Stress Corrosion Cracking PDF

Stress Corrosion Cracking (SCC)
1. Examples
2. Mechanisms
3. SCC in the main Groups of Materials
Structural Integrity: stress corrosion cracking, corrosion fatigue

Universidad Polytecnica de Madrid, May 2012
M. Wollmann
Clausthal University of Technology
What is Stress Corrosion Cracking ?
Stress corrosion cracking is cracking due to a

process involving conjoint corrosion and straining
of a metal due to residual or applied stresses.
- definition is based on that due to ISO

- cracking may occur as a result of elastic strain alone
- the word strain does not imply plastic strain

M. Wollmann
Stress Corrosion Cracking
and what are residual stresses?

Residual stresses are stresses that remain after the original
cause of the stresses has been removed.
Original causes:
- Machining
- Deformation
- heat gradients
- internal precipetions
- Welding
- etc.

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1.
Examples for SCC

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Stress Corrosion Cracking in the

hardenable Alumnium Alloy EN AW-7020
7020 is used for welded parts

in the automotive and
mechanical engineering.
Intergranular cracking in 7020 (AlZn4,5Mg1)
Cause of the increase in strength are the precipitions of

intermetallic phases that are formed in well defined ways.
Copyright: Hydro Aluminium

M. Wollmann
Stress Corrosion Cracking in Brass
Formed brass components with stress

corrosion cracking attacks
Copyright: DKI

Percentage composition
Constituent just
below the
solidification
point
Constituent after
slow cooling
to 400C
Copper
Zinc
100 to 67.5
0 to 32.5
67.5 to 63
32.5 to 37
63 to 61
37 to 39
61 to 55.5
39 to 45.5
+ `
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Stress Corrosion Cracking in Pure Copper
Crack
Inner surface of a
copper pipe.
Corrosion product: CuO
Copyright: Clausthal Materials Consulting

Intergranular cracking
in pure copper (micrograph)
Copyright: DKI
M. Wollmann
Transgranular Stress Corrosion Cracking in

Austenitic Stainless Steel X5CrNiMo17-12-2
SCC in 316 stainless steel.

Typical multi-branched
transgranular crack pattern.
Copyright: Corrosion doctors

M. Wollmann
2.
Mechanisms

M. Wollmann
Mechanisms
The occurrence of SCC depends on the
simultaneous achievement of three requirements:
susceptible material
environment that causes SCC for that material
sufficient tensile stress to induce SCC
Consequently, SCC is relatively rare, though failures

can be very dangerous, costly and destructive when
they do occur!
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Swimming Pool Roof Collapse

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What causes the different Mechanisms?
For basic mechanisms have been identified:
active path dissolution

Film rupture model
Hydrogen embrittlement
Film-Induced cleavage

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Active Path Dissolution

Accelerated corrosion along
the path of higher corrosion
susceptibility.
homogeneous
Intergranular and transgranular

SCC in X15CrNiSi20-12
Copyright: Trostmann, Korrosion
Cr-concentration
inhomogeneous
Copyright: Trostmann, Korrosion
grain boundary
Copyright :Iser
The bulk of the material is

typically being passive.
Chromium depletion at
grain boundaries.
M. Wollmann

Accelerated corrosion along
the path of higher corrosion
susceptibility.
homogeneous
inhomogeneous
Cr-concentration
The effect of the applied

stress is probably mainly to
open up the cracks,
thereby allowing easier
diffusion of corrosion
products away from the
crack tip and allowing the
crack tip to corrode faster.
grain boundary
Copyright :Iser
The bulk of the material is

typically being passive.
Chromium depletion at
grain boundaries.
M. Wollmann

Active dissolution at cracks without films gives rise to
crack propagation.
An increase of active sites takes place at crack tips caused
by plastic microdeformation.
This model cannot explain
- the brittleness of SCC
- the difference between crack propagation rates
electrochemically estimated and experimentally obtained
- the apparent discontinuous behavior of crack advance

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Film Rupture Model
corrosive medium
corrosive medium
protective layer
protective layer
High stacking fault energy:

strain gives rise to the movement
of single dislocations
ferritic stainless steel
austenitic stainless steel
Stress ruptures the passive film locally and

sets up an active-passive cell.
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Hydrogen-induced SCC
Hydrogen formed on the surface of the steel
by cathodic polarization can diffuse into the
material
Crack path in a high-strength

steel, intergranular,
Copyright: Bosch GmbH

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Hydrogen-induced SCC
Transformable ferritic steels are susceptible to hydrogeninduced SCC in a wide range of aqueous media.
1. The electro chemical corrosion in aqueous solutions gives rise to
the production of certain amounts of hydrogen. Under normal
conditions, the hydrogen recombines and escapes.
2. In the presence of certain promoters (eg H2S) the recombination
of atomic hydrogen to H2 is not possible.
3. High activated atomic hydrogen may diffuse into the material,
causing embrittlement, and, if the region is subject to tensile
stress, cracking can result.

M. Wollmann
Stress Corrosion Cracking in the

Main Groups of Materials
Carbon and Low-Alloy Steel
Stainless Steel
- Austenitic
- Duplex
- Martensitic
High Strength Aluminium Alloys
Titanium Alloys
Copper and Copper Alloys

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Carbon and Low-Alloy Steel

- SCC occurs in wide range of environments
- steels tend to form a protective passivating film of oxide or other
species
- caustic cracking of steam-generating boilers was a serious
problem in the late 19th century
the necessary strong caustic solution was produced by evaporation of
the very dilute solution inside the boiler as it escaped through leaks in the
riveted seams
- boiler explosions led to significant loss of life
- more recently gas transmission pipelines have cracked in
carbonate solutions produced under protective coatings as a
result of cathodic protection systems
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Range of Environments for SCC in Carbon

and Low-Alloy Steel
Environment
Concentration
Temp
Mode
high (around boiling), > 40C
Hydroxides
high (around 1 M)
Nitrates
moderate (up to 1 M) moderate
Carbonate/bicarbonate low (up to 10-2 M)
moderate
liquid ammonia
low (ambient)
CO/CO2/H2O
low (ambient)
Aerated water
very high (above boiling)

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SCC in Sodium Hydroxide
Stress corrosion cracking in a tub for 50 % sodium hydroxide solution at

50 C. The solution has high pH values. The presence of tensile stresses
prevented grain boundary passivation.
The active / passive transition is in context with the formation

of magnetite. At more positive potentials occurs a rapid
passivation one of the grain boundaries
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SCC in Nitrate-containing Solutions
Stress corrosion cracks after

repair welding in 13rMo4 4
Stress corrosion cracking in the
transition zone of non-alloy steel
The grain boundary activation occurs at high anodic

polarization. This breakthrough potential is moved in the
negativ direction with increasing tensile stress.

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No Normalizing after Welding: SCC in

Alloy Heat Resistant Steel
Material: 13rMo4 4
Corrosive solution: 50% NH4NO3
Temperature: 115 C
Cracking start
Cracking end

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Intergranular Stress Corrosion Cracking

of Studs
drilling
Material:
low-alloy quenched and tempered steel
Corrosive solution: HNO3
Application: High pressure reactor

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SCC in Liquid Ammonia in Fine

Grain Structural Steel (S355N)
SCC may occur when
ammonia is contaminated
with air.
Shot peened
welding zone
S355N structural steel Chemical analysis -% by mass:
Si
Mn
Al min
Cu
Ni
CE
0.20
0.50
0.90 1.65
0.030
0.025
0.015
0.02
0.55
0.50
0.12
0.43

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Weld in a Fine Grain Steel for Pressure

Vessel
Areas in which the total
load of residual- and load
stresses are proned to
cracking.
It occurs particularly in
pressure vessel.
Weld in a fine grain steel for pressure vessel.

Stress corrosion cracking attacks are clearly
identifiable .

Welds and cold deformed

areas are particularly
affected.
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High Strength Aluminium Alloys

composition
microstruce
near-surface external and internal tensile stresses, about 50%
of the yield strength
corrosion medium

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Tensile Tests on Aluminum Alloys
Traction (kN)
Tensile test
In air
Tensile test in
Chloride solution
Elongation (mm)
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surface mass loss rate/ gm-2 h-1
Stability of the Passive Layer of Aluminum
pH
Copyright: Wendler-Kalsch, Grfen

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Typical Conditions for the Occurrence of

SCC in Aluminum
crack initiatian with
intergranular crack path during
the simultaneous action of
tensile stress and corrosive
media
low fracture deformation, no
visible corrosion products
AlZnMg- and AlZnMgCu- alloys,
AlMg-alloys normally with Mg >
3%; unfavorable microstructural
conditions are necessary
AlMgSi1 rarely and never in
AlMgSi0.5; usually naturally
aged
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Appearance of Cracks in Alumnium

Alloys
Inter-crystalline stress corrosion

cracking in extruded AlZnMg1

Inter-crystalline brittle fracture by

stress corrosion cracking in AlZnMg3
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Mechanism of Stress Corrosion Cracking

in Aluminum
F
active crack tip:

Al Al3+ + 3ehydrolysis:
Al3+ + H20 Al(OH)2+ + H+
H+ + e- Had Hab
active/passive transition:
Al Al3+ + 3eAl3+ + 3H20 Al(OH)2 + 3H+
_________________________
Al + 3H2O Al(OH)3 + 3H

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Possible Positions of Hydrogen in

Aluminum
Copyright: Rbel, Michael; Dissertation

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Stainless Steel
Type
Environment
Concentration
Temperature
Mode
Austenitic
chloride
high (around 1M)
high (boiling)
Duplex
chloride
high (around 1M)
high (boiling)
Martensitic chloride (usually + H2S)
high (around 1M)
moderate ( < 100 C)
Ferritic
low (up to 10-2 M)
low (ambient)
thiosulphate
or polythionate

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Local Element Formation and Stress

Corrosion Cracking
passive layer
passive layer
cathode
cathode
anode
F
metal

metal
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Stress Corrosion Cracking in Austenitic

Stainless Steel Rods (X5CrNi18-10)
anchored in
the roof structure
tensile stress in the bar

from the weight of the
ceiling
transgranular branched
Cracks that is typical of
chloride Induced SCC in
1.4301
Copyright: EMPA
10 mm
The roof was supported by stainless steel rods in

tension, which failed due to stress corrosion cracking.
anchored in concrete
hanging ceiling
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Stress Corrosion Cracking in Austenitic

Stainless Steel Rods (X5CrNi18-10)
anchored in
the roof structure
tensile stress in the bar

from the weight of the
ceiling
transgranular branched
Cracks that is typical of
chloride Induced
SCC in
1.4301
Number
1.4301
10 mm
Acronym
Cr
Ni
X5CrNi18-10
0.07
17.0 19.5
8.0 10.5
anchored in concrete
hanging ceiling
Copyright: EMPA

M. Wollmann
Conditions for SCC in Swimming Pools

1) the use of susceptible grades of stainless steel
2) a relatively high tensile stress relative to the yield
strength (0.2% proof strength), either from structural
loading or present as residual stresses from forming
or welding operations during manufacture and
installation
3) the presence of a specific aggressive environment;
chlorine containing compounds (by-products of
disinfection)may transfer via the pool atmosphere
even to surfaces remote from the pool
itself. These compounds can produce a highly
corrosive film, which can lead to SCC
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Stainless Steels for Swimming Pools

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SCC in an elbow in chrome-nickel steel
Trans-crystalline stress corrosion cracking in a

condensate line. Corrosive medium: hot
oxygen-and chloride-containing condensate,
crack - extending from inside to outside in cold
weld zones formed

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SCC of an insulated Stainless-Steel

Condensate Line
insulation
Water wetted the insulation and caused

chlorides to leach from the insulation onto
the hot metal surface.
Copyright: NASA

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Susceptibility of and copper-base

alloys to SCC
Type
Environment
pure
copper
nitrite
brass
HgN03, (NH4)2SO4 + CuSO4

Outdoor
NaN02, citrates and
tatrates, moist SO2, S042aqueous ammonia
-brass
aliquatic amine (NH4S04)
-brass
deionized water

Conc. Temp. Mode
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Stress Corrosion Cracks in a Copper Tube
SCC in pure caused by nitrite containing

insolating material
Copyright:Rckert, BAM

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SCC in Brass
Stress corrosion cracking in an elbow.

Material: CuZn37
Conditions: 24% NH3 /12.5 h

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Trans-crystalline cracks with intergranular

Branches
overview
detail
Material: CuZn36Pb2As
Conditions: 12.5% NH3/24 h
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Inter-crystalline cracking in Brass
overview
detail
Scanning electron micrograph of the

left images. Open spaces" between
the grains can be seen.
Material: CuZn39Pb3
Conditions: 5 % NH3 /16 h
M. Wollmann

M. Wollmann

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Stress Corrosion Cracking (SCC)

Structural Integrity: stress corrosion cracking, corrosion fatigue

What is Stress Corrosion Cracking ?

Stress corrosion cracking is cracking due to a

- definition is based on that due to ISO

Structural Integrity: stress corrosion cracking, corrosion fatigue