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H O S T E D BY
ScienceDirect
Defence Technology xx (2015) 1e10
www.elsevier.com/locate/dt
Department of Manufacturing Engineering, Annamalai University, Annamalai Nagar, Tamil Nadu 608002, India
Center for Materials Joining and Research (CEMAJOR), Department of Manufacturing Engineering, Annamalai Nagar, Tamil Nadu 608002, India
c
Materials Technology Division, Indira Gandhi Centre for Atomic Research (IGCAR), Kalpakkam, Tamilnadu 603102, India
Received 13 May 2015; accepted 15 May 2015
Available online
Abstract
Super 304H austenitic stainless steel with 3% of copper posses excellent creep strength and corrosion resistance, which is mainly used in heat
exchanger tubing of the boiler. Heat exchangers are used in nuclear power plants and marine vehicles which are intended to operate in chloride
rich offshore environment. Chloride stress corrosion cracking is the most likely life limiting failure with austenitic stainless steel tubing. Welding
may worsen the stress corrosion cracking susceptibility of the material. Stress corrosion cracking susceptibility of Super 304H parent metal and
gas tungsten arc (GTA) welded joints were studied by constant load tests in 45% boiling MgCl2 solution. Stress corrosion cracking resistance of
Super 304H stainless steel was deteriorated by GTA welding due to the formation of susceptible microstructure in the HAZ of the weld joint and
the residual stresses. The mechanism of cracking was found to be anodic path cracking, with transgranular nature of crack propagation. Linear
relationships were derived to predict the time to failure by extrapolating the rate of steady state elongation.
Copyright 2015, China Ordnance Society. Production and hosting by Elsevier B.V. All rights reserved.
Keywords: Super 304H; Chloride stress corrosion cracking; Constant load test; Gas tungsten arc welding
1. Introduction
Austenitic stainless steels are the desired material for use in
high temperatures under highly corrosive environment. Heat
exchangers are used in nuclear power plants and marine vehicles which are intended to operate in chloride rich offshore
environment. The efficiency of the power cycle is function of
the operating temperature and pressure. Development and
selection of materials with required high temperature strength
and corrosion resistance is vital in further improvement in
* Corresponding author. Tel.: 91 9751014430 (mobile).
E-mail addresses: vinothmecho@gmail.com (M. VINOTH KUMAR),
visvabalu@yahoo.com (V. BALASUBRAMANIAN), srkcemajor@gmail.
com (S. RAJAKUMAR), shaju@igcar.gov.in (S.K. ALBERT).
Peer review under responsibility of China Ordnance Society.
1
Tel.: 91 9443412249 (mobile).
http://dx.doi.org/10.1016/j.dt.2015.05.009
2214-9147/Copyright 2015, China Ordnance Society. Production and hosting by Elsevier B.V. All rights reserved.
Please cite this article in press as: VINOTH KUMAR M, et al., Stress corrosion cracking behaviour of gas tungsten arc welded super austenitic stainless steel
joints, Defence Technology (2015), http://dx.doi.org/10.1016/j.dt.2015.05.009
+
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Table 1
Chemical composition (wt.%) of parent metal (PM) and filler metal (FM).
PM
FM
Si
Mn
Cr
Ni
Cu
Nb
Mo
0.086
0.1
0.23
0.3
0.81
3.3
0.021
<0.01
0.0003
<0.01
18.18
18.3
9.06
15.7
0.095
0.16
3.080
2.9
0.045
0.5
e
0.7
0.0039
e
Table 2
Tensile properties of parent metal and weld joint.
Parent metal
Weld joint
0.2% yield
strength YS/MPa
Ultimate tensile
strength UTS/MPa
Elongation in 25 mm
gauge length/%
Joint efficiency /%
284.2
349.6
575.8
614.6
71.8
52.3
e
106.7
57.1 mm and wall thickness of 3.5 mm. For GTA welding, the
joints with single V butt configuration were welded with
addition of filler metal. Filler metal composition was suitably
modified to achieve delta ferrite free weld metal by increasing
the Ni content; the resultant weld metal microstructure was
fully austenitic, as preferred in high temperature applications
[9]. Mo was added to avoid the risk of hot cracking in the fully
austenitic weld metal by modifying the S inclusions and
enhance the resistance to pitting corrosion [14,15]. The
chemical compositions of the parent metal and filler metal are
presented in Table 1. The welding was carried out with
average heat input of 0.68 kJ/mm, in which argon was used as
the shielding and purging gas.
The specimens for transverse tensile test and SCC tests
were extracted from the parent metal and weld joints using
wire-cut electric discharge machining. The tensile properties
of as-received parent metal and weld joints are listed in Table
2. In order to reveal the susceptibility of Super 304H parent
metal and weld joint to intergranular corrosion (IGC), the
specimens were subjected to oxalic acid etch test as per ASTM
A262 practice A. The specimens were probed under light
microscope to reveal the level of Super 304H's susceptibility to
IGC before and after welding.
The SCC test was carried out using the smooth tensile
specimen (shown in Fig. 1) in a custom-built constant load
setup with maximum loading capacity of 10 kN. The applied
loads are measured using a load cell with an accuracy of
10 N. The strain measurements were done using an LVDT
with measurable range of 5 mm and an accuracy of <1 mm.
The schematic representation of the SCC constant load setup
is shown in Fig. 2. The environment for SCC testing of Super
304H was chosen as 45% MgCl2 boiling at 155 C, and the
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Fig. 2. Schematic representation of the SCC constant load setup with boiling
MgCl2.
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Fig. 5. Typical corrosion elongation curve of Super 304H and its parameters in
boiling MgCl2 solution.
shows grain coarsening due to the weld thermal cycles, however no liquation of grain boundaries nor sensitization is
observed from SEM micrograph.
The fusion zone of the weld next to fusion line is shown in
Fig. 3(e) which shows the mixed morphology (cellular and
dendritic) of the austenite in this zone. The white dotted line
marks the transition of the austenitic weld from dendrite near
the fusion line to cell morphology towards the weld enter. The
magnified image of the area marked in Fig. 3(e) is shown in
Fig. 3(f). The marked arrow indicates the primary ferrite
dendritic core formed by F-A solidification mode and subsequently transformed to secondary austenite by solid state
diffusion. This confirms that both A type (cellular) and F-A
type of solidification have prevailed in the fusion zone next to
fusion line [16].
3.2. Oxalic acid etch structure
matrix, and their XRD pattern is shown in Fig. 3(b). The XRD
pattern confirmed the presence of Nb(C,N), M23C6 carbides in
the parent metal. The SEM micrograph of weldmetal in the
center of the joint is shown in Fig. 3(c), which reveals fully
austenitic grains with cellular morphology and carbides (NbC,
M23C6) precipitated along the boundaries. The fusion line (FL)
of the weld joint shown in Fig. 3(d) reveals the epitaxial grain
growth. The heat affected zone (HAZ) next to the fusion line
Fig. 6. Corrosion elongation curves for parent metal and weld joints of Super 304H in boiling MgCl2 at 100%, 80%, 60% and 40% of the yield strength.
Please cite this article in press as: VINOTH KUMAR M, et al., Stress corrosion cracking behaviour of gas tungsten arc welded super austenitic stainless steel
joints, Defence Technology (2015), http://dx.doi.org/10.1016/j.dt.2015.05.009
MODEL
Fig. 8. Prediction of time to failure of Super 304H parent metal and weld joint
by SCC in boiling MgCl2.
Cracking surface S0
s
1
Propogation time tp
sr
where So is initial cross section; tp is time for crack propagation after crack initiation (tss); s is initial applied stress; and
Table 3
Corrosion elongation curve parameters for Super 304H in boiling MgCl2 solution.
Material
Applied tensile
stress/MPa
% of applied
tensile stress
Parent metal
280
230
170
110
280
230
170
110
1.0
0.8
0.6
0.4
1.0
0.8
0.6
0.4
Weld joint
YS
YS
YS
YS
YS
YS
YS
YS
Time to
failure tf/h
Time to
transition tss/h
tss/tf
Elongation
rate iss/(mm$s1)
Crack growth
rate Vc/(mm2$h1)
6.75
12.17
22.17
25.92
4.17
9.75
10.08
11.00
2.75
5.32
14.80
19.65
1.25
2.50
6.10
7.97
0.48
0.5
0.67
0.75
0.3
0.26
0.6
0.72
2.70E-06
6.15E-07
2.01E-07
1.66E-07
1.32E-03
5.33E-06
1.98E-07
2.42E-08
1.57
1.07
1.17
1.58
1.81
0.92
2.03
3.12
Please cite this article in press as: VINOTH KUMAR M, et al., Stress corrosion cracking behaviour of gas tungsten arc welded super austenitic stainless steel
joints, Defence Technology (2015), http://dx.doi.org/10.1016/j.dt.2015.05.009
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Fig. 9. Fracture characteristics of Super 304H parent metal SCC specimens tested in boiling MgCl2 solution at different stress levels.
Please cite this article in press as: VINOTH KUMAR M, et al., Stress corrosion cracking behaviour of gas tungsten arc welded super austenitic stainless steel
joints, Defence Technology (2015), http://dx.doi.org/10.1016/j.dt.2015.05.009
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Fig. 10. Fracture characteristics of Super 304H GTAW joints SCC specimens tested in boiling MgCl2 solution at different stress levels.
Please cite this article in press as: VINOTH KUMAR M, et al., Stress corrosion cracking behaviour of gas tungsten arc welded super austenitic stainless steel
joints, Defence Technology (2015), http://dx.doi.org/10.1016/j.dt.2015.05.009
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Fig. 11. Crack propagation characteristics in SCC specimen tested in boiling MgCl2 solution at different applied stress levels.
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Acknowledgements
The authors wish to express their sincere thanks to M/s
Mailam India Ltd, Pondicherry, India for providing the funds
to carry out this research work through Mailam India Research
(MIR) Fellowship, M/s Salzgitter Mannesmann Stainless
Tubes Italia Srl, Italy for supplying the Super 304H tubes and
Department of Science and Technology (DST-SERB), Government of India, for providing the stress corrosion cracking
setup wide project no. SB/FTP/ETA-281/2012.
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Please cite this article in press as: VINOTH KUMAR M, et al., Stress corrosion cracking behaviour of gas tungsten arc welded super austenitic stainless steel
joints, Defence Technology (2015), http://dx.doi.org/10.1016/j.dt.2015.05.009
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Please cite this article in press as: VINOTH KUMAR M, et al., Stress corrosion cracking behaviour of gas tungsten arc welded super austenitic stainless steel
joints, Defence Technology (2015), http://dx.doi.org/10.1016/j.dt.2015.05.009