Table Of ContentEnvironment-Induced Cracking
of Materials
Volume 2:
Prediction, Industrial Developments and Evaluation
Proceedings of the Second International Conference on Environment-
Induced Cracking of Metals (EICM-2),T he Banff Centre, Banff, Alberta,
Canada, September 19-23,2004
Edited by
S.A. Shipilov
Metallurgical Consulting Services, Calgary, Alta., Canada
R.H. Jones
Exponent Failure Analysis Associates, Bellevue, WA, USA
J.-M. Olive
Universite Bordeaux 1, Talence Cedex, France
R.B. Rebak
Lawrence Livermore National Laboratory, Livermore, CA, USA
Amsterdam Boston Heidelberg London New York Oxford
Paris San Diego San Francisco Singapore Sydney Tokyo
ELSEVIER
Elsevier
Radarweg 29, PO Box 211, 1000 AE Amsterdam, The Netherlands
Linacre House, Jordan Hill, Oxford OX2 8DP, UK
First edition 2008
Copyright @ 2008 Elsevier Ltd. All rights reserved
No part of this publication 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 prior written permission of the publisher
Permissions may be sought directly from Elsevier’s Science & Technology Rights
Department in Oxford, UK: phone (+44)( 0) 1865 843830; fax (+44)( 0) 1865 853333;
email: [email protected] lternatively you can submit your request online by
visiting the Elsevier web site at http://elsevier.com/locate/permissions, and selecting
Obtaining permision to use Elsevier material
Notice
No responsibility is assumed by the publisher for any injury and/or damage to persons
or property as a matter of products liability, negligence or otherwise, or from any use
or operation of any methods, products, instructions or ideas contained in the material
herein. Because of rapid advances in the medical sciences, in particular, independent
verification of diagnoses and drug dosages should be made
British Library Cataloguing in Publication Data
A catalogue record for this book is available from the British Library
Library of Congress Cataloging-in-Publication Data
A catalog record for this book is available from the Library of Congress
ISBN: 978-0-08-045348-4
ISSN: 978-0-08-044635-6
For information on all Elsevier publications
visit our web site at books.elsevier.com
Printed and bound in Great Britain
080910 1 0 9 8 7 6 5 4 3 2 1
I I
www.elsevier.com www.bookaid.org www.sabre.org
ix
Preface
This volume is the second of two containing most of the papers presented at the
Second International Conference on Environment-Induced Cracking of Metals (EICM-2),
which was held at The Banff Centre, Banff, Alberta, Canada in September 2004.’ This
conference was the fifth in a series of major international meetings sponsored or co-
sponsored by NACE in the area of environment-induced cracking. The previous four
conferences, recognized as landmark events, were the:
International Conference on Fundamental Aspects of Stress Corrosion Cracking
held at the Ohio State University, Columbus, OH, USA, 1967
International Corrosion Fatigue Conference held at the University of Connecticut,
Storrs, CT, USA, I97 I
International Conference on Stress Corrosion Cracking and Hydrogen Embrittle-
ment of Iron Base Alloys held in Unieux-Firminy, France, 1973
First International Conference on Environment-Induced Cracking of Metals held
in Kohler, WI, USA, 1988
EICM-2 was jointly sponsored by the Committee TEG 186X on Environmentally
Assisted Cracking of NACE International, the Working Party WP5 on Environment
Sensitive Fracture of the European Federation of Corrosion and the Joint ASM/TMS
Corrosion and Environmental Effects Committee in association with the Technical
Committee of Hydrogen Embrittlement and Stress Corrosion of the Chinese Society of
Corrosion and Protection and the Technical Committee TC 10 on Environmentally
Assisted Cracking of the European Structural Integrity Society. This conference was
international in scope and attracted a significant number of researchers and
professionals. There were 1 15 participants from countries that included Australia, Japan,
China, India, Saudi Arabia, Israel, Russia, Ukraine, Poland, Slovak Republic, Austria,
Slovenia, Italy, Sweden, Germany, Belgium, France, the United Kingdom, Brazil, the
United States and Canada. The conference provided a forum for dialogue, assessment
and critique among researchers committed to different methodologies and actively
promoted discussion and cross-fertilization of ideas among established and emerging
researchers working in different areas related to the problem of environment-induced
cracking in materials.
The technical program consisted of three plenary sessions, I2 technical sessions
with 72 oral presentations, a poster session and a luncheon talk. In total, 87 papers that
described both fundamental research studies and more practical engineering
applications were presented. Topics included but were not limited to: SCC, hydrogen
embrittlement, corrosion fatigue, liquid metal embrittlement, localized environment-
induced attack, modeling environmental effects, crack growth mechanisms, hydrogen
permeation and transport, hydrogen-plasticity interaction, test methods and
interpretation of test data, materials degradation in service, failure analysis, life
prediction of corrodible structures, and the history of ElCM research. Together the
papers provided a comprehensive account of advances in research on environment-
induced cracking and constituted the most recent fundamental and industrial survey of
’
Volume I is published under the title “Environment-Induced Cracking of Materials: Chemistry,
Mechanics and Mechanisms,” S.A. Shipilov, R.H. Jones, J.M. Olive, R.B. Rebak (Editors),
Elsevier, Oxford, 2007 564 pages.
X Preface
the subject. Plenary lectures were presented by Richard Gangloff, Digby Macdonald,
Roger Newman, Roger Staehle, Alan Turnbull and Robert Wei. A luncheon lecture
entitled “Growing Old Gracefully? A Perspective on Pipeline Safety” was given by
Alan Murray of the National Energy Board Canada. A highlight of the conference was
the General Discussion which featured a panel comprising the plenary speakers with
John Scully as a moderator. During the discussion, recent developments and a number
of key questions in environment-induced cracking research were considered, including
how to move from theory to validation to practice, needs and opportunities for
mechanistic advances, progress towards life prediction/prognosis/damagee volution, the
challenge to mitigate and control EICM, and needs and opportunities for technological
and practical progress.
As the potential audience for the proceedings represents a wide spectrum of
professionals, including researchers, engineers, practitioners and consultants with
different background and specific research and/or industrial interests, it was found
feasible to divide the papers into two volumes, each with a specific focus - as indicated
in their titles - which can then be sold and/or used together or separately. This
necessitated a different arrangement of the papers in the books than the order in which
they were presented at the conference. In each volume, the papers are organized to
provide a reasonable reflection of research development in the subject areas. Either
volume may be used as an independent reference source that reviews the current state
of the fundamental and/or industry-oriented research and provides a comprehensive
introduction to the field. Applied researchers and specialists in industry may find
volume two highly relevant, especially if they are engaged in the areas related to
nuclear power generation, oil and gas transportation, the disposal of radioactive waste,
aircraft maintenance, chemical and marine applications, failure analysis in industrial
equipment, and assessing the SCC resistance; while volume one may find a ready
audience among researchers who focus upon investigating the phenomenological
aspects of SCC, hydrogen embrittlement, liquid metal embrittlement and corrosion
fatigue, including environmental, microstructural, electrochemical and mechanistic
aspects, in high performance steels, nonferrous alloys, ceramics and glasses. Whatever
the individual reader’s preference, there are synergies and connections across the
volumes which make their simultaneous publication an important occasion for
researchers and practitioners alike.
Of the 87 papers that were presented at the conference, 81 are offered to the reader
across the two volumes. The papers were rigorously peer-reviewed, revised and edited
extensively to meet the high standards for scientific publications intended for an
international and discerning audience. The present volume contains 38 papers divided
into eight sections and is the first publication in the field of environment-induced
cracking that addresses a broad range of industrial applications, including nuclear
power generation, the disposal of radioactive waste, oil and gas transportation, aircraft
maintenance, chemical and marine applications, failure analysis, and assessing the SCC
resistance. Section 1 titled “Prediction of stress corrosion cracking” composes of two
plenary papers: “Predicting failures in light water nuclear reactors which have not yet
been observed - microprocess sequence approach (MPSA)” by R.W. Staehle and “The
electrochemistry of stress corrosion cracking from theory to damage prediction in
-
practical systems” by D.D. Macdonald et al., which are concerned with the prediction
of in-service SCC failures in water-cooled nuclear reactors. New insights into the issues
associated with the SCC of stainless steels and Ni alloys used as components of light
Preface xi
water reactors, including boiling water reactors and pressurized water reactors, are
provided in Section 2 titled “Stress corrosion cracking in LWR environments.” Section
3 titled “Corrosion and cracking of waste package materials” is devoted to localized
corrosion and SCC of Alloy 22 and Alloy EP-823, which are the materials
recommended for containers used to dispose high-level radioactive waste and spent
nuclear fuel in Yucca Mountain. Various aspects of corrosion fatigue and SCC in C-Mn
and micro-alloyed steels used as components of oil and gas pipelines are covered in
twelve papers that compose Sections 4 and 5 titled “Crack growth in pipeline steels
under cyclic loading” and “SCC and hydrogen embrittlement of pipeline steels”
respectively. The emphasis on hydrogen charging and embrittlement in most of these
papers reflects the strong focus in recent years on the role of hydrogen in the service
failures of buried pipelines having cathodic protection. Section 6 titled “Degradation of
materials under in-service conditions” composes of six papers that investigate the
“time-dependent’’ degradation of steels and alloys in different industrial applications
where components and structures come into contact with natural or technological
environments. Eleven cases of service failures caused by corrosion and ElCM in
industrial equipment are investigated in Section 7 under the heading “Stress corrosion
cracking case studies” and further demonstrate the complexity of the ElCM problem in
industry. The final section titled “New test methods for SCC studies” describes several
experimental techniques which were recently developed for assessing the susceptibility
of materials to SCC. The total number of references to the literature in this volume is
664.
Many individuals and organizations contributed to the success of EICM-2 and these
volumes, and I would like to acknowledge their assistance. The conference and its
proceedings would not have been possible without the generous support of my co-
editors, Russ Jones, Jean-Marc Olive and Raul Rebak. These dedicated individuals
contributed greatly of their time and skills to arrange various aspects of the meeting.
They were instrumental in helping to develop the program, with organizing sessions
and assisting with reviewing the manuscripts. I also wish to thank Winston Revie for
his assistance at the early stage of the planning of the conference. Special
acknowledgments are extended to chairs of sponsoring committees for helping to
organize international participation: Jorge Perdomo, Jean-Marc Olive, Raul Rebak,
Lijie Qiao and Wolfgang Dietzel. Pierre Crevolin, President of NACE in 2003/2004
and Interim Executive Director in 2004, his staff and especially Gretchen Jacobson,
Publishing Director, provided invaluable assistance in publicizing EICM-2. Special
thanks go to my students, Don Boll, Vicky Carathanassis, Christie Millington, Enoch
Ng, Krishna Panchalingam, Feng Wang and Hong Wang, who helped with registration
and assisted me through all stages of the conference, including the preparation of
several graphs for this publication. Sincere thanks also to Kim Allan for providing
technical support for the conference website. I would like to extend my special thanks
to the session chairs, Jenny Been, Anne-Marie Brass, Steve Bruemmer, Jacques ChCne,
Wolfgang Dietzel, Noam Eliaz, Russ Jones, Rob Kelly, Fraser King, Amar Kumar,
Graham Lobley, Stan Lynch, Jean-Marc Olive, Alan Plumtree, Raul Rebak, John Scully,
Raman Singh, Brian Somerday, Bob Sutherby, Mirna Urquidi-Macdonald and Marc
Vankeerberghen, who worked very effectively to keep the program organized and the
floor discussions effective. I greatly appreciate the work of the technical experts who
joined in reviewing the manuscripts for these volumes, and who approached the
manuscript reviews with the detail and exacting standards that mark the review process
xii Preface
at technical journals. The names of these reviewers are listed on the next page. Without
the generosity of our financial sponsors, and the individuals who secured sponsorship
funds, the conference would not have happened and these papers would not have seen
the light of day. Hence, my heartfelt thanks to NACE International (Pierre Crevolin),
National Energy Board Canada (Alan Murray), Metallurgical Consulting Services Ltd.
(lain Le May), the University of Calgary (Ron Bond), Canadian Energy Pipeline
Association (Jake Abes), NOVA Chemicals Corporation (Fraser King), ASM Canada
Council (Steve Yue), ASM Calgary Chapter (Sammy Tang), and Broadsword
Corrosion Engineering Ltd. (Pat Teevens). During the preparation of the proceedings, I
was very ably assisted by Michael Aleksiuk who provided diligent and insightful
proofreading of several of the manuscripts, and by Lucy Dickinson, Nicola Jones and
Kristi Green of Elsevier Ltd. for their kind co-operation at all stages of the work. My
sincere thanks go to the authors of the papers for making time in their busy lives to put
their work in the public domain. To all those who have helped, I express my sincere
“Thanks!”
Last, but certainly not least, I would like to acknowledge my thanks and appreciation
to my wife, Hyacinth, whose support, encouragement and companionship sustained me
through both the organizing of EICM-2 and the preparation of this publication.
Sergei Shipilov
Editor and Conference Chair
V
Contents
Preface ............................................................. ix
...
List of reviewers ................................................... xi11
Section I PREDICTION OF STRESS CORROSION CRACKING
Predicting failures in light water nuclear reactors which have not yet been observed
microprocess sequence approach (MPSA)
-
R.W.Staehle ......................................................... 3
The electrochemistry of stress corrosion cracking - from theory to damage
prediction in practical systems
D.D. Macdonald, G.R. Engelhardt and I. Balachov .......................... .55
Section 2 STRESS CORROSION CRACKING IN LWR ENVIRONMENTS
Insights into stress corrosion cracking mechanisms from high-resolution
measurements of crack-tip structures and compositions
S.M. Bruemmer and L.E. Thomas ................................... ....9 5
Quantification of the effects of crack tip plasticity on environmentally-assisted
crack growth rates in LWR environments
T. Shoji, Z. Lu, H. Xue, K. Yoshimoto, M. Itow, J. Kuniya and K. Watanabe .... 107
The role of hydrogen and creep in intergranular stress corrosion cracking
of Alloy 600 and Alloy 690 in PWR primary water environments - a review
F.H. Hua and R.B. Rebak .............................................. 123
Modelling of primary water stress corrosion cracking (PWSCC) at control rod
drive mechanism (CRDM) nozzles of pressurized water reactors (PWR)
O.F. Aly, A.H.P. Andrade, M. Mattar Neto, M. Szajnbok and H.J. Toth ......... 143
lnterdendritic crack introduction before SCC growth tests in high-temperature
water for nickel-based weld alloys
M. Ozawa, Y. Yamamoto, M. Itow, N. Tanaka, S. Kasahara and J. Kuniya ..... 153
Influence of low-temperature sensitization on stress corrosion cracking of 304LN
stainless steels
V. Kain, R. Samantaray, S. Acharya, P.K. De and V.S. Raja ..................1 63
Section 3 CORROSION AND CRACKING OF WASTE PACKAGE MATERIALS
Overview of corrosion issues for the Yucca Mountain waste container
R.H.Jones ........................................................ 175
vi Contents
Stress corrosion cracking evaluation of a target structural material by different
techniques
M.K.HossainandA.K.Roy ............................................ 185
Section 4 CRACK GROWTH IN PIPELINE STEELS UNDER CYCLIC LQADING
SCC growth in pipeline steel
A. Plumtree, B.W. Williams, S.B. Lambert and R. Sutherby .................. 199
Environmental effects on near-neutral pH stress corrosion cracking in pipelines
W. Chen, R.L. Eadie and R.L. Sutherby .................................. .21 1
Environmentally assisted cracking of pipeline steels in near-neutral pH
environments
J. Been, F. King and R. Sutherby ....................................... .22 I
Section 5 SCC AND HYDROGEN EMBRITTLEMENT OF PIPELINE STEELS
Crack initiation of line pipe steels in near-neutral pH environments
J.A. Colwell, B.N. Leis and P.M. Singh .................................. .233
A mechanistic study on near-neutral pH stress corrosion cracking of pipeline steel
B.T. Lu and J.L. Luo ................................................ .243
The role of hydrogen in EAC of pipeline steels in near-neutral pH environments
J. Been, H. Lu, F. King, T. Jack and R. Sutherby ........................... .255
The roles of crack-tip plasticity, anodic dissolution and hydrogen in SCC of mild
and C-Mn steels
D. Delafosse, B. Bayle and C. Bosch .................................... .267
Effect of microstructure on the hydrogen-embrittlement behaviour of HSLA steels
under cathodic protection
L. Barsanti, M.C abrini, T. Pastore and C. Spinelli ......................... .279
Hydrogen-embrittlement resistance of X I00 steels for long-distance high-pressure
pipelines
L. Barsanti, F.M. Bolzoni, M.C abrini, T. Pastore and C. Spinelli ............... 291
Influence of strain rate on the stress corrosion cracking of X70 pipeline steel in
dilute near-neutral pH solutions
B. Fang, J.Q. Wang, E. Han, Z. Zhu and W. Ke ........................... .303
Assessment of stress corrosion cracking and hydrogen embrittlement susceptibility
of buried pipeline steels
A.H.S. Bueno, B.B. Castroand J.A.C. Ponciano ........................... .313
Contents vii
Change of physicochemical parameters of soils near stress-corrosion defects on
gas pipelines
S.K. Zhigletsova, V.B. Rodin, V.V. Rudavin, G.E. Rasulova, N.A. Alexandrova,
G.M. Polomina and V.P. Kholodenko ................................... .323
Section 6 DEGRADATION OF MATERIALS UNDER INSERVICE CONDITIONS
Stress corrosion cracking of carbon steel in fuel ethanol service
J.G.MaldonadoandR.D.Kane ........................................ 337
Hydrogen degradation of steels under long-term in-service conditions
H.M. Nykyforchyn, K.-J. Kurzydlowski and E. Lunarska ................... .349
Corrosion and hydrogen absorption of commercial reinforcing steel in concrete
after 33 years of service on the Baltic Sea beach
S.M. Beloglazov, K.V. Egorova and N.V. Kolesnikova ..................... .363
Stress corrosion cracking of aluminium brass induced by marine organism fouling
L. Lin and Y. Zhao .................................................. .369
Modeling of prior exfoliation corrosion in aircraft wing skins
M. Liao, G. Renaud, D. Backman, D.S. Forsyth and N.C. Bellinger ............ .375
Section 7 STRESS CORROSION CRACKING CASE STUDIES
Case studies of corrosion and environmentally induced cracking in industry
I. Le May and C. Bagnall ............................................. .389
Stress corrosion cracking: cases in refinery equipment
G.R.Lobley ........................................................ 401
Embrittlement cracking of a stabilized stainless steel wire mesh in an ammonia
converter
V. Kain, V. Gupta and P.K. De ........................................ .41 I
Environment-induced transgranular stress corrosion cracking of 304L stainless
steel instrument line tubes
M. Clark, 0. Yong, A.M. Brennenstuhl and M. Lau ....................... .421
Stress corrosion cracking of austenitic stainless steel in a nuclear power plant
environment
M. Brezina and L. Kupca ............................................. .43I
Section 8 NEW TEST METHODS FOR SCC STUDIES
High-resolution, in-situ, tomographic observations of stress corrosion cracking
T.J. Marrow, L. Babout, B.J. Connolly, D. Engelberg, G. Johnson,
J.-Y. Buffiere, P.J. Withers and R.C. Newman ............................ .439
...
Vlll Contents
Detection of SCC by the simultaneous use of electrochemical noise and acoustic
emission measurements
M. Leban, 2. Bajt, J. Koval! and A. Legat ................................ .449
Circumferential notch tensile (CNT) tests for determination of Kls,--, using small
fracture mechanics specimens
R. Rihan, R.K. Singh Raman and R.N. Ibrahim ........................... .459
Development of spiral notch torsion test: a new fracture mechanics approach to
determination of Klscc
R.K. Singh Raman, R. Bayles, S.P. Knight, Jy-An Wang, B.R.W. Hinton and
B.C. Muddle ...................................................... .471
Issues in stress corrosion testing of welded super martensitic stainless steels for
oil and gas pipelines
A. Turnbull and B. Nimmo ........................................... .483
Evaluation of the resistance to hydrogen embrittlement by the slow bending test
M. Cabrini, G. D’Urso and T. Pastore .................................. .493
Author index ...................................................... .503
Subject index ..................................................... .505
