Biofouling and microbially influenced corrosion of stainless steels

Stainless steels are among the most investigated materials on biofouling and microbially-influenced corrosion (MIC). Although, generally corrosion-resistant owing to tenacious and passive surface film due to chromium, stainless steels are susceptible to extensive biofouling in subsoil, fresh water and sea water and chemical process environments. Biofilms influence their corrosion behavior due to corrosion potential ennoblement and sub-surface pitting. Both aerobic and anaerobic microorganisms catalyse microbial corrosion of stainless steels through biotic and abiotic mechanisms. MIC of stainless steels is common adjacent to welds at the heat-affected zone. Both austenite and delta ferrite phases may be susceptible. Even super stainless steels are found to be amenable to biofouling and MIC. Microbiological, electrochemical as well as physicochemical aspects of MIC pertaining to stainless steels in different environments are analyzed.

Identification of MnCr2O4 nano-octahedron in catalysing pitting corrosion of austenitic stainless steels

Pitting corrosion of stainless steels, one of the classical problems in materials science and electrochemistry, is generally believed to originate from the local dissolution in MnS inclusions, which are more or less ubiquitous in stainless steels. However, the initial location where MnS dissolution preferentially occurs is known to be unpredictable, which makes pitting corrosion a major concern. In this work we show, at an atomic scale, the initial site where MnS starts to dissolve in the presence of salt water. Using in situ ex-environment transmission electron microscopy (TEM), we found a number of nano-sized octahedral MnCr2O4 crystals (with a spinel structure and a space group of Fd (3) over barm) embedded in the MnS medium, generating local MnCr2O4/MnS nano-galvanic cells. The TEM experiments combined with first-principles calculations clarified that the nano-octahedron, enclosed by eight {1 1 1} facets with metal terminations, is "malignant", and this acts as the reactive site and catalyses the dissolution of MnS. This work not only uncovers the origin of MnS dissolution in stainless steels, but also presents an atomic-scale evolution in a material's failure which may occur in a wide range of engineering alloys and biomedical instruments serving in wet environments. (C) 2010 Acta Materialia Inc. Published by Elsevier Ltd. All rights reserved.

Influence of surface texture on the galling characteristics of lean duplex and austenitic stainless steels

Two simulative test methods were used to study galling in sheet forming of two types of stainlesssteel sheet: austenitic (EN 1.4301) and lean duplex LDX 2101 (EN 1.4162) in different surface conditions. Thepin-on-disc test was used to analyse the galling resistance of different combinations of sheet materials and lubricants. The strip reduction test, a severe sheet forming tribology test was used to simulate the conditionsduring ironing. This investigation shows that the risk of galling is highly dependent on the surface texture of theduplex steel. Trials were also performed in an industrial tool used for high volume production of pumpcomponents, to compare forming of LDX 2101 and austenitic stainless steel with equal thickness. The forming forces, the geometry and the strains in the sheet material were compared for the same component.It was found that LDX steels can be formed to high strain levels in tools normally applied for forming ofaustenitic steels, but tool adaptations are needed to comply with the higher strength and springback of thematerial.

Microstructural and electrochemical characterization of friction stir welded duplex stainless steels

Conselho Nacional de Desenvolvimento Científico e Tecnológico (CNPq)

Brazeability of UNS 32101 and UNS S32304 lean duplex stainless steels

CAPES

Damage tolerance of cold drawn ferritic-austenitic stainless steels wires for prestressed concrete

Damage tolerance of high strength cold-drawn ferritic–austenitic stainless steel wires is assessed by means of tensile fracture tests of cracked wires. The fatigue crack is transversally propagated from the wire surface. The damage tolerance curve of the wires results from the empirical failure load when given as a function of crack depth. As a consequence of cold drawing, the wire microstructure is orientated along its longitudinal axis and anisotropic fracture behaviour is found at macrostructural level at the tensile failure of the cracked specimens. An in situ optical technique known as video image correlation VIC-2D is used to get an insight into this failure mechanism by tensile testing transversally fatigue cracked plane specimens extracted from the cold-drawn wires. Finally, the experimentally obtained damage tolerance curve of the cold-drawn ferritic–austenitic stainless steel wires is compared with that of an elementary plastic collapse model and existing data of two types of high strength eutectoid steel currently used as prestressing steel for concrete.

Biofouling on PM stainless steels

Powder metallurgy (PM) consists in obtaining pieces of powder metal that are processed at high temperatures and pressure. Due to its characteristic manufacturing process, the materials can have a specific and controlled porosity, which makes it possible to obtain porous parts such as ball bearings, gears, and roller bearings, etc. This porosity is what made us think about how easy biofouling would be on these materials and its possible environmental applications.

Transpassivation of Fe-Cr-Ni stainless steels

A transpassivation model was proposed for Fe–Cr–Ni stainless steels. In this model, the important steps and processes involved in transpassivation were illustrated. With some reasonable assumptions, transpassivation behaviours were predicted, such as the changes in film composition, film thickness, anodic current density and AC impedance spectrum in transpassive and secondary passive regions. It was demonstrated that these theoretical predictions were in good agreement with experimentally observed transpassivity of Fe–Cr–Ni stainless steels.

The breakdown of stainless steels in strong acids

A study was made of the corrosion behaviour in the ASTM standard Nitric acid and Oxalic acid tests, of two commercial AISI type 304L steels in the as received condition and after various heat treatments. Optical microscopy and SEM, TEM and STEM in conjunction with energy dispersive x-ray analysis, were used to correlate the corrosion behaviour of these steels with their microstructure. Some evidence of phosphorus segregation at grain boundaries was found. The corrosion behaviour at microstructural level was studied by examining on the TEM thin foils of steel that had been exposed to boiling nitric acid. Banding attack in the nitric acid and oxalic acid tests was studied using SEM and EPNA and found to be due to the micro-segregation of chromium and nickel. Using two experimental series of 304L, one a 17% Cr, 91 Ni, steel with phosphorus additions from 0.006% to 0.028%, the other a 20% Cr, 121 Ni steel with boron additions from 0.0011 to 0.00B51. The effect of these elements on corrosion in the nitric acid test was studied. The effect of different cooling rates and different solution treatment temperature on the behaviour of these steels was examined. TEM and STEM in conjunction with energy-dispersive x-ray analysis were again used to study the microstructure of the steels. Phosphorus was found to affect the corrosion behaviour but no effect was found with boron.