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Briony Holmes
Failures in stainless steel welds – examples and causes
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Overview of a few real-life examples
1. Intermetallic precipitation – Sigma phase 2. HAZ Liquation cracking 3. Solidification cracking 4. Stress corrosion cracking (SCC) 5. Heat tint
Content
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Case Study A Loss of corrosion resistance Case Study B Embrittlement
1. Sigma phase
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Case Study A
Sigma Phase
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Subsea spoolpiece Weld metal/HAZ crack Hydrogen embrittlement
Superduplex stainless steel
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Pitting corrosion and preferential phase corrosion due to sigma phase
Sigma phase
Sigma phase
Preferential phase attack
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Superduplex stainless steel Girth weld repair
High heat input Sigma phase precipitation Pitting corrosion Hydrogen embrittlement crack
Hydrogen from corrosion Tensile stress
Causes of Failure
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Case Study B
Sigma Phase
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Dye penetrant showing weld metal/HAZ crack
Duplex stainless steel
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Fracture face
Brittle fracture due to sigma phase
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Duplex stainless steel Microstructure
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Composition of phases EDX spectrum
Sigma phase (white) Rich in Cr and Mo
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Duplex stainless steel Sigma phase precipitation Incorrect heat treatment of forging Tensile stress
Residual stress Applied stress during hydrotest
Causes of failure
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2. HAZ Liquation cracking
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Short intergranular cracks: In high-temperature zone of the HAZ, or In previously deposited weld metal, during a
subsequent run Due to formation of grain boundary liquid films
at temperatures below the alloy melting temperature
On cooling this liquid is unable to accommodate tensile strains, caused by contraction, and cracks may form
http://www.twi.co.uk/technical-knowledge/knowledge-summaries/liquation-cracking/
HAZ Liquation Cracking
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HAZ Liquation Cracking
1a) Photomacrograph of HAZ liquation cracking in austenitic stainless steel cladded with a nickel alloy weld metal. Location of liquation cracking indicated by arrows; 1b) Liquation cracking in AISI 316 austenitic stainless steel weld metal, reheated by subsequent weld bead. Location of liquation cracking indicated by arrows; 1c) HAZ liquation cracking in AISI 310 austenitic stainless steel (Magn. x 114); 1d) Scanning electron micrograph of liquated film on liquation crack surface in an AISI 316 austenitic stainless steel weld metal (Magn. x 1800)
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Factors affecting liquation cracking
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3. Solidification Cracking
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Butt weld Repair weld
Solidification crack arrowed
Solidification crack
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Solidification crack fracture face
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Duplex stainless steel Less common than austenitic
Bend test failure Factors involved in solidification cracking
Tensile stress Delta ferrite content Sulphur
Cause - Unusually wide weld bead due to
weaving?
Causes of failure
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4. Stress corrosion cracking (SCC)
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Austenitic stainless steel, pipe girth weld
Stress corrosion cracking
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Stress corrosion cracking
Austenitic stainless steel Branched, transgranular cracks
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Chloride-containing environment Residual tensile stresses from welding Weld profile
Difficult to drain – liquid collection Concentration of chlorides
Elevated temperature (55-60°C)
Causes of Failure
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5. Heat tint
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Lowered corrosion resistance Corrosion pits in heat tint
Heat tint Pitting and crevice corrosion
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Heat tint
304L stainless steel welded pipe Pitting corrosion much larger under the
surface than visible on the surface
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Oxidation of the root bead + adjacent HAZ during welding of SS.
Cr-rich scale is formed, the surface becomes Cr-depleted which impairs corrosion resistance.
Avoid heat tint: Need good shielding and backing (purging) gas.
Shield: Ar, Ar/He, Ar/N mixtures. Purge: Ar or N2.
Use several volumes of purge gas before welding. Maintain purge for 3 or 4 weld passes in multi-pass
weld. May also pickle and passivate
Causes of failure
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Welding can introduce or promote various failure mechanisms
Best practice for welding should be followed
For further guidance: http://www.twi-global.com/technical-knowledge/
Summary
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Contact
Briony Holmes Materials Department (Stainless Steels and Non-Ferrous Alloys) TWI Ltd Tel: +44 (0)1223 899 000 E-mail: [email protected] Web: www.twi-global.com
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Presentation prepared for the Offshore Wind Validation Centre – Technology Transfer Project
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