Materials Today: Proceedings xxx (xxxx) xxx

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Materials Today: Proceedings

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Electrochemical studies of welded joints corrosion resistance made from

stainless steels
Mark Kovalev a,⇑, Aleksey Shakhmatov b, Aleksey Alhimenko a
a
Peter the Great St. Petersburg Polytechnic University, St. Petersburg, Russian Federation
b
Weatherford, St. Petersburg, Russian Federation

a r t i c l e i n f o a b s t r a c t

Article history: The use of stainless steels with anticorrosive properties is common in various industries where operation
Received 13 December 2019 takes place in aggressive conditions. However, most products and structures cannot do without a welded
Accepted 3 January 2020 joint. The chance of corrosion processes in the weld metal and the heat-affected zone is higher compared
Available online xxxx
to other parts of the product due to heating and cooling during welding, as well as due to the use of filler
material. Violation of welding technology can lead to premature failure of the product due to corrosion
Keywords: damage in the weld zone. Such incidents are common and require analysis to identify the exact causes of
Corrosion
the damage and prevent it in the future. In the work were considered the failure incidents of stainless-
Welding joints
Stainless steel
steel products. The damage was concentrated in the weld zone. In the work were used methods of elec-
Pitting corrosion trochemical studies which were applied to assess the corrosion properties of various sections of products
Electrochemistry and their welded joints. Based on the results of the work, characteristic zones of destruction were iden-
tified and the causes of their occurrence were determined.
Ó 2020 Elsevier Ltd. All rights reserved.
Selection and Peer-review under responsibility of the scientific committee of the Materials Science:
Composites, Alloys and Materials Chemistry.

1. Introduction was used to determine the chemical composition. Table 1 shows

Studies were conducted on samples of welded joints selected
from the products destroyed during operation. The main task was
to show the methods of testing and research to determine the causes
of products failure. Samples were selected for the studies, from the
product that was operated in an aggressive environment and from
the witness sample. Aggressiveness was created due to the presence
of wet gas with a possible chloride content. Information on the envi-
ronment in which the products were operated is limited, so the aim
of the study was to show the possibility of using electrochemical
research methods to identify areas prone to corrosion destruction
within a single product. The product witness was made by the same
technology. A distinctive feature of the considered cases was the
presence of corrosion damage to the weld and the heat affected zone.
There was no damage to the base metal. The appearance of the sam-
ples selected for research is shown in Fig. 1.
Both products were made of AISI 304 steel. The method of
quantitative elemental analysis optical emission spectral analysis
the results of chemical analysis of the base metal and weld metal.
Corrosion damage in the form of pitting was present on the
samples after operation. The lesions are concentrated in the weld
metal and in the heat affected zone. There was no damage to the
base metal. The appearance of weld lesions is shown in Fig. 2.
Corrosive environment during operation was present both from
the outside and from the inside. On the inner side, the nature of the
damage is similar, in the zone of the welded joint lesions in the
form of pitting, on the base metal damage was absent (Fig. 3).
According to the literature, stainless steel AISI 304 has a high
corrosion resistance [1–4]. In this case, this is indirectly confirmed
by the fact that the base metal was not subjected to corrosion dam-
age. Non-compliance with welding technology in the manufacture
of stainless-steel products is the most common cause of failure
[5,6]. Metallography, corrosion tests, and electrochemical research
methods were used to understand the causes of defects.
2. Methods

Metallographic studies were carried out on an optical micro-

⇑ Corresponding author. scope. Samples taken from the base metal, heat affected zone
E-mail address: kovalev.ma@edu.spbstu.ru (M. Kovalev). and weld metal were examined. Pitting corrosion tests according

https://doi.org/10.1016/j.matpr.2020.01.034
2214-7853/Ó 2020 Elsevier Ltd. All rights reserved.
Selection and Peer-review under responsibility of the scientific committee of the Materials Science: Composites, Alloys and Materials Chemistry.

Please cite this article as: M. Kovalev, A. Shakhmatov and A. Alhimenko, Electrochemical studies of welded joints corrosion resistance made from stainless
steels, Materials Today: Proceedings, https://doi.org/10.1016/j.matpr.2020.01.034
2 M. Kovalev et al. / Materials Today: Proceedings xxx (xxxx) xxx

Fig. 1. Weld samples.

to ASTM G48 [7] were carried out to assess the corrosion resistance
of the materials under study. Both welded and non-welded seg-
ments were investigated. Samples in the form of plates with a hole Fig. 2. Pitting in the weld area.
for hanging were placed in a solution of iron chloride and kept for
15 h at room temperature. Before weighing the samples were pre-
cleaned, degreased and dried. Weighing was carried out on analyt-
ical scales with an accuracy of 0,0001 g the corrosion Rate was
determined by the formula (1)
Dm
V¼ ð1Þ
Ss
where Dm – mass loss, g; S-surface area of the sample, m2; s-test
duration, h; Electrochemical methods were also used to determine
the standard electrochemical potential of the base metal, the weld
metal and the heat affected zone. The test surface was prepared by
grinding with sanding papers with consistently decreasing grain size
of the abrasive. Next, the sample was soldered to the current collec-
tor in the form of a copper wire. Parts of the sample that were not
subjected to the study were insulated with a heat-resistant paint
coating. The tests were carried out using the Versa Princeton Applied
Research potentiostat, equipped with specialized software that
allows you to set different test cycles, sweep speeds and perform
tests in potentiodynamic mode. For electrochemical tests, the fol-
lowing conditions were created: the test solution was a simplified Fig. 3. Pitting on the inner surface of the product.
model of seawater containing a solution of sodium chloride with a
concentration of 8 wt%. Sample was placed in an open three-
electrode electrochemical cell, after which the cell was filled with a According to the results of mass loss of samples and visual
working electrolyte. The tests were carried out at room temperature assessment of their damage, it was revealed that the weld metal
(T = 25 ± 2 °C). The study consisted of immersing the sample in the and heat affected zones are most susceptible to pitting formation.
test environment, measuring the equilibrium corrosion potential The calculated corrosion rates shown in Table 2 have a significant
(Ecor) for 30 min (1800 s). The electrochemical test cell is shown in spread. This is due to the non-standard shape of the samples, as
Fig. 4. well as a high tendency to pitting corrosion of the weld metal.
When mechanically exposed to a small diameter needle to search
3. Results and discussion for hidden corrosion damage, an accumulation of pitting in the
weld metal and in the HAZ was found. Sample after cleaning is pre-
3.1. Results of pitting corrosion tests sented on Fig. 6.
Pitting lesions are localized in the weld metal and the heat
The pitting corrosion test results are presented in Table 2. The affected zone, there are through lesions. On the witness samples
Fig. 5 shows the samples before testing. (Fig. 7, a) the total area of lesions is smaller, but there are also

Table 1
Chemical composition of the samples.

Sample Mass fractions of components, %

C S Si Mn Cr Ni Cu Mo Ti
After operation 0,04 0,022 0,50 1,21 18,1 8,2 0,05 0,05 <0,01
Witness 0,05 0,005 0,33 1,45 18,6 8,15 0,53 0,37 0,01
Weld joint after operation – – 0,79 1,78 18,5 10,1 0,05 1,48 –
Witness weld joint – – 0,53 1,47 18,99 8,1 0,44 0,21 –
AISI 304 <0,08 <0,03 <1,0 <2,0 18–20 8–10,5 – – –

Please cite this article as: M. Kovalev, A. Shakhmatov and A. Alhimenko, Electrochemical studies of welded joints corrosion resistance made from stainless
steels, Materials Today: Proceedings, https://doi.org/10.1016/j.matpr.2020.01.034
 M. Kovalev et al. / Materials Today: Proceedings xxx (xxxx) xxx 3

Fig. 4. Electrochemical cell: a) appearance b) electrolytic cell circuit: 1-cell, 2-electrolyte, 3-working electrode-test sample, 4-auxiliary platinum electrode, 5-reference
electrode, 6-heater, 7-gas saturation system, 8-chiller, 9-potentiostat, 10-computer with software.

Table 2
Results after pitting corrosion tests.

Sample Average Average mass The average conditional

area, m2 loss, g speed of pitting corrosion,
g * m-2 * h-1
After operation 0,0035 1,43 ± 0,27 24,2
Witness 0,0036 0,6 ± 0,04 10,94
Weld joint after 0,0034 0,58 ± 0,06 11,23
operation
Witness weld joint 0,0039 0,34 ± 0,1 5,72

Fig. 7. Samples after mechanical action (a) witness sample, (b) samples after
operation.

Fig. 8 shows the appearance of samples without a weld after

pitting corrosion tests.
Samples with a welded seam have a lower resistance to pitting
compared to the base metal, which is due to the heterogeneity of
Fig. 5. Specimens for pitting corrosion.
the structure and the formation of chromium carbides, as well as
a violation of the structure of the passive film.

through pitting. Comparison of samples before operation and after 3.2. Results of pitting electrochemical studies
in this case is not indicative, since the samples after operation
already had a large number of pitting, which in the process of test- In the course of electrochemical studies, the potential values for
ing could become additional zones of damage localization [8]. all the studied zones were obtained. The results of measuring the

Fig. 6. Sample after mechanical action (a) without impact, (b) after mechanical impact.

Please cite this article as: M. Kovalev, A. Shakhmatov and A. Alhimenko, Electrochemical studies of welded joints corrosion resistance made from stainless
steels, Materials Today: Proceedings, https://doi.org/10.1016/j.matpr.2020.01.034
4 M. Kovalev et al. / Materials Today: Proceedings xxx (xxxx) xxx

Fig. 8. Specimens after pitting corrosion test.

Table 3 Fig. 11. Knife corrosion in the fusion zone.

Results of electrochemical tests.

Sample Investigated zone Ecor, mV

After operation base metal 0,22
HAZ 0,42
weld joint 0,38
Witness base metal 0,26
HAZ 0,20
weld joint 0,38

Fig. 12. Microstructure of HAZ.

Fig. 9. Corrosion potential of the sample after operation.

Fig. 10. Corrosion potential of the witness specimen.

corrosion potential in aqueous NaCl solution are presented in

Table 3.
The Fig. 9 shows the results of measuring the corrosion poten-
tial of the base metal samples, heat affected zone and weld
Fig. 13. Microstructure of the welded joint specimen of a witness.
selected from the product after operation.

Please cite this article as: M. Kovalev, A. Shakhmatov and A. Alhimenko, Electrochemical studies of welded joints corrosion resistance made from stainless
steels, Materials Today: Proceedings, https://doi.org/10.1016/j.matpr.2020.01.034
 M. Kovalev et al. / Materials Today: Proceedings xxx (xxxx) xxx
The Fig. 10 shows the results of measuring the corrosion poten-
tial of the base metal samples, heat affected zone and weld
selected from the product is not in operation. In the case of the
sample after operation in the welded joint there is a potential dif-
ference between the base metal and the heat affected zone leaving
200 mV. On the witness sample the situation is similar, the differ-
ence between the weld metal and the heat affected zone was
180 mV.
The potentials obtained in the course of electrochemical studies
suggest that in the area of the weld during operation was possible
the appearance of local anode and cathode. As a result, in the area
with a lower electrochemical potential, provided the electrolyte is
available, the metal will dissolve.
3.3. Results of pitting electrochemical studies
According to the results of metallographic studies of samples
taken from the product after operation, it was found that in the
fusion zone at the boundary between the base metal and the weld
metal there are corrosion damage, called knife corrosion (Fig. 11).
this type of corrosion in a narrow region between the weld metal
and the base metal during dissolution of stabilizing carbides of
the TiC type and formation Of Cr23C6 carbides upon cooling [9,10].
Due to the fact that the base metal does not contain elements of
stabilizers (titanium, niobium), the formation of this type of
defects is natural. At a distance of a few millimeters from the weld,
there are pitting depths of 14–20 mm (Fig. 12). The appearance of
pitting corrosion is associated with the action of chlorine ions or
other halides in places ‘‘weakened” from the point of view of cor-
rosion, which adsorptively displace passivating oxygen [11].
The figure shows that these damages do not extend to the grain
boundaries, which confirms the absence of intergranular corrosion.
On the sample before operation at the boundary of the weld
metal and the base metal is distinguishable zone with etchings
on the grain boundaries, which is probably due to the formation
of chromium carbides (Fig. 13). When exposed to a corrosive envi-
ronment (water with chlorides) in this area is also highly likely to
undergo knife corrosion, due to the loss of passivity in the border
areas due to the formation of chromium carbides.
Thus, as a result of welding changes occur in the microstructure
and the passive layer, leading to knife and pitting corrosion in the
heat affected zone. These damages are typical for unstabilized
stainless austenitic steels, as well as for violations of welding tech-
nology [12–16].
4. Conclusions
The conducted researches allowed to establish the reason of
occurrence of corrosion defeats in a zone of a welded seam. It
was found that as a result of violations of the welding technology
of stainless steels in the zone of the welded joint formed zones
with different electrochemical potentials, which led to the local
Please cite this article as: M. Kovalev, A. Shakhmatov and A. Alhimenko, Electrochemical studies of welded joints corrosion resistance made from stainless
steels, Materials Today: Proceedings, https://doi.org/10.1016/j.matpr.2020.01.034
5
dissolution of the metal under the influence of a corrosive environ-
ment. By means of electrochemical researches potentials of various
zones of welded connection were estimated and corrosion active
areas are revealed. In this case, the most vulnerable from the point
of view of corrosion processes was the zone of thermal influence.
Pitting corrosion tests and metallographic studies have confirmed
this theory.
Declaration of Competing Interest
The authors declare that they have no known competing finan-
cial interests or personal relationships that could have appeared
to influence the work reported in this paper.
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