Papers by Keyword: Corrosion Fatigue

Abstract: In corrosive geothermal environment corrosion fatigue lowers the lifetime expectancy of high alloyed steels. The load type is directly affecting corrosive and mechanical failure mechanism. Therefore, main objective is to gain general understanding upon the formation of the passivation layer and corrosion fatigue failure of duplex stainless steel AISI 2205 specimen tested under pure axial push/pull load and rotation bending load in a specifically designed corrosion chamber surrounded by the Northern German Basin electrolyte at 369 K. The thickness of the passive layer directly depends on flow direction and velocity of the corrosive media and under rotation bending additionally of the rotation speed of the specimen. Crack initiation and failure are associated with corrosive degradation of the passive layer and pit formation while mechanical degradation is secondary.

Abstract: The understanding of crack growth and therefore failure of components in geothermal energy production could lower maintenance costs tremendously. During in-situ corrosion fatigue experiments of high alloyed steel in geothermal brine the electrochemical potential was measured as well as temperature, frequency and pH of the surrounding geothermal brine. The decline of the electrochemical potential is in good agreement with estimated increasing linear crack propagation velocity. During initial crack propagation the electrochemical potential is in good agreement with the stress amplitude applied revealing that a steeper decline of potential indicates faster crack propagation. However, towards the end of propagation, this potential becomes independent of the stress amplitude.

Abstract: Corrosion fatigue is a phenomenon in which corrosion damage is superimposed on fatigue damage and can result in a significant decrease in fatigue strength. Because corrosion fatigue cracks initiate from the bottom of corrosion pits, corrosion fatigue strength evaluation methods based on the corrosion pit shape have been proposed and put into practical use. However, corrosion fatigue strength evaluation methods have not been fully investigated for cases in which only corrosion damage precedes. Therefore, the state of the corroded surface due to corrosion damage was evaluated using the arithmetic mean waviness Wa. The arithmetic mean waviness Wa is an appropriate parameter for evaluating the degree of corrosion damage in structural steel immersed in synthetic sea water for long period.

Abstract: IIn a geothermal environment, cathodic protection is employed to improve resistance against corrosion fatigue. However, during the cathodic reactions under applied potential, hydrogen is generated and assimilated, leading to a reduced lifetime expectancy of high-alloyed steels. The corrosion fatigue mechanism of a standard duplex stainless steel X2CrNiMoN22-5-3 (1.4462) specimen loaded with hydrogen was studied in a corrosion chamber specifically designed for the purpose, surrounded by the electrolyte of the Northern German Basin at 369 K. The microstructural reactions resulting in hydrogen incorporation significantly decrease the number of cycles to failure of the specimen. This reduction is attributed to hydrogen enhancing crack propagation and causing early failure, primarily due to the deterioration of the mechanical properties of the ferritic phase rather than corrosion reactions or corrosive degradation.

Abstract: Standard duplex stainless steel X2CrNiMoN22-5-3 is resistant to both, corrosion and mechanical stress, but corrosion fatigue (CF) lowers the lifetime expectancy in a geothermal environment such as the Northern German Basin. Laboratory experiments used the in-situ electrolyte at 369 K in a specifically designed corrosion chamber applying rotation bending cyclic load to failure. CF behaviour was compared to pure push-pull load. Corrosion kinetics are independent of the load applied. Failure is initiated by pits resulting in mechanical degradation. Increased thickness of the passivating layer surrounding pits enhances degradation or delamination. Also, sharp notches located along the pit edge increase notch effects and stress concentration consequently leading to fast crack propagation and early failure.

Abstract: In geothermal environment corrosion fatigue lowers the lifetime expectancy of high alloyed steels. Therefore, cathodic protection enhances corrosion resistance although hydrogen is produced during the cathodic reactions under applied potential. Corrosion fatigue of standard duplex stainless steel X2CrNiMoN22-5-3, 1.4462 specimen loaded with hydrogen was investigated in a specifically designed corrosion chamber surrounded by the Northern German Basin electrolyte at 369 K. The reactions of the microstructure associated with hydrogen incorporation lowers the number of cycles to failure of specimen significantly at various stress amplitudes, for example at σ_a = 275 MPa and U_SHE = -36 mV by 80%. Hydrogen enhances crack propagation and early failure due to the degradation of the mechanical properties of the ferritic phase.

Abstract: AISI D3 material finds wide use as Dies in Tableting Machines for Pharmaceutical applications owing to its good strength, toughness and moderate corrosion resistance combined with cost effectiveness. However, 10-15% of AISI D3 Dies used in rotary Tableting Machines were found to fail within 4-6 months of service resulting in frequent disruption of regular production and loss in overall productivity besides having potential long-term risks such as metal contamination in the output product. Visual examination of the failed Die showed 180^o crack across the top Die face with rust marks, but no such crack was found on the bottom face. Also, the crack on the top Die face had a jagged morphology and those cracks on the Outer Diameter (OD) surface oriented in the axial direction were found to be straight and sharp. Macro-examination of Die sectioned diametrically and perpendicular to the crack on the Die face revealed jagged axial cracks on the Internal Diameter (ID) surface. Cluster pitting marks centered around mid-height of the Die were observed on the ID surface and the cut open sections of the Die along the crack revealed extensive corrosion. While microstructural examination of samples taken on the ID surface showed presence of banded carbides oriented axially in tempered martensite matrix, the same examination carried out on samples taken on Die face revealed fine needle like carbides in tempered martensite matrix. Fractography analysis conducted in the cluster pitting zone on the ID surface clearly showed presence of micro-cracks having multiple points of origin with clear indications of propagation into the cross section of the Die. Scanning Electron Microscopy (SEM) carried out in the aforementioned zone near ID surface also showed the presence of multiple micro-cracks. The SEM-EDX analysis in the referred zone at specific locations in the vicinity of microcracks confirmed inadequate Chromium oxide content leading to lack of corrosion resistance in the material. Based on the investigation & analyses and the detailed study of the Tableting Process in rotary Tableting Machines that revealed the nature of applied load to be cyclic, a comprehensive failure mechanism was arrived at, and it was inferred that the predominant mode of AISI D3 Die failure was Corrosion Fatigue. Finally, recommendation has been proposed to prevent such failures during service.

Abstract: The new method for a comprehensive assessment of the strength, durability and material capacity of the critical elements of the main gas pipelines, taking into account the combined impact of factors causing damage (environment, corrosion, random loading, geometry variation, material defects, etc.), which are changing the bearing capacity and material capacity of these structures, is proposed. As the main damaging factor, the process of corrosion fatigue is accepted, the qualitative and quantitative assessment of which are realized by applying a set of equations of comparable fatigue lines obtained by fatigue tests carried out in air and in corrosive environment. By the joint solution of these equations, the functions of the corrosion action coefficients are obtained in a wide range of cyclic strength and durability, which in standard calculation procedures are performed only for cyclic strength and only at the inflection point of the fatigue lines (N_G  5  10⁶ cycles).The issues of reducing the material consumption and ensuring the cost-effectiveness of structures, by using relatively cheap materials for pipelines - low-carbon and low-alloy structural steels subjected to surface hardening in stressed sections of pipes (edge welds) in order to significantly increase the physical and mechanical characteristics of the used steel grades are considered. In order to increase the corrosion resistance of these sections, contemporary polymer anticorrosive coatings are used.

Abstract: Based on the constant amplitude CF test of oil well tube material TP140small specimen, the procedures of predicting the variable amplitude corrosion fatigue (VACF) life of given reliability of TP140 were developed. Through the multi-sample sinusoidal loading constant amplitude CF life texts, the reliability distribution of CF life was analyzed. The CF life prediction of the specified reliability was obtained under 4 different stress levels, and the corresponding P-S-N curve expressions were obtained. Using VACF loading block spectrum and P-S-N curve expressions, the VACF life was calculated without considering the loading sequence effect. Furthermore, 5 VACF life tests were carried out using the same loading block spectrum. The VACF life with reliability was predicted by the principle of reliability and statistics. VACF life was calculated and compared with the predicted life. Test results and analysis show that the predicted results agree well with the experimental results, and CF life of TP140 casing steel follows a lognormal distribution at the given equivalent stress level, which has been substantiated.

Abstract: Tensile residual stress can cause a reduction in the fatigue strength of steel not only in air but also in corrosive environments. In air, for example, the effect of residual stress on fatigue strength can be estimated by using relations between fatigue strength and mean stress such as the modified Goodman diagram. However, it is not clear whether a sort of fatigue strength estimation can be applicable to corrosion fatigue properties. This paper presents an experimental method to evaluate the effect of welding residual stress on corrosion fatigue properties quantitatively, where corrosion fatigue tests were conducted in synthetic seawater by using characteristic fatigue specimens that have two parts, a tensile residual stress part and the other supporting part. Bead-on-plate welding was performed for applying welding residual stress in the tensile residual stress part. Residual stress relaxation was measured using the X-ray diffraction method in the midst of fatigue testing. Effects of tensile residual stress on corrosion pit growth and S-N curves were discussed.