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Steel Corrosion TABLE 1. ALLOYING ELEMENTS AFFECT STAINLESS-STEEL CORROSION PROPERTIES

Department Editor: Scott Jenkins ELEMENT EFFECT ON STAINLESS STEEL
Chromium Forms a passive film with oxygen that prevents further diffusion of oxygen into the

C
orrosion of steel is a key surface of the steel
concern in many industrial Nickel Increases ductility and toughness; increases corrosion resistance to acids;
settings, both from an asset- Ni addition creates non-magnetic structure
Molybdenum Increases pitting and crevice corrosin resistance; increases resistance to chlorides
management perspective and from
Copper Increases corrosion resistance to sulfuric acid
a safety perspective. The following Manganese Acts as a substitute for nickel in 200-series stainless steel
briefly describes corrosion mecha- Titianium/Niobium Ties up carbon and prevents inter-granular corrosion in welded zone of ferritic grades
nisms for various classes of steel,
Nitrogen Increases strength and corrosion resistance in austenitic and duplex grades
and provides information on the cor-
rosion resistance of these ubiquitous Silicon Improves resistance to high-temperature scaling
iron-based alloys. Sulfur Usually kept low except for “free-machining” grades
Carbon steels contain only iron Carbon Usually kept low; used in martensitic grades to increase strength and hardness
and carbon, with carbon making up Source: “Alloying Elements in Stainless Steel” by Pierre-Jean Cunat,
between 0.002 and 2.1 wt.%. Low- Published by the Internation Chromium Development Association
alloy steels contain a variety of other
elements added to achieve desired wt.% Ni minimum in the more cor- Specific corrosive environments,
properties of corrosion resistance, rosion-resistant 316) broadens the such as the presence of chlorides,
strength, formability and other char- range of passivity established by the combined with tensile stress, can
acteristics. Steel is classified as stain- chromium. Further, addition of mo- crack stainless steels in a mode of
less steel if its chromium content is at lybdenum (2 wt.% minimum in 316) attack known as stress corrosion
least 10.5 wt.%, and its carbon con- further expands the passivity range cracking (SCC).
tent is less than 1.20 wt.%, as de- and improves corrosion resistance Another corrosion mechanism in-
fined in ASTM Standard A240 (ASTM (see table). volves the metal’s microscopic grain
International; West Conshohocken, structure. Rapid corrosive attack of
Pa.; www.astm.org). Corrosion mechanisms immediately adjacent grain boundar-
Stainless steel resists general corro- ies with little or no attack of the grains
Iron oxidation sion well, but several mechanisms is called intergranular corrosion.
Steel corrosion is an electrochemical can result in localized corrosion of
process requiring the simultaneous stainless steel. For example, pitting Corrosion resistance
presence of water and oxygen. The occurs in areas where the stainless Corrosion of carbon steel can be
anode reaction involves the forma- steel’s protective passive layer breaks minimized with protective paints and
tion of Fe2+ ions and the release of down on an exposed surface. Once coatings, or by cathodic protection,
electrons, while the cathode reaction initiated, the growth rate of the pit can such as galvanizing (applying a zinc
involves a reduction of dissolved ox- be relatively rapid and can result in lo- coating to interfere with the natural
ygen, with water as an electrolyte. calized, deep cavities. electrochemical reactions in corro-
Crevice corrosion occurs in loca- sion). Modifying the operating envi-
Fe0 —> Fe2+ + 2e– tions where oxygen cannot freely cir- ronment with corrosion inhibitors can
O2 + 2H2O + 4e– —> 4OH– culate, such as tight joints, under fas- also be effective in some cases. The
tener heads and in other areas where resistance of a stainless steel to lo-
Iron ions react with the hydrox- pieces of metal are in close contact. calized attack is strongly related to
ide to form iron hyroxides [such as Pitting and crevice corrosion of its alloy content.
Fe(OH)2], which react further with stainless steels generally occurs in Chemical passivation refers to the
oxygen to give Fe2O3·H2O (rust). The the presence of halide ions (chloride chemical treatment of stainless steel
presence of acids and chlorides ac- is most common). Moisture from the with a mild oxidant, such as nitric
celerates the corrosion process. environment, along with chloride salts acid or citric acid solution, for the
and pollutants, accumulates in the purpose of enhancing the spontane-
Stainless steel crevices, creating an acidic environ- ous formation of the protective pas-
The chromium in stainless steels al- ment inside the crevice where oxygen sive chromium oxide film. !
lows the generation of a complex is depleted and chloride concentra- For more on corrosion, see Chem. Eng., March 2014, pp.
chromium-oxide surface layer that tion is elevated. This environment 40–43 and July 2012, pp. 26–29.
resists further oxidation (passive lay- promotes the breakdown of the pas- Relevant links
er). The chromium-oxide layer is thin sive film and anodic dissolution. 1. Specialty Steel Industry of North America. www.ssina.
com/overview/alloyelements_intro.html
(microns) but tough. It will reform if The main environmental factors
2. ASTM International. Standard A380. www.astm.org/
removed by scratching or machining. that favor localized attack include Standards/A380/
The addition of nickel to the structure higher chloride concentration, el- 3. Steelconstruction.info
(8 wt.% Ni minimum in the commonly evated temperature, lower pH and 4. Corrosionist. www.corrosionist.com/Pitting_Crev-
used 304 type stainless steel and 10 more cathodic corrosion potentials. ice_Corrosion.htm

46 CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM MARCH 2015