested stainless steel products in order to evaluate the efficiency of CP. The study includes a modeling work aiming at predicting and designing adapted CP protection to modeled stainless steel units. An excellent correlation between modeling work and field measurements was found.

Interpretation of electrochemical measurements made during micro-scale abrasion-corrosion

This paper brings together and analyzes recent work based on the interpretation of the electrochemical measurements made on a modified micro-abrasion-corrosion tester used in several research programmes. These programmes investigated the role of abradant size, test solution pH in abrasion-corrosion of biomaterials, the abrasion-corrosion performance of sintered and thermally sprayed tungsten carbide surfaces under downhole drilling environments and the abrasion-corrosion of UNS S32205 duplex stainless steel. Various abrasion tests were conducted under two-body grooving, three-body rolling and mixed grooving-rolling abrasion conditions, with and without abrasives, on cast F75 cobalt-chromium-molybdenum (CoCrMo) alloy in simulated body fluids, 2205 in chloride containing solutions as well as sprayed and sintered tungsten carbide surfaces in simulated downhole fluids. Pre- and post-test inspections based on optical and scanning electron microscopy analysis are used to help interpret the electrochemical response and current noise measurements made in situ during micro-abrasion-corrosion tests. The complex wear and corrosion mechanisms and their dependence on the microstructure and surface composition as a function of the pH, abrasive concentration, size and type are detailed and linked to the electrochemical signals. The electrochemical versus mechanical processes are plotted for different test parameters and this new approach is used to interpret tribo-corrosion test data to give greater insights into different tribo-corrosion systems. Thus new approaches to interpreting in-situ electrochemical responses to surfaces under different abrasive wear rates, different abrasives and liquid environments (pH and NaCl levels) are made. This representation is directly related to the mechano-electrochemical processes on the surface and avoids quantification of numerous synergistic, antagonistic and additive terms associated with repeat experiments. (C) 2010 Elsevier Ltd. All rights reserved.

Evaluación del comportamiento mecánico, estructural y frente a la corrosión, de una nueva armadura de acero inoxidable dúplex bajo en níquel

La durabilidad de las estructuras de hormigón armado no es ilimitada, en especial en determinados ambientes. El ingreso de agentes agresivos en el hormigón, fundamentalmente dióxido de carbono e iones cloruros, rebasando el espesor del recubrimiento y alcanzando las armaduras, reducen el alto pH del hormigón hasta alcanzar un umbral crítico, por debajo del cual, el acero queda despasivado. Posteriormente, si existe el suficiente aporte de humedad y oxígeno, el acero se corroe, lo que supone drásticas reducciones de la vida de servicio de estas estructuras y su inevitable reparación. La utilización de armaduras de acero inoxidable es una alternativa que está recibiendo cada vez más consideración. Su resistencia a la corrosión en los ambientes más agresivos, incluso con ataque de cloruros, lo convierte en el material idóneo para prolongar de forma muy considerable la vida útil de la estructura. En este trabajo se ha evaluado el comportamiento mecánico y estructural, y de resistencia a la corrosión, de un nuevo acero inoxidable dúplex de bajo contenido en níquel, el EN 1.4482 (AISI 2001), y se ha comparado con el inoxidable austenítico más utilizado, el EN 1.4301 (AISI 304), con el dúplex EN 1.4362 (AISI 2304) y con el tradicional acero al carbono B-500-SD. El estudio mecánico y estructural se ha realizado en tres niveles diferentes: a nivel de barra, estudiando las propiedades mecánicas y de ductilidad de los cuatro aceros citados; a nivel de sección, estudiando su comportamiento a flexión con diferentes cuantías de armado por medio de los diagramas momento-curvatura; y a nivel de pieza, ensayando una serie de vigas armadas con diferentes aceros y cuantías, y comprobando su comportamiento a desplazamiento y resistencia por medio de los diagramas carga-desplazamiento. El estudio de resistencia a la corrosión se ha realizado embebiendo barras corrugadas, de los tres aceros inoxidables mencionados, en probetas de mortero contaminadas con diferentes cantidades de cloruros, y realizando mediciones electroquímicas durante un periodo de al menos un año. Se han preparado probetas de mortero para dos comparativas diferentes. La primera, manteniendo las probetas en un desecador con el 95 % de humedad relativa durante todo el periodo de mediciones. La segunda, sumergiendo parcialmente las probetas en una solución tampón para carbonatar el mortero. Los resultados de los ensayos mecánicos han demostrado dos aspectos diferentes. Uno, que las armaduras de acero inoxidable tienen un comportamiento muy similar a las de acero al carbono en lo referente a las resistencias alcanzadas, en el límite elástico y en rotura, pero distinto en cuanto al módulo de deformación longitudinal, cuyo valor es claramente inferior al del acero al carbono, por lo que su utilización en las estructuras de hormigón necesita tener en cuenta ese dato en los análisis lineales de cálculo. El segundo aspecto es que las armaduras de acero inoxidable laminadas en caliente presentan una ductilidad muy superior a las de acero al carbono, por lo que ofrecen una mayor seguridad frente a su rotura o al colapso de la estructura, lo que se debe tener en cuenta en el análisis de cálculo plástico. En cambio, las armaduras de acero inoxidable laminadas en frío sólo cumplen con los límites mínimos de ductilidad establecidos en la instrucción EHE-08 para los aceros soldables, y no para los aceros con características especiales de ductilidad. El estudio a nivel de sección refleja la paradoja de obtener secciones menos dúctiles con las armaduras de acero inoxidable laminadas en caliente que con las armaduras de acero al carbono. Para subsanarlo, se definen los conceptos de curvatura última de rotura y ductilidad de la sección en rotura, que tienen en cuenta las altas deformaciones alcanzadas por las armaduras de acero inoxidable. Los resultados a nivel de pieza permiten identificar el comportamiento estructural del hormigón armado con barras corrugadas de acero inoxidable y compararlo con el de las estructuras de hormigón armado convencionales, verificando los resultados experimentales con los teóricos obtenidos con la formulación recogida en la instrucción EHE- 08. Los ensayos de resistencia a la corrosión por cloruros demuestran, durante el primer año y medio de vida de las probetas, un comportamiento muy similar entre el nuevo acero inoxidable dúplex bajo en níquel y el austenítico y el dúplex utilizados para la comparación, incluso para las probetas carbonatadas. Por último, se añade una comparativa económica, realizada sobre dos edificaciones tipo, para cuantificar el sobrecoste que supone la utilización de armaduras de acero inoxidable respecto a las de acero al carbono. El alto coste inicial de las armaduras de acero inoxidable se ve compensado en el coste final de la estructura de muy diferentes formas, principalmente dependiendo del grado de acero elegido y de si se emplean en el total de la estructura o solamente en los elementos más expuestos. The durability of the concrete structures is limited, especially in certain environments. The attack of aggressive agents in the concrete, mainly carbon dioxide and chloride ions, penetrating the thickness of concrete cover and reaching the reinforcements, reduce the high pH of concrete to the point of reaching a critical threshold, under which, the steel despasivates. Therefore, if there is enough humidity and oxygen, the steel corroes, causing drastic reductions in the service life of these structures and its inevitable repair. Despite the high initial cost compared to carbon steel, the usage of stainless steel reinforcements is an alternative with a major consideration nowadays. Its resistance to corrosion in the most aggressive atmospheres, including chlorides attack, makes the stainless steel a suitable material to extend considerably its lifetime. In this study, it’s been evaluated the mechanical and structural behaviour, and the corrosion resistance, of a new low-nickel duplex stainless steel EN 1.4482 (AISI 2001), and it has been compared with the most widely used austenitic type EN 1.4301 (AISI 304), with duplex steel EN 1.4362 (AISI 2304) and with the traditional carbon steel B-500-SD. The mechanical and structural study has been carried out in three different levels: bar level, studying mechanical properties and ductility of the four steels; section level, studying its behaviour when blending with different amounts of reinforcement through the moment-curvature diagrams; and structural element level, testing a series of reinforced beams with different steels and amounts, and checking its sag and resistance through the load-deflection diagrams. The corrosion resistance study was performed by embedding ribbed bars, using the three stainless steel listed, on mortar specimens contaminated with different amounts of chlorides, and taking electrochemical measurements over a period of at least one year. Mortar specimens have been prepared for two different comparisons. The first, keeping the specimens at 95% of relative humidity during the measurement period. The second, immersing the specimens partially in a carbonate buffer solution. The results of those tests have proved two different aspects. Firstly, that stainless steel reinforcements show a very similar behaviour to carbon steel, according to the reached levels of mechanical resistance, yield stress and steel strength, but a different behaviour in Young’s modulus, which value is clearly lower than the carbon steel. Therefore, when using in concrete structures it is need to consider on that point the existing calculus of linear analysis. The second aspect is that stainless steel reinforcement manufactured by hot-rolling process show a very higher ductility than carbon steel, offering a better security on cracks or structure collapse, which it has to be taken into account on plastic calculus analysis. However, the stainless steel reinfor9 cement cold-rolled bars only meet the minimum thresholds of ductility established by EHE-08 for welded steel, and not for steels with special ductility. The results at the section level reflect the paradox of getting less ductile sections with hot rolled stainless steel reinforcement than with carbon steel reinforcements. To overcome that, the concepts of last break curvature and break ductility section have been defined, which take into account the high deformation value achieved by stainless steel reinforcements. The results at the structural element level allow to identify the structural behaviour of reinforced concrete with stainless steel reinforcements and compared with that of conventional steel reinforcement, contrasting the experimental with the theoretical results obtained from the formulation contained in the instruction EHE-08. Tests on resistance of chloride corrosion show during the first year and a half of specimens life, a similar behaviour between the new low nickel duplex stainless steel and austenitic and duplex used for comparison, even for carbonated specimens. Finally, it has been included an economic comparison on two differents building types, to quantify the additional cost involved on the use of stainless steel reinforcement compared to that of carbon steel. The high initial cost of stainless steel reinforcements is offset in the final cost of the structure in many different ways, mainly depending on the chosen steel grade and whether the reinforcement is used in the total structure or only in risky structural elements.

Colonización bacteriana y oxidación de aceros inoxidables austeníticos, ferríticos y dúplex sinterizados

Las características y capacidades de los aceros inoxidables sinterizados se han investigado en una doble vertiente. Por una parte con vista a sus capacidades de resistencia a la oxidación en caliente y por otra parte se ha investigado su capacidad para retener microorganismos que contribuyan a la descontaminación de un ambiente. Por ello, para cada una de estas funciones se han utilizado los aceros inoxidables sinterizados, que se han considerado más adecuados. Para estudiar sus capacidades de resistencia a la oxidación en caliente se ha utilizado un acero inoxidable austenítico AISI 304L, un acero inoxidable ferrítico AISI 430L y un acero inoxidable Fe-16Cr-3Al. Para estudiar sus capacidades para retener microorganismos se ha utilizado un acero inoxidable austenítico AISI 316L, un acero inoxidable ferrítico AISI 430L y un acero inoxidable dúplex 50%/50% de los anteriores. Para esta última finalidad los aceros se han compactado a tres diferentes presiones 300, 500 y 700 MPa, a las que corresponden diferentes porosidades. En relación con el comportamiento frente a la oxidación en caliente, se han cuantificado los incrementos positivos o negativos de volumen, masa y densidad en los diferentes tipos de sinterización y estados de tratamiento de oxidación. Como tónica general de comportamiento, puede decirse que los aceros sinterizados bajo vacío son más resistentes a la oxidación, que los sinterizados en atmósfera de N2-5H2 y que los aceros inoxidables austeníticos son algo más resistentes, que los Cr-Al y estos, a su vez, más que los aceros inoxidables ferríticos. Respecto a la retención de microorganismos, los tres aceros inoxidables sinterizados se han ensayado en diferentes medios de cultivo, utilizando cuatro especies de bacterias. Los mejores resultados se han obtenido con Staphylococcus aureus, muy favorable para su observación y recuento. Se han cuantificado, una vez sinterizados y colonizados por los microorganismos, para cada material y presión de compactación, las áreas de cada uno de los poros y el número de microorganismos situados en los poros y en la superficie sin poros. Se ha establecido en cada caso la densidad de microorganismos en las zonas de poros y en las zonas sin poros. Como tónica general puede decirse, que los aceros inoxidables austeníticos aparecen más favorables para estos estudios, que los aceros dúplex y estos más que los inoxidables ferríticos. Asimismo, se desprende que las áreas de los poros dependen de forma unívoca de la presión de compactación y que para áreas de poros decrecientes las densidades de microorganismos son crecientes. En consecuencia, podría deducirse, que a igualdad de área de poros en una superficie, aquella que tuviera los poros más pequeños, retendría mayor cantidad de bacterias. ABSTRACT The characteristics and capacities of sintered stainless steels have been researched from two perspectives: firstly, with a view to their resistance to hot oxidation, and secondly their capacity to retain microorganisms able to decontaminate the environment. For both these functions, sintered stainless steels were used, which are considered to be the most fit for purpose. To study their resistance to hot oxidation, we used austenitic stainless steel AISI 304L, ferritic stainless steel AISI 430L and stainless steel Fe-16Cr-3Al. To study their ability to retain microorganisms, we used austenitic stainless steel AISI 316L, ferritic stainless steel AISI 430L, and duplex stainless steel, being a 50/50 blend of the two former ones. For this last purpose, the steels were compacted at three different pressures (300, 500 and 700 MPa) corresponding to different porosities. With regard to the hot oxidation, we quantified the positive or negative increments in volume, mass and density in the different types of sintering and oxidation treatment states. As a general performance trend, we observed that vacuum sintered steels are more resistant to oxidation than those sintered in an atmosphere of N2-5H2, and that austenitic stainless steels are slightly more resistant than the Cr-Al steels which, in turn, are more resistant than the ferritic stainless steels. With regard to the retention of microorganisms, the three sintered stainless steels were tested in different culture media using four types of bacteria. The best results for observation and counting were obtained with Staphylococcus aureus bacteria. Once sintered and colonized by microorganisms, for each material and compacting pressure we quantified the areas of the pores and the number of microorganisms situated in the pores and on the pore-free surface. In each case, the density of microorganisms in the pores and in the pore-free areas was established. As a general rule, we can say that the austenitic stainless steels appear to be more favourable for this type of study than the duplex steels which, in turn, are more favourable than the ferritic stainless steels. It also emerged that the areas with the pores depend unequivocally on the compacting pressure, and that the smaller the area of the pore the higher the density of the microorganisms. Consequently, it can be deduced that comparing an equal area of pores on a surface, the one with the smaller pores would retain a larger number of bacteria.