Corrosion Analysis

Corrosion Analysis of
Stainless
steel
Introduction
Corrosionis deterioration of essential

properties in a material due to reactions
with its surroundings.
Millions of dollars are lost each year
because of corrosion.
Much of this loss is due to the corrosion
of iron and steel, although many other
metals may corrode as well.
What is Stainless steel?
Stainless Steel is a common name

for metal alloys that consist of
10.5% or more Chromium (Cr) and
more than 50% Iron (Fe).
10.5%<Cr<27%= Stainless Steel
used for corrosion resistance
Types of stainless steel
Austenitic Stainless Steel

Martensitic Stainless Steel
Ferritic stainless steel
Duplex stainless steel
Precipitation hardening stainless
steel
Austenitic Stainless Steel

Grade type is 304
16 26% Cr, 6 23% Ni
Have a face-centered-cubic (fcc) structure
Nonmagnetic, tough, ductile
Ex. Type 304 most widely used in the world
Type 304L is always preferred in more corrosive
environments
Applications: domestic kitchen sinks,
commerical food processing equipment
Ferritic Stainless Steel

Grade type is 430
12 25% Cr
This simplest form of stainless steel
Easy to machine
They are moderate corrosion resistance
Application: automotive trim and inside
dishwashers and clothes
dryers.
Martensitic Stainless Steel

Grade type is 410
6 18% Cr, upto 2% Ni
Strong, hard and magnetic
Used for mild corrosive enviornments
Application: knives, razor blades and
corrosion
resistance bearing
Precipitation Hardening
S.S
Type 17-4
High strength
Higher corrosion resistance than
martensite stainless steel
Application: they are usually used in
aerospace
and defense industries.
Corrosion
A process in which metal is

destroyed by chemical
reaction. When metal is iron,
the process is called rusting.
Example: Rusting of
automobiles,buildings and
bridges, etc.
Did you know?
Internationally, 1 tonne of steel turns

into rust every 90 seconds.
The energy required to make 1 tonne of

steel is approximately equal to the
energy an average family consumes
over three months.
Stainless Steel Corrosion
The name originate from the fact

stainless steel does not stain, corrode
or rust as easily as ordinary steel.
Stainless steel have resistance to
oxidation(rust)and corrosion in many
natural and man made environments.
UNIVERSALITY OF CORROSION
Not only metals, but non-metals like plastics,

rubber, ceramics are also subject to
environmental degradation
Even living tissues in the human body are
prone to environmental damage by free
radicals-Oxidative stress- leading to
degenerative diseases like cancer, cardiovascular disease and diabetes.
WHY DO METAL CORRODE?
Any spontaneous reaction in the universe is

associated with a lowering in the free energy
of the system. i.e. a negative free energy
change
All metals except the noble metals have free
energies greater than their compounds. So
they tend to become their compounds
through the process of corrosion
FORMS OF CORROSION AFFECTING

STAINLESS STEEL
Corrosion may be classified in different ways
Wet / Aqueous corrosion & Dry Corrosion
Room Temperature/ High Temperature
Corrosion
WET & DRY CORROSION

Wet / aqueous corrosion is the major form of
corrosion which occurs at or near room
temperature and in the presence of water
Dry / gaseous corrosion is significant mainly
at high temperatures
WET /AQUEOUS CORROSION OF S.S

Based on the appearance of the corroded
metal, wet corrosion may be classified as
Uniform or General Corrosion Of Stainless
steel
Pitting Corrosion
Crevice Corrosion
Galvanic or Two Metal Corrosion
Intergranular
Dealloying
UNIFORM CORROSION OF STAINLESS STEEL

The reaction starts
at surface and proceeds
uniformly.
e.g.. Atmospheric
corrosion.
Maximum metal loss
Not dangerous, rate can be measured in the laboratory.
This type of corrosion occurs when there is an overall
breakdown of the passive film formed on the stainless
steel.
GALVANIC CORROSION OF STAINLESS STEEL
Galvanic corrosion occur when

two dissimilar metals electrically
contact with each other and are
immersed in electrolyte.
When a galvanic couple forms,
Steel screw in Mg
one of the metals in the couple
becomes the anode and corrodes
faster than it would all by itself, while the other becomes
the cathode and corrodes slower than it would alone.
Requirements For Galvanic

Corrosion
In order for galvanic corrosion to occur,

three elements are required
a) Dissimilar metals
b) Metal to metal contact
c) Metals in same conduction solution
(usually
called electrolyte)
If any of these elements is missing,
galvanic corrosion cannot occur.
PITTING CORROSION OF STAINLESS STEEL
Pitting corrosion is a form

of extremely localized corrosion
that leads to creation of small
holes in metal.
It occurs when the corrosive
environment penetrates the passivated film in only a
few areas as opposed to the overall surface.
halogens will penetrate passivated stainless steel.
INTERGRANULAR CORROSION OF STAINLESS STEEL
Intergranular corrosion is due

to the formation of chromium
carbides at high temperatures
(450- 859C).
Carbides of chromium
form in the grain boundary regions
thus reducing the chromium content
and resulting in a path of lower corrosion resistance around the
grains.
ERROSION CORROSION OF STAINLESS STEEL
Erosion corrosion is the

result of a combination of
an aggressive chemical
environment and high
fluid-surface velocities.
The flow will carry away any protective layer that was
intended to protect the material, and even abrade the
flow surface.
STRESS CORROSION CRACKING OF

STAINLESS STEEL
Stress Corrosion Cracking (SCC) is the cracking induced from

the combined influence of tensile stress and a corrosive
environment. The impact of SCC on a material usually falls
between dry cracking and the fatigue threshold of that material.
Failure is along grain boundaries

in a 316 stainless steel.
.
PRINCIPAL ALLOYING ELEMENTS THAT AFFECT

CORROSION RESISTANCE OF STAINLESS STEEL
Chromium(Cr):
Essential element in forming the passive film.The

passive film is observed at about 10.5% chromium.
As chromium content increased , the corrosion
protection increase.
Chromium at 25 to 30%, the passivity of protective
film is very high.
Nickel(Ni)
When nickel is increased to about 8 to 10%
resistance to stress corrosion cracking is decrease.
However, when nickel is increased beyond that level,
resistance to stress-corrosion cracking increase with
increases nickel content.
Manganese(Mn)
Effects of manganese on corrosion are not well
documented.
Manganese combines with sulfur to form sulfides.
Sulfide composition have substantial effect on the
corrosion resistance of stainless steel.
Molybdenum(Mo)
Addition of molybdenum to the Cr-Fe-Ni matrix adds
resistance to localized pitting attack.
Its better resistance to crevice corrosion.
Corrosion Protection of S.S
Protection of Anode
Reduce the activity of cathode and
or electrolyte.(Polarization)
Sacrificial Layer
Impressed Voltages
Passivation of The Anode
Passivation, A thin chromium oxide

layer forms on the surface and isolates
the metal from the environment, called
passive film.
Passive Film
(Only microns thin,
invisible and self
repairing)
POLARIZATION
This is the effect which reduce the actual

chemical potential driving cell. If the
thermodynamic force driving the ion into
solution is reduced, this is polarization.
Easy example: Hydrogen reduction at
cathode, if
there are not enough hydrogen ions
available for
reaction at the cathode, the corrosion
potential will decrease.
SACRIFICAL LAYER
Galvanization of Steel
Dip steel sheet in molten zinc. Get a pretty
thin coating.
Zinc will be anode. Steel exposed by crack is
the cathode. Since we have a huge anode
having to be served by a small cathode,
corrosion rate will beTiny
slow.
cathode (steel)
Large area
anode (zinc)
ANOTHER EXAMPLE
Zinc is attached to the sheet hull of the vessel.
Attachment points
Stainless Steel For Coastal And Salt

Corrosion
Upgrading the use of stainless steel

from 304 to 306 has significant help in
reducing the effects of corrosion in
several application.
Molybdenum alloyed grades of type 316
are normally specified for marine
atmosphere.
Street Level Application

There is no
corrosion on type
316 bench and
railing in
downtown Chicago
after 5 year of
service. A smooth
polished finished
was used.
These type 304

railing were
corroded after one
winter in
Pittsburgh. They
are uphill from a
busy highway and
salt laden road mist
is blown on to
them. The rough
surface finish hold
the salt the railing
making corrosion
worse.
Street Level Application

Type 316 light poles
were installed at
Jones Beach, New
York in 1967 with
No.4 smooth
finish. Although
they are in
parking area
immediately
adjoining to
beach and
exposed to coastal
salt, there is no
sign of corrosion
Similar light poles

of type 304, shown
in right bottom was
installed in a
sheltered location
few blocks from
Miami Beach,
Florida. After one
year chloride
corrosion is visible.
COST OF CORROSION
Direct & Indirect losses

Direct loss: Material cost, maintenance cost,
over-design, use of costly material
Indirect losses: Plant shutdown & loss of
production, contamination of products, loss of
valuable products due to leakage etc, liability
in accidents
CORROSION DAMAGE
Disfiguration or loss of appearance

Loss of material
Maintenance cost
Extractive metallurgy in reverse- Loss of
precious minerals, power, water and manpower
Loss in reliability & safety
Plant shutdown, contamination of product etc
Conclusion
No metal, except for gold and platinum in

their natural state, are completely corrosion
proof. But stainless steel has proven in
thousands of applications, that it is one of the
most economical solution's to combat the
ever present elements that cause corrosion.
Yet as its name implies - it is stain-less,
not stain-proof
Thank You..

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Corrosion Analysis of

Corrosionis deterioration of essential

What is Stainless steel?

Stainless Steel is a common name

Types of stainless steel

Austenitic Stainless Steel

Austenitic Stainless Steel

Ferritic Stainless Steel

Martensitic Stainless Steel

A process in which metal is

Did you know?

Internationally, 1 tonne of steel turns

The energy required to make 1 tonne of

Stainless Steel Corrosion

The name originate from the fact

Not only metals, but non-metals like plastics,

WHY DO METAL CORRODE?

Any spontaneous reaction in the universe is

FORMS OF CORROSION AFFECTING

WET & DRY CORROSION

WET /AQUEOUS CORROSION OF S.S

UNIFORM CORROSION OF STAINLESS STEEL

GALVANIC CORROSION OF STAINLESS STEEL

Galvanic corrosion occur when

Requirements For Galvanic

In order for galvanic corrosion to occur,

PITTING CORROSION OF STAINLESS STEEL

Pitting corrosion is a form

INTERGRANULAR CORROSION OF STAINLESS STEEL

Intergranular corrosion is due

ERROSION CORROSION OF STAINLESS STEEL

Erosion corrosion is the

STRESS CORROSION CRACKING OF

Stress Corrosion Cracking (SCC) is the cracking induced from

Failure is along grain boundaries

PRINCIPAL ALLOYING ELEMENTS THAT AFFECT

Essential element in forming the passive film.The

Corrosion Protection of S.S

Passivation of The Anode

Passivation, A thin chromium oxide

This is the effect which reduce the actual

Zinc is attached to the sheet hull of the vessel.

Stainless Steel For Coastal And Salt

Upgrading the use of stainless steel

Street Level Application

These type 304

Street Level Application

Similar light poles

Direct & Indirect losses

Disfiguration or loss of appearance

No metal, except for gold and platinum in

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