INTERGRANULAR

CORROSION
Nurul Nurdiyana binti Rusdi
50215217132
DEFINITION

Localized attack at & adjacent to grain boundaries, with

relatively little corrosion of the grains.

Intergranular
corrosion

Microstructure of a type 304 stainless steel

FACTORS OF INTERGRANULAR CORROSION

Impurities at the grain boundaries

Enrichment of one of the alloying elements

Depletion/ Reduction of one of these elements that affects

its corrosion resistance in grain boundary areas.
 AUSTENITIC STAINLESS STEELS

◦Steels become sensitized or susceptible to intergranular corrosion when

heated in approximately the temperature range 950-1450°F.

WHY?
- The impoverishment or depletion of chromium in the grain-
boundary areas.
• More than 10% Chromium is needed to make SS.
• The lower the Chromium, the lower the resistance towards corrosion.
• Chromium is less mobile, the surface that already at the grain boundary
facilitates the formation of a new surface named as Chromium Carbide.

• The insoluble of Chromium Carbide can be removed out from solid

solution if C content is less than 0.03%

AISI Wt% Wt% Wt% Wt% Wt% Wt%

Grade C max Cr Si max S max Ni Mn max

316 0.08 16.0- 1.0 0.045 10.0- 2.0

18.0 14.0
310S 0.08 24.0 - 1.2 0.045 19.0- 2.0
26.0 22.0

👉 304 0.08 18.0 1.0 0.045 8.0-10.5 2.0

304N 0.08 18.0- 1.0 0.045 8.0-10.5 2.0
20.0

Table: Chemical composition of Important Austenitic Stainless Steel

 Mechanism

The chromium-depleted zone near the grain

boundary is corroded

The excess carbon is available for combining

with chromium to precipitate the carbide

Carbon diffuse out more towards the grain

boundaries at sensitizing temperature but
chromium is less mobile

That’s why Cr23C6 is formed on the grain

boundaries
 WELD DECAY

Occur seriously in austenitic SS that contains 0.05% carbon &

above.

Occurs as the result of sensitization (region susceptible to

corrosion) in HAZ during welding operation.

Happened when HAZ experiences a particular temperature

range/ sensitization temperature.
MECHANISM
Diffusion of alloy elements in the grain boundary at high
temperature such as during welding.

At sensitization temperature, Cr and C at grain boundary

will react to form chromium carbide when the time is
enough.

Chromium carbide will precipitate upon cooling.

The region adjacent to grain boundary will depleted the Cr

due to diffusion.

Depleted Cr area will corrode when exposed to corrosive

environment.
CONTROLS FOR AUSTENITIC STAINLESS STEELS
Employing high-temperature solution heat treatment
• -Quenching-annealing or solution-quenching

Adding elements that are strong carbide formers

• -Stabilizers

Lowering the carbon content

• -To below 0.03%
EMPLOYING HIGH-TEMPERATURE SOLUTION HEAT TREATMENT

Solution-quenching + heating to 1950°F- 2050°F followed by

water quenching
- Chromium carbide dissolved at this temperature
- More homogenous alloy is obtained

The equipment must be quench-annealed to avoid weld decay if

welding is used during fabrication.

Quenching (rapid cooling) from the solution temperature is

important. If cooling is slow, the entire structure will be
susceptible to intergranular corrosion.
ADDING ELEMENT OF STRONG CARBIDE FORMER

◦ Columbium is used to produce stainless steel of type 347 and titanium in

type 321.
◦ The elements much greater affinity for carbon & are added in sufficient
quantity to bond with carbon in steel.
◦ The precipitation is suppressed during welding & weld decay cannot be
form.
LOWERING THE CARBON CONTENT
◦ Lowering the C to below 0.03%
will lead to insufficient carbide
to perform intergranular
attack.
◦ The steel known as extra-low-
carbon (ELC) steels.
◦ Blow oxygen through the melt
to burn out carbon until low-
carbon ferrochrome is
developed in order to lower the
carbon content.
◦ Stainless steel has high
solubility for carbon (molten
state) & has tremendous
propensity for picking up
carbon.
◦ Caused premature failure.
◦ Carbon pickup (surface
carburization) is when steel
surface absorb the carbon
when steel is heated.
◦ Occurs when steel casted into
mold containing carbonaceous
material.
 HOW TO DETECT CARBON PICKUP?

Carbon content near

Casting are attacked
the surface is higher
more than wrought
than in the main body
components
of the casting

2 castings of same Intergranular attack

alloy show a occurs on a low-
substantial difference carbon (0.03%)
attack material
 KNIFE-LINE ATTACK
◦ Occurs at :
- the stabilized stainless
steel.
- narrow band in parent
metal adjacent to the
weld (attack in razor
sharp)
- along adjacent or
connected weld posts at
grain boundary.
MECHANISM
◦ For stabilized SS, carbon is bonded with stabilizers
(Ti).
◦ But the stabilizing elements failed to perform its
function.
◦ Precipitation of chromium carbide is possible
◦ Corrosion is extremely narrow line, besides the
line of fusion.
DIFFERENCES OF KLA & WELD DECAY

Knife-Line Attack Weld Decay

Occurs in stabilized steels Occurs in normal, un-

stabilized steel

Occurs at the fusion zone Occurs at a great distance

from weld (HAZ)
PREVENTION
Weld decay
▫Use low carbon grade of SS (304L, 316L)
▫Use stabilized grades alloyed with titanium (Type
321) or niobium (Type 347)
▫Re-dissolve carbides by PWHT

Knife-Line Attack
▫Heat treatment : heat the weld to 1065°C to re-
stabilize the material.
INTERGRANULAR CORROSION OF OTHER
ALLOYS
Duraluminium-type alloys (Al-Cu)
◦ Strong because precipitation of compound CuAl2
◦ Substantial potential differences between the copper-
depleted area & adjacent material have been
demonstrated.
◦ When these alloys are solution-quenched to keep the
copper in solution, their susceptibility to intergranular
corrosion is very small but they posses low strength.
 THANK YOU,
“ dyanarusdi