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Amtec Consultants Expert Guide To Stainless Steel Corrosion Resistance Problems
Amtec Consultants Expert Guide To Stainless Steel Corrosion Resistance Problems
Resistance Problems
Amtec consultants provide corrosion expertise in the field of metallic corrosion. This
Guide is one of a series on our website dealing with a number of Corrosion & Coating
Breakdown topics. Other pages are focused on areas such as marine
corrosion, Industrial corrosion,Corrosion in Hot Water & heating Systems. Other guides
deal with Aluminium Corrosion & Copper Corrosion.
For more in depth information contact Amtec - enquiries@amteccorrosion.co.uk
surface film much more uniform and resistant to localised corrosion. Further increases
in alloying content give rise to duplex stainless steels, which are again more chemically
resistant.
With each increase in alloying content there is an increase in the cost of the material.
However the strength of the steel increases and some of the cost penalty can be
regained by using reduced cross sectional areas and thicknesses.
Common grades of austenitic stainless steel are 301, 303, 304, 316, 317, 321,
314 (in increasing alloy content). Where only low levels of corrosion resistance are
required grade 3CR12 could be considered as a low cost option (non austenitic option) if
some degree of pitting and general rust staining is acceptable.
Grade 301contains slightly less chromium (16-18%) & less nickel (6-8%) than
grade 304 although the two grades can overlap with a good quality grade 301 being
equivalent to a poor quality grade 304. Depending on the amount of cold work grade
301 can be differentiated from grade 301 due to it being mildly magnetic. Sub grades of
301 are 301L & 301LN. Grade 301L has a low carbon content for better ductility
whereas 301LN is a low nitrogen variant which work hardens more easily. It will also
have a higher PREN number and better pitting resistance than the standard grade.
Grade 304 is the "Classic" 18/8 stainless and generally contains between 17.5 - 20.0 %
Chromium & between 8 & 11% nickel. It is generally non-magnetic. The advantage of
this grade is that it can be easily deep drawn into shapes such as sinks and saucepans
together with other highly formed industrial articles. It has excellent corrosion
resistance in many atmospheric corrosion environments, however it is quite susceptible
to pitting and crevice corrosion in warm chloride containing environments and as such
its use should be avoided in Marine applications or applications in the food industry
where chloride containing cleaning agents are employed. Contact with body fluids
should also be avoided.
Grades 321 and 347 stainless steel are modifications to grade 304 to which titanium
or niobium have been added to desensitize the material from carbide precipitation
which results in inter granular corrosion and occurs as a result of heating the material
during welding.
Grade 316 stainless-steel is the most corrosion resistant of the commonly found
stainless steel grades. It contains between 16 and 18.5% chromium, between 10 and
14% nickel, and between 2 and 3% molybdenum. It is the material of choice where
high levels of pitting and crevice corrosion resistance are required in chloride containing
environments. It is chosen for its good surface appearance in the architectural and
transportation areas, however exposure to warm chloride containing environments can
still result in unsightly rust staining and cosmetically undesirable small pits.
Grade 314 is an austenitic stainless containing between 23-26% Chromium & between
19 & 22 % nickel. It has excellent corrosion resistance without having the welding
problems of duplex grades.
levels of both pitting corrosion and crevice corrosion by making the anodic area more
alkaline. Arranging for the environment to have greater flow will also cut down the
effects of both forms of localised corrosion.
Other passive materials such as aluminium and its alloys are susceptible to both crevice
corrosion and pitting corrosion. Pitting and crevice corrosion of aluminium occurs by
similar mechanisms to that of stainless steel.
Grade
PREN
430
16
444
25
304
19
304LN
21
316
26
316LN
27.5
904L
36
Zeron 100
41
SAF 2507
42
Alloy
2304
15
904L
15
2205
30
255
50
6Mo
70
S32760
70
The most common austenitic grades of stainless steel will, therefore, be above the
critical pitting temperature under many common service applications. However,
passivation treatments and control of the surface finish can be used to minimise the
effect of adverse service conditions.
Passivation Treatments
This is carried out by treating the surface with oxidising acids that dissolve iron but not
the oxides of the alloying elements. ASTM A967-1 gives citric acid at 8% for 3 hours at
room temperature as a common treatment and it is relatively safe to handle. Nitric acid
at 20% for 30 minutes at 55oC is a faster passivation treatment. 2% sodium
dichromate can also be added to the nitric acid treatment to improve the passivation,
however there are greater health and safety issues. Hydrofluoric acid can also be used
for passivation of stainless steel, but it is a very dangerous process. In the
pharmaceutical industry passivation is sometimes carried out using a very pure solution
of phosphoric acid. The acids used for passivation treatments should be virtually free of
chloride or fluoride ions otherwise pitting of the stainless steel can be initiated.
The rate of both the nitric acid and citric acid passivation processes can be increased by
raising the temperature. Passivation times can vary from a few minutes to several days,
depending upon the grade of stainless steel to be treated.
ASTM standards are a guideline only, as the passivation treatment chemicals, process
conditions and time have to be matched to both the operating conditions and the
corrosive environment.
Tests for the effectiveness of the passivation treatment can be electro-chemical, using
polarisation curves and potential mapping, or chemical, using either copper sulphate or
ferricyanide tests. The electrochemical polarization and potential mapping techniques
are far superior, providing more information and better accuracy. Amtec consultants and
corrosion experts are specialists in both types of passivation testing and interpretation
of the resulting data.
The sharp peak of low current pointing leftwards on the graphs, occurs when the
current goes through zero. This zero current is called the rest potential. For
potentiostatic curves, this is the same potential as the natural, unpolarised equilibrium
potential, which is also known as the corrosion potential.
For potentiodynamic curves, this potential is shifted by the non-equilibrium conditions.
For very passive surfaces, the shift is greater than for those with a weaker passive film.
The curves are often carried out starting from the bottom of the graph (electronegative)
and sweeping towards the top (electropositive). At the highest voltage, the sweep can
be immediately reversed and the voltage returned to the negative starting point, at the
same rate. A second zero current potential often occurs, followed by a more extensive
cathodic region.
The lag of the current behind the voltage is called the hysteresis. This causes the shift
in rest potentials and sometimes results in a lag in the curves after the reversal point.
Strongly passive surfaces produce the greatest hysteresis.
Where the positive part of the curve is vertical, or nearly vertical, this is a passive area
where a high resistance, voltage independent, thin chromium film is present on the
surface. The voltage range over which this film is stable is an indication of the quality of
the passive film. The projection of this line down to the X (current) axis shows the
corrosion current that could be expected when the film is present on the surface.
A second measurement of the corrosion current can be obtained by extrapolating the
electronegative (cathodic) part of the curve back to the zero current potential.
The passive surface of stainless steel is constantly reforming. If the steel comes into
contact with non-stainless or ferritic steel then these can smear across the surface and
cause local anodes. The resulting corrosion is unsightly & contact between stainless &
non-standard grades should be avoided. Seperate tools & work areas should be kept for
the two types of material.
Stainless steel can be supplied in a diversity of surface conditions & finishes. The photo
above shows a milled surface but brushed, ground & polished surfaces are also
common. Usually the choice of stainless steel surface finish is a cosmetic one made by
architects or designers but consideration should also be given to corrosion resistance
issues. In general the smoother the surface condition, the more resistant the stainless
steel surface is to corrosion & rust staining. Rough surfaces tend to initiate surface
pitting in conditions where smoother surfaces would be resistant. Rough surfaces tend
to accumulate contamination & require more maintenance. Grades such as 304 or 316
which are only marginally resistant to rust staining in food processing or marine
conditions are definitely susceptable when used in a rougher surface condition.
warm water containing surfactants will be required to keep the surface in good cosmetic
condition. A typical wasing interval will be in the order of six months, however in more
severe conditions more regular washing will be required. Cleaners containing active
ingredients such as ammonia or chlorides should be strictly avoided. Should the
stainless steel surface become stained or pitted then the surface staining can be
removed with "Scotchbite" pads. Once pitting has initiated then more regular cleaning
will be required.
Corrosion of Architectural Stainless Steel
The photo above shows how a poor cleaning regime can lead to corrosion in an
industrial kitchen. Components such as stainless steel shelving or stainless steel work
surfaces tend to be constructed from lesser grades than 316 as they are more easily
formable. Industrial refrigerators & industrial dish washers are almost always made
from 316 or 316L & generally are stain resistant.
Kitchen stainless steel surfaces can corrode rapidly if the equipment is supplied in a
poor condition. An example of poor manufacturing is shown in the above photograph
where the contrast between the two different surface manufacturing conditions is
apparent.
The severe pitting and corrosion shown above is an extreme case where a chlorine
containing cleaner has caused corrosion of an industrial sink unit. Milder forms of this
type of corrosion occur when the wrong type of cleaner or bleach is left in contact with
stainless steel.
Many pharmaceutical plants process saline solutions & are constructed from type 316L
stainless steel. Generally the stainless steel performs well, however if clamped flanges
are left in contact with saline solutions the type of crevice corrosion shown in the
photograph above can occur. When steam sterilising is carried out the surface of the
stainless can have a red rust stain called "rougeing". Stainless steel in pharmaceutical
situations can also be subject to pitting if insufficient flow is present in the process fluid.
Stagnant solutions may also cause corrosion of stainless steel ball & butterfly valves.
Sterilising vapours such as peracetic acid used for gassing can also attack stainless
steels. Where speed controlled pumps are used the stainless steel may also be subject
to stray current corrosion.
The photograph above shows the blackening that occurs on type 316L stainless steel on
a vessel that was regulary carrying acids. Such staining is a common feature of
chemical tankers & is often associated with a degree of surface roughening. Stainless
steels such as 316L can be sucessfully used in such applications. Stainless steel heating
pipes in product carriers regulary carring naptha can suffer pitting corrosion if they are
subject to surface damage prior to & during installation. Stainless steel doors & air
conditioning plant will need regular cleaning and preventative oiling.
The photo above shows a stainles steel spray nozzle from a dairy that is corroding from
the inside out. Often dairy or other food products contain salt & if they are left in long
term contact with stainless steel then corrosion can occur.
Food processing conveyors such as that shown above can rapidly corrode if supplied in
an incorrect surface condition. This surface had been bead blasted, similar brushed
surfaces in the same plant remained in good condition. As sterile surfaces in meat
processing are essential, often chloride containing cleaners have to be used. These
should be carefully removed fron the surface after use.
Corrosion of Stainless Steel in Swimming Pools
Stainless steel hand rails are common in swimming pools and are generally resistant to
corrosion from the pool chemicals. The corrosion shown above was due to the use of
incorrect floor cleaning chemicals. When stainlesss steel components or signs are
specified for internal use in swimming pools then regular cleaning & washing would be
expected.
For more in depth information contact Amtec: enquiries@amteccorrosion.co.uk
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