Corrosion of Weldments

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2006 ASM International. All Rights Reserved.

Corrosion of Weldments (#05182G)

www.asminternational.org

Corrosion of Weldments

Edited by
J. R. Davis
Davis & Associates

ASM International
Materials Park, OH 44073-0002
www.asminternational.org

2006 ASM International. All Rights Reserved.


Corrosion of Weldments (#05182G)

www.asminternational.org

Copyright 2006
by
ASM International
All rights reserved
No part of this book may be reproduced, stored in a retrieval system, or transmitted, in any form
or by any means, electronic, mechanical, photocopying, recording, or otherwise, without the written permission of the copyright owner.
First printing, December 2006
Great care is taken in the compilation and production of this Volume, but it should be made clear
that NO WARRANTIES, EXPRESS OR IMPLIED, INCLUDING, WITHOUT LIMITATION,
WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE,
ARE GIVEN IN CONNECTION WITH THIS PUBLICATION. Although this information is
believed to be accurate by ASM, ASM cannot guarantee that favorable results will be obtained
from the use of this publication alone. This publication is intended for use by persons having technical skill, at their sole discretion and risk. Since the conditions of product or material use are outside of ASM's control, ASM assumes no liability or obligation in connection with any use of this
information. No claim of any kind, whether as to products or information in this publication, and
whether or not based on negligence, shall be greater in amount than the purchase price of this
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EVENT SHALL EITHER PARTY BE LIABLE FOR SPECIAL, INDIRECT OR CONSEQUENTIAL DAMAGES WHETHER OR NOT CAUSED BY OR RESULTING FROM THE
NEGLIGENCE OF SUCH PARTY. As with any material, evaluation of the material under enduse conditions prior to specification is essential. Therefore, specific testing under actual conditions is recommended.
Nothing contained in this book shall be construed as a grant of any right of manufacture, sale, use,
or reproduction, in connection with any method, process, apparatus, product, composition, or system, whether or not covered by letters patent, copyright, or trademark, and nothing contained in
this book shall be construed as a defense against any alleged infringement of letters patent, copyright, or trademark, or as a defense against liability for such infringement.
Comments, criticisms, and suggestions are invited, and should be forwarded to ASM International.
Prepared under the direction of the ASM International Technical Books Committee,
Yip-Wah Chung, FASM, Chair (20052006).
ASM International staff who worked on this project include Charles Moosbrugger,
Product Developer; Diane Grubbs, Editorial Assistant; Madrid Tramble, Senior Production
Coordinator; Diane Wilkoff, Production Coordinator; Scott Henry, Senior Manager of Product
and Service Development; Bonnie Sanders, Manager of Production and Eleanor Baldwin,
Research Librarian.
Library of Congress Cataloging-in-Publication Data
Corrosion of weldments / edited by J. R. Davis.
p. cm.
Includes bibliographical references and index.
ISBN-13: 978-0-87170-841-0
ISBN-10: 0-87170-841-8
1. Steel, StructuralWelding. 2. Steel, StructuralCorrosion. 3. Welded joints. I.
Davis, J. R. (Joseph R.)
TS227.2.C68 2006
671.52dc22
2006051209
SAN: 204-7586
ASM International
Materials Park, OH 44073-0002
www.asminternational.org
Printed in the United States of America

2006 ASM International. All Rights Reserved.


Corrosion of Weldments (#05182G)

www.asminternational.org

Contents

Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .vii
Chapter 1

Basic Understanding of Weld Corrosion . . . . . . . . . . . . . . . . . . . 1


Factors Influencing Corrosion of Weldments . . . . . . . . . . . . . . . . . 1
Weld Microstructures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Forms of Weld Corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Welding Practice to Minimize Corrosion . . . . . . . . . . . . . . . . . . . 10

Chapter 2

Corrosion of Carbon Steel and Low-Alloy Steel


Weldments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Classification of Steels and Their Welding
Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Carbon Steels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Low-Alloy Steels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Corrosion Considerations for Carbon and Low-Alloy
Steel Weldments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Corrosion of Carbon Steel Weldments . . . . . . . . . . . . . . . . . . . . . 19
Influence of Weld Microstructure . . . . . . . . . . . . . . . . . . . . . 19
Residual Stress . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Geometrical Factors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Preferential HAZ Corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Preferential Weld Metal Corrosion . . . . . . . . . . . . . . . . . . . . 21
Mitigation of Preferential Weldment Corrosion . . . . . . . . . . 21
Galvanic Corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Environmentally Assisted Cracking (EAC) . . . . . . . . . . . . . . . . . 24
Wet Hydrogen Sulfide Cracking . . . . . . . . . . . . . . . . . . . . . . 25
Stress-Corrosion Cracking . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Hydrogen-Induced Cracking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Effect of Welding Practice on Weldment Corrosion . . . . . . . . . . . 35

Chapter 3

Corrosion of Austenitic Stainless Steel Weldments . . . . . . . . . 43


Grade Designations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Standard Grades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Nonstandard Grades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Properties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
General Welding Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Corrosion Behavior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Intergranular Corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
iii

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Preferential Attack Associated with Weld


Metal Precipitates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Pitting and Crevice Corrosion . . . . . . . . . . . . . . . . . . . . . . . . 53
Stress-Corrosion Cracking . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Microbiologically Induced Corrosion . . . . . . . . . . . . . . . . . . 62
Other Factors Influencing Corrosion of Weldments . . . . . . . 66
Chapter 4

Corrosion of Ferritic Stainless Steel Weldments . . . . . . . . . . . 77


Grade Classifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Properties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
General Welding Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Corrosion Behavior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Hydrogen Embrittlement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Intergranular Corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Avoiding Intergranular Corrosion . . . . . . . . . . . . . . . . . . . . . 84
Example 1: Leaking Welds in a Ferritic Stainless Steel
Wastewater Vaporizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Example 2: Weld Failure Due to Intergranular Corrosion
and Cracking in a Heat-Recovery Steam Generator . . . . . 89

Chapter 5

Corrosion of Duplex Stainless Steel Weldments . . . . . . . . . . . . 99


Duplex Stainless Steel Development and Grade Designations . . . 99
Microstructure and Properties . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
General Welding Considerations . . . . . . . . . . . . . . . . . . . . . . . . . 103
Corrosion Behavior of Weldments . . . . . . . . . . . . . . . . . . . . . . . 105
Corrosion Behavior of Alloy 2205 Weldments . . . . . . . . . . . . . . 109

Chapter 6

Corrosion of Martensitic Stainless Steel Weldments . . . . . . . 115


Grade Designations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Standard Grades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Nonstandard Grades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Properties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
General Welding Considerations . . . . . . . . . . . . . . . . . . . . . . . . . 118
Corrosion Behavior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

Chapter 7

Corrosion of High-Nickel Alloy Weldments . . . . . . . . . . . . . . 125


Types of Corrosion-Resistant Alloys (CRAs) . . . . . . . . . . . . . . . 125
General Welding Considerations . . . . . . . . . . . . . . . . . . . . . . . . . 130
Welding Metallurgy of CRAs Containing Molybdenum . . . . . . 132
Welding Metallurgy of Ni-Cu, Ni-Cr, and Ni-Cr-Fe CRAs . . . . 134
Corrosion Behavior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Phase Stability of Nickel-Base Alloys and
Corrosion Behavior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137

Chapter 8

Corrosion of Nonferrous Alloy Weldments . . . . . . . . . . . . . . 143


Aluminum and Aluminum Alloys . . . . . . . . . . . . . . . . . . . . . . . . 143
General Welding Considerations . . . . . . . . . . . . . . . . . . . . . 143
Corrosion Behavior of Aluminum Alloy Weldments . . . . . 144
Copper and Copper Alloys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
General Welding Considerations . . . . . . . . . . . . . . . . . . . . . 155
Corrosion Behavior of Copper Weldments . . . . . . . . . . . . . 155
iv

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Titanium and Titanium Alloys . . . . . . . . . . . . . . . . . . . . . . . . . . 156


General Welding Considerations . . . . . . . . . . . . . . . . . . . . . 157
Corrosion Behavior of Titanium and Titanium Alloy
Weldments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
Zirconium and Zirconium Alloys . . . . . . . . . . . . . . . . . . . . . . . . 160
General Welding Considerations . . . . . . . . . . . . . . . . . . . . . 161
Corrosion Behavior of Zirconium and Zirconium Alloy
Weldments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
Tantalum and Tantalum Alloys . . . . . . . . . . . . . . . . . . . . . . . . . . 164
General Welding Considerations . . . . . . . . . . . . . . . . . . . . . 164
Corrosion Behavior of Tantalum and Tantalum Alloy
Weldments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
Chapter 9

Corrosion of Dissimilar Metal Weldments . . . . . . . . . . . . . . . 169


Factors Influencing Joint Integrity . . . . . . . . . . . . . . . . . . . . . . . . 169
Corrosion Behavior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173

Chapter 10 Weld Corrosion in Specific Industries and Environments . . 177


Corrosion of Weldments in Petroleum Refining and
Petrochemical Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
Fabricability Considerations . . . . . . . . . . . . . . . . . . . . . . . . 177
Wet H2S Cracking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
Hydrogen-Induced Disbonding . . . . . . . . . . . . . . . . . . . . . . 181
Liquid Metal Embrittlement . . . . . . . . . . . . . . . . . . . . . . . . . 181
Stress-Corrosion Cracking of Weldments in BWR Service . . . . 183
BWR Piping Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
Stress-Corrosion Cracking of Pipe Weldments . . . . . . . . . . 183
Model for IGSCC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
Weld Residual Stresses . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
Mitigation of IGSCC in Boiling Water Reactors . . . . . . . . . 187
Materials Solutions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
Tensile Stress Reduction Solutions . . . . . . . . . . . . . . . . . . . 189
Environmental Solutions . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
Corrosion in the Pulp and Paper Industry . . . . . . . . . . . . . . . . . . 191
Pulp Production . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
Corrosion of Weldments in Pulp Bleach Plants . . . . . . . . . . 196
Chapter 11 Monitoring and Testing of Weld Corrosion . . . . . . . . . . . . . . 203
Corrosion Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
Direct Testing of Coupons . . . . . . . . . . . . . . . . . . . . . . . . . . 203
Electrochemical Techniques . . . . . . . . . . . . . . . . . . . . . . . . 206
Nondestructive Testing Techniques . . . . . . . . . . . . . . . . . . . 207
Corrosion Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
Tests for Intergranular Corrosion . . . . . . . . . . . . . . . . . . . . . 209
Tests for Pitting and Crevice Corrosion . . . . . . . . . . . . . . . . 213
Tests for SCC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
Tests for MIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217

2006 ASM International. All Rights Reserved.


Corrosion of Weldments (#05182G)

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Preface

Welding is one of the most important processes for fabricating metallic structures. The
study of welding metallurgy has long been addressed by academia, industry, and organizations such as the American Welding Society and the Edison Welding Institute in the
United States and The Welding Institute in the United Kingdom. Similarly, extensive
research has been carried out on the fundamentals of corrosion and the various types of
corrosion that can render a structure useless. Corrosion of Weldments explores both of
these important disciplines and describes how the welding process can influence both
microstructural and corrosion behavior. Hydrogen-induced cracking of steel weldments, sensitization and subsequent intergranular corrosion of stainless steel weldments, sulfide stress cracking of pipeline steel weldments, microbiologically induced
corrosion of weldments, and stress-corrosion cracking of weldments are addressed in
detail. Although emphasis has been placed on carbon steels and stainless steels, nonferrous alloys such as high-nickel alloys, aluminum alloys, and titanium alloys also are
covered. Weld corrosion in some important industries and environments also is
reviewed as are methods for monitoring corrosion and testing of weldments.
As always I would like to acknowledge the support of the ASM editorial and production staffs during work on this project. In particular, I would like to thank Project
Editor Charles Moosbrugger for his help and patience. I hope our combined efforts will
result in a lasting contribution to the technical literature.
Joseph R. Davis
Davis & Associates
Chagrin Falls, Ohio

vii

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technical skill, at their sole discretion and risk. Since the conditions of product or material use are
outside of ASM's control, ASM assumes no liability or obligation in connection with any use of this
information. As with any material, evaluation of the material under end-use conditions prior to
specification is essential. Therefore, specific testing under actual conditions is recommended.
Nothing contained in this publication shall be construed as a grant of any right of manufacture, sale,
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