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Synopsis
The possibility that type 430 stainless steel can become sensitized
during annealing after hot-rolling was studied by simulated cycles
of continuous-annealing heat treatments, and by calculation of the
carbon solubility. It was found that the lower-carbon steel could be
sensitized at lower annealing temperatures than the higher-carbon
steel, which is in line with plant experience. The difference in
sensitization behaviour is ascribed to the lower rate of recovery of
the lower-carbon steel during cooling, since recovery is sensitive to
the grain size. At practical heat-treatment temperatures, austenite
formation does not play a role.
,
Introduction
The Journal of The South African Institute of Mining and Metallurgy MAY/JUNE 1996 119 ....
Sensitization of type 430 ferritic stainless steel during continuous annealing
chromium content in those regions of the alloy adjoining For the simulated annealing cycles, specimens 2 mm
chromium-rich grain-boundary carbides2-9. The observed thick, 19 mm wide, and 65 mm long were cut from the hot-
differences between the sensitization behaviour of ferritic rolled steel. The specimens were heated in a welding
steels and that of austenitics stem from the much more rapid simulator, spending approximately 120 seconds at the peak
diffusion of both carbon and chromium in ferrite6,lO. Because temperature. Typical thermal cycles are illustrated in Figure 2.
of this rapid diffusion, the precipitation of carbides (and the The time at peak temperature and the subsequent cooling rate
associated sensitization) in commercial ferritic stainless were selected to be similar to the actual annealing cycle in a
steels can generally not be prevented even by water plant. Peak temperatures ranged from 745 to 980°C.
quenching from the temperature range where carbon is
soluble in the metal matrix5. However, this effect is mitigated
1000
by the rapid recovery of the alloy, which restores the
corrosion resistance by diffusion of chromium into the
chromium-depleted areas adjacent to the grain boundaries.
800
Once the alloy is in the recovered state, it is no longer
sensitized, and it can be re-sensitized only if it is re-heated
to the temperature range where the carbides re-dissolve; it is
"....,
600
generally stated5.6,1l that the carbides dissolve above about ()
0
950°C, although this temperature is expected to depend on
'-"
the amounts of both chromium and carbon in the alloy4. f-
400
Sensitization testing showed that, subsequent to hot
rolling, type 430 stainless steel is in the recovered condition.
Hence, sensitization during annealing is possible only if the
200
chromium carbides are re-dissolved. The typical annealing
temperature is 880°C, which appears too low for the
dissolution of carbide in the light of the results cited above.
0
The present investigation aimed to show whether annealing 0 50 100 150 200 250
below 950°C can dissolve sufficient carbon for sensitization
to occur. The approach involved the use of experimental t (s)
annealing cycles, and the calculation of the carbon solubility Figure 2-Typical thermal cycles to which the hot-rolled specimens
from thermodynamic data. were subjected to simulate continuous annealing. The two cycles
shown are for the highest and lowest annealing temperatures
considered
Experimental
Annealing cycles
Sensitization testing
Two AISI type 430 steels were tested in the hot-rolled
condition; the compositions are given in Table I. The major Potentiostatic etching was used in a test of whether the
difference between the steels concerned the carbon content. specimens were sensitized after the annealing cycle. This
Plant experience suggested that gold dusting is much less procedure is based on the effect of chromium content on the
frequent on steels with a higher carbon content (around 0.04 passivation potential of iron-chromium alloys in 0.5 M
per cent C) than on those with less carbon (around 0.015 per H2S04, as illustrated in Figure 3. If the potential of an alloy is
cent C). below its passivation potential, the alloy dissolves actively
with a high anodic current, whereas the alloy is passive for
potentials above the passivation potential, giving a low
Table I anodic current. Hence, if the potential is controlled at a given
Compositions (in mass per cent) of the two grades of value, Eetch,those parts of the microstructure containing less
AISI type 430 stainless steel used in this investigation chromium than that which gives a passivation potential of
Eetchwill corrode actively, while parts containing more
Stainless steel 1
(higher carbon)
chromium will be passive. As Figure 3 shows, if the potential
is controlled at 0.100 V relative to the saturated calomel
16.60 electrode, regions with less than approximately 11 per cent Cr
0.0370
0.0171
(Le. chromium-depleted regions) are active. In this way, the
0.73 current density during potentiostatic etching gives a quanti-
0.54 tative indication of the presence of chromium-depleted
0.17
0.03 regions. In addition, microscopic investigation after the
0.005 etching treatment can identify those regions which had
0.093 dissolved.
0.001
0.017 For the potentiostatic etching, an area of 1.23 cm2 of each
0.06 specimen was exposed to an electrolyte of 0.5 M H2S04 at
0.013
0.024 25°C. The potential was maintained at 0.100 V (relative to
0.003 the saturated calomelelectrode)for 300 seconds, recording
the current density at the end of this period. The period of
~ 120 MAY/JUNE 1996 The Joumal of The South African Institute of Mining and Metallurgy
Sensitization of type 430 ferritic stainless steel during continuous annealing
0.6 0.8
0.5
10 20 30
0 10 20 30 90 100
Weight percentage chromium Cr in ferrite or austenite (wt. %)
Figure 3-Passivation potential of binary iron-chromium alloys in 0.5 M Figure 4-Molar ratio Cr/(Cr +Fe) (Yc,) in the M23C6 carbide in
H~04 at room temperature (data from Rocha and Lennartz12, King and equilibrium with austenite and ferrite of varying composition. The solid
Uhlig13, Frankenthal and Pickering8, and Kirchheim et al.14) symbols refer to ferrite, and the open symbols to austenite. The points
represent the experimental data of Benz et al.16, while the lines were
calculated from the thermodynamic data compiled by Arai et al.15
The Journal of The South African Institute of Mining and Metallurgy MAY/JUNE 1996 121 ....
Sensitization of type 430 ferritic stainless steel during continuous annealing
"~
.
0 higher carbon
lower carbon .. . I
100
0
"-
! 8
0
0
0
~ 0
'00 11
c:
Q)
'"Cl
c
10
.. 0
8
0
0
t::J 0
;
0
U .
. ~8 8
1
700 800 900 100e
Peak temperature (OC)
(a)
Figure 5-Current density, after 300 seconds of potentiostatic etching
at 0.100 VSCEin 0.5 M H2S04, for hot-rolled specimens of the lower-
carbon and higher-carbon type 430 stainless steels, after simulated
continuous annealing at different peak temperatures, Current densities
higher than approximately 4 lIA/cm2 indicate sensitization, Multiple
points were obtained from replicate experiments
~ 122 MAY/JUNE 1996 The Journal of The South African Institute of Mining and Metallurgy
Sensitization of type 430 ferritic stainless steel during continuous annealing
(e) (i)
(f)
01
(g) (k)
The Journal of The South African Institute of Mining and Metallurgy MAY/JUNE 1996 123 ...
Sensitization of type 430 ferritic stainless steel during continuous annealing
confidence in the predictions of the calculations. The proportional to the width of the chromium-depleted zone.
calculated phase diagrams in Figure 7 predict little difference Since the M23C6carbide forms at an approximately stoichio-
in the carbon solubility in the two steels up to the metric ratio of chromium to carbon ( with Yaround 0.7,
temperature of austenite formation. Figure 4), a thicker grain-boundary carbide 'film' will result
in a wider chromium-depleted zone. If one assumes that
carbide precipitation occurs to an equal extent on all grain
boundaries (which is approximately so, as indicated in Figure
1000 6(i) and (j)), then the thickness of the carbide film is propor-
Cl Cl + 'Y tional to the amount of carbon that precipitates from
-16.6% Cr
solution, and inversely proportional to the ratio of the grain-
17% Cr
, 950 boundary area to the grain volume. These arguments have
.
u been quantified by Stawstrom and Hillert19, who arrived at
'--'
Q) the following approximate expression for the time for
I.-
:J recovery (that is, the time required to increase the chromium
+'0 900
l.-
Q) content adjacent to the carbide to above the minimum value
a. for passivity):
E
Q)
Cl + M23CS
I- 2
850
(Xcr~~.13 )
t . [1]
'" D
800
0.00 0.01 0.02 0.03 0.04 0.05 In equation [1], the expression between brackets is
C (wt %) proportional to the chromium-diffusion distance, with h the
ratio of the grain volume to the grain-boundary area (which
Figure 7-Calculated pseudo-binary phase diagrams for the two type approximates to d/6, where d is the average grain diameter);
430 steels featuring in the present study
Xc the molar fraction of carbon in solution, which precipitates
out as a carbide film; Xc, the molar fraction of chromium in
the alloy; 0.13 the minimum molar fraction of chromium in
In summary, the results show that the lower-carbon steel the solid solution that is assumed to be required for
is more susceptible to sensitization (Figure 5), despite the passivity; and D the diffusion coefficient of chromium.
facts that the carbon solubility in the two steels is identical in From equation [1] it is apparent why the time for
the temperature range where the sensitization difference recovery will be longer for the lower-carbon alloy. Consider,
arises (Figure 7), that no martensite forms in this for example, the situation after annealing at 859°c. While
temperature range (Figure 6 (k), and Figure 7), and that both alloys have 0.002 per cent C in solid solution (Figure 7),
grain-boundary carbides form in both steels (Figure 6(i) and and thus Xc = 1.0 x 10-4, the average grain diameter of the
(j)). It is thought that the difference in intergranular lower -carbon alloy is approximately three times that of the
corrosion behaviour can be explained, not by the carbide higher-carbon alloy (Figure 6(g) and (h)), resulting in a
precipitation step, but by the recovery step. In principle, three recovery time that is nearly an order of magnitude larger. For
requirements can be stated for the sensitization of a ferritic example, if one considers recovery at a constant temperature
steel: firstly, sufficient carbon must be brought into solution of 700°C, where the diffusion coefficient of chromium2o is
during annealing to allow subsequent grain-boundary precip- approximately 3.1 x 10-17m2/s, and uses average grain
itation; secondly, grain-boundary carbide precipitation must diameters of 8411m and 2711m for the lower-carbon and
occur during cooling; and, lastly, recovery must not take higher-carbon steels respectively, the recovery times are
place. From the presence of grain-boundary carbides, Figure calculated as 25 seconds and 2.6 seconds respectively. This
6 (i) and (j), it is evident that the first two requirements are difference appears to be sufficient to explain why the lower-
met by both steels. It is therefore concluded that the carbon alloy does not recover during the particular cooling
difference between the two steels lies in their recovery cycle that was employed here (Figure 2), while the higher-
behaviour: the higher-carbon steel is not susceptible to carbon alloy does recover. (It is not thought that sensitzation-
intergranular corrosion after annealing at 859°C, despite the free carbide precipitation, such as that which occurs in
presence of grain-boundary carbides. This indicates that this austenitic stainless steels19, plays a role here. The reason for
steel recovered during cooling. It is not unexpected that this is that the chromium concentration in equilibrium with
recovery plays a prominent role in determining whether M23C6and carbon in solution is strongly temperature-
ferritic stainless steel is susceptible to intergranular corrosion dependent. For example, it has been calculated that the
given the rapidity of carbide precipitation, which, as chromium concentration-in ferrite-in equilibrium with
mentioned in the introduction, cannot be suppressed by 0.002 per cent C in solution drops from 17 per cent at 859°C
water quenching. to 10 per cent at 830°C, and to 6 per cent at 800°C.)
In this light, the differences in the susceptibility of the Differences in the rate of recovery can also be used to
two steels to intergranular corrosion after annealing can be explain the observed effect of increased sensitization with
explained by different rates of recovery. The rate of recovery increased annealing temperature (Figure 5). Higher
depends on the distance over which chromium must diffuse annealing temperatures bring more carbon into solution
to replenish the chromium-depleted zones; this distance is (Figure 7), as well as causing grain growth; as expressed by
~ 124 MAY/JUNE 1996 The Joumal of The South African Institute of Mining and Metallurgy
Sensitization of type 430 ferritic stainless steel during continuous annealing
equation [1], both factors promote a wider chromium- 4. ROCKEL,M.B. Interpretation of the second anodic current maximum on
polarization curves of sensitised chromium steels in IN H2S04. Corrosion,
depleted zone, for which the recovery time is longer. In this
vo!. 27.1971. pp. 95-103.
way, more sensitization is retained after the alloy has cooled 5. HODGES,R.J. Intergranular corrosion in high-purity ferritic stainless steels:
to room temperature from a higher annealing temperature. Isothermal time-temperature sensitization measurements. Corrosion, vo!.
27. 1971. pp. 164-167.
6. DEMo, J.J. Mechanism of high temperature embrittlement and loss of
Conclusion corrosion resistance in AISI type 446 stainless steels. Corrosion, vo!. 27,
1971. pp. 531-544.
The lower-carbon type 430 stainless steel can be sensitized 7. STREICHER,M.A. The role of carbon, nitrogen, and heat treatment in the
by continuous annealing below 880°C (the annealing dissolution of iron-chromium alloys in acids. Corrosion. vo!. 29. 1973. pp.
temperature used during production), while the higher- 337-360.
carbon steel is sensitized only at annealing temperatures of 8. FRANKENTHAL.
R.P.. and PICKERING.
H.W. Intergranular corrosion of a ferritic
897°C or higher. The differences in sensitization behaviour stainless stee!. Journal if the Electrochemical Society, vo!. 120. 1973.
pp. 23-26.
appear to be explicable by differences in the rate of recovery
9. BAuMEL, A. Korrosion in der WarmeeinfluJ1.zone geschweiJ1.ter chemisch
during cooling after annealing: less recovery takes place in
bestandiger Stahle und Legierungen und ihre Verhiitung. Werkstqffe und
the lower-carbon steel because of its larger grains, which Korrosion, vo!. 26. 1975. pp. 433-443.
result in wider chromium-depleted zones. The lower -carbon 10. HODGES,R.J. Intergranular corrosion in high purity ferritic stainless steels:
steel appears to be inherently more susceptible to grain Effect of cooling rate and alloy composition. Corrosion, vo!. 27. 1971.
pp. 119-127.
growth because of less grain-boundary pinning by carbides.
11. COWAN,R.L., and TEDMoN,c.s. Intergranular corrosion of iron-nickel-
From these results, it appears plausible that the gold-dusting
chromium alloys. Advances in corrosion science and technology, vo!. 3.
defect is caused by sensitization during continuous
1973. pp. 293-400.
annealing. The results also suggest practical measures that 12. ROCHA.H.-J., and LENNARTZ,G. Die Aktivierungspotentiale van
can be taken to prevent sensitization. These include a Eisen-Chrom-Legierungen und ihre Beziehungen zu der chemischen
limiting of the annealing temperature to 840°C (which is still Bestandigkeit in Schwefelsaure. Archiv fur das Eisenhiittenwesen, vo!. 26.
sufficient for recrystallization) , a lowering of the cooling rate 1955. pp. 117-123.
13. KING,P.F., and UHLlG,H.H. Passivity in the iron--chromium binary alloys.
after annealing (by the use of batch annealing, for example),
Journal if Physical Chemistry, vo!. 63. 1959. pp. 2026-2032.
and a limiting of grain growth.
14. KIRCHHEIM.
R., HEINE, B., FISCHMEISTER,
H., HOFMANN,S., [NOTE. H., and
STall. U. The passivity of iron--chromium alloys. Corrosion Science,
Acknowledgements vo!. 29. 1989. pp. 889-917.
15. ARAI, H., TAKEDA,S., and ARATA,Y. Theoretical analysis of the suscepti-
Thanks are due to Columbus Stainless Steel for providing test bility of ferritic stainless steel to intergranular corrosion caused by
welding. Transactions ifJWRI. vo!. 16. 1987. pp. 131-137.
material and technical information, Pieter Pistorius for the
16. BENZ, R., ELLIOTT,J.F., and CHIPMAN,J. Thermodynamics of the carbides in
use of the welding simulator, and the Electron Microscopy the system Fe-Cr-c. Metallurgical Transactions, vo!. 5. 1974.
Unit of the University of Pretoria for the use of their facilities. pp. 2235-2240.
17. TRICOT,R., and CASTRO.R. Etude des transformations isothermes dans les
aciers inoxydables semi-ferritiques a 17% de chrome. Ill. Role des
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The Journal of The South African Institute of Mining and Metallurgy MAY/JUNE 1996 125 ....