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Electrochimica Acta 56 (2011) 17011710

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Electrochimica Acta
journal homepage: www.elsevier.com/locate/electacta

New ndings on intergranular corrosion mechanism of stabilized stainless steels


Jeong Kil Kim a,b , Yeong Ho Kim b , Bong Ho Lee c , Kyoo Young Kim a,
a
Pohang University of Science and Technology (POSTECH), Graduate Institute of Ferrous Technology, Pohang, 790-784, Republic of Korea
b
POSCO Technical Research Laboratories, Pohang, 790-704, Republic of Korea
c
National Center for Nanomaterials Technology, Pohang, 790-784, Republic of Korea

a r t i c l e i n f o a b s t r a c t

Article history: Number of different sets of stabilized both ferritic and austenitic stainless steels with various alloying
Received 17 June 2010 elements were evaluated to verify new ndings on the intergranular corrosion mechanism. The inter-
Received in revised form 10 August 2010 granular segregation and precipitation were analyzed by using a transmission electron microscopy with
Accepted 11 August 2010
an energy dispersive X-ray spectroscopy and a laser assisted three-dimensional atom probe. On the basis
Available online 19 August 2010
of the current result, it is newly proposed that the intergranular corrosion occurring in the stabilized
both ferritic and austenitic stainless steels is induced by Cr-depletion due to segregation of un-reacted
Keywords:
Cr atoms around carbides of stabilizer elements (Ti or Nb) along the grain boundary, but not due to for-
Intergranular corrosion
Stainless steel
mation of Cr-carbide. A prevention method for this type of intergranular corrosion is also suggested after
Stabilizer effect critical evaluation on the effect of Cr, C, and Ni.
Segregation 2010 Elsevier Ltd. All rights reserved.
Chromium

1. Introduction Recently, however, it was reported that automotive exhaust sys-


tem made of Ti-stabilized 11 wt% Cr ferritic stainless steel (11Cr
The intergranular corrosion (IGC) in stainless steels has been one FSS) developed IGC due to the corrosive exhaust gas and con-
of the most extensively studied issues since IGC results in severe densed water with Cl , SO4 2 , SO3 2 , CH3 COOH, CO3 2 and HCO3
loss of corrosion resistance, strength and ductility of the stainless [6,7,9,15], although the contents of C, N and stabilizers in the
steels. IGC of stainless steels is known to be induced by electro- materials meet the requirements of ASTM standard specication
chemical potential difference between the matrix and Cr-depleted mentioned above.
zone which is developed by formation of Cr-carbide in the grain For the present study, it is assumed that IGC in Ti-stabilized
boundary area [17]. stainless steels may be induced by a new mechanism other than
The Cr-carbides and Cr-carbontrides are usually regarded as the the conventional IGC mechanism. To clarify the new ndings on
reason for the Cr-depleted zone, although several studies assert IGC mechanism, the intergranular segregation and precipitation
that other Cr compounds such as sigma (CrFe compound) and chi are critically analyzed by using a transmission electron microscopy
(CrMoFe compound) phases also deplete Cr concentration in the (TEM) equipped with an energy dispersive X-ray spectroscopy
region along the grain boundaries [1,3]. (EDS) and a laser assisted three-dimensional atom probe (3DAP).
Many studies to reduce the risk of IGC have been focused on In this article, a new IGC mechanism is established rstly with Ti-
the practices to prevent the precipitation of Cr-carbides and Cr- stabilized 11Cr FSS. Then, the effects of the content of Cr and C,
carbonitrides along the grain boundaries in stainless steels. The type of matrix and stabilizers on the IGC and intergranular precipi-
effective practical methods to prevent IGC are decreasing the C tation are examined with the stabilized both ferritic and austenitic
or N content and adding stabilizers such as Ti and Nb. Bond has stainless steels with various amount of alloying elements.
reported that C and N contents should be lower than 0.01 wt% to
resist the IGC in 17 wt% Cr ferritic stainless steel (FSS) [8]. Proper 2. Experimental
amount of stabilizers such as Ti or Nb has also been recommended
as 920 (wt% C + wt% N) for 1820 wt% Cr stainless steels [914]. Table 1 lists the composition and matrix phase of the eight
The guideline for the stabilizer addition is proposed on the basis of kinds of ferritic and austenitic stainless steels used in this study.
the standard specication (ASTM A 240/a 240M-08). The contents of C and N are not more than 0.006 wt% for FSS
and about 0.01 wt% for austenitic stainless steel (ASS), and the
content of stabilizers (Ti, Nb or Ti + Nb) are around 20 times that
Corresponding author. Tel.: +82 54 279 9018. of C and N in all FSS. This stabilizing ratio (Stabilizers/(C + N)) in
E-mail address: kykim@postech.ac.kr (K.Y. Kim). FSS well matches to the guide lines suggested by previous studies

0013-4686/$ see front matter 2010 Elsevier Ltd. All rights reserved.
doi:10.1016/j.electacta.2010.08.042
1702 J.K. Kim et al. / Electrochimica Acta 56 (2011) 17011710

Table 1
Chemical composition of various stabilized stainless steels.

Specimen C Cr Ni Ti Nb N Ti/(C + N) Matrix

11Cr 0.0054 11.10 0.246 0.0047 24.35 Ferritic


12Cr 0.0060 12.15 0.232 0.0051 20.9 Fenitic
13Cr 0.0040 13.17 0.238 0.0046 27.67 Ferritic
18Cr 0.0060 17.64 0.290 0.0064 23.38 Fenitic
Low C-11Cr 0.0023 11.30 0.212 0.0021 48.18 Fenitic
Nb 11Cr 0.0060 11.53 0.30 0.0058 25.42 Fenitic
Ti-Nb11Cr 0.0060 11.75 0.170 0.150 0.0050 29.1 Fenitic
18Cr-9Ni 0.0109 17.91 9.23 0312 0.0112 14.12 Austenitic

and standard specication (ASTM A 240/a 240M-08) [814]. All in water, followed by aging treatment at 400700 C for 0.510 h.
experimental steels were vacuum-melted, rolled to 1.2 mm thick Intergranular corrosion resistance of 1113 wt% Cr FSS was exam-
sheet and annealed at 950 C for 5 min. The as-annealed steels ined by the chemical corrosion test using a modied copper acid
were then solution treated at 1300 C for 10 min and quenched sulfate solution (0.5% H2 SO4 + 6% CuSO4 ) introduced by Devine

Fig. 1. No-etched surfaces of 11 wt% Cr FSS after the chemical corrosion test: (a) as-annealed, (b) solution treated, (c) aged for 1 h at 500 C, and (d)
timetemperaturesensitization curve.
J.K. Kim et al. / Electrochimica Acta 56 (2011) 17011710 1703

determined from DL-EPR test. Fig. 3 compares IGC morphologies


observed after two different test methods of the chemical corrosion
test and DL-EPR test for type 409L FSS aged at 500 C for various
aging times. In the result, it is clearly observed that in the speci-
mens with Ir /Ia > 0.03 the grain dropouts are clearly observed from
the chemical test result and DL-EPR test result also indicates the
ditch structure which is the evidence of IGC. However, IGC does
not occur if the value of Ir /Ia < 0.018.
Fig. 4 depicts TEM and EDS analysis on the matrix and the grain
boundaries in as-annealed 11Cr FSS in which IGC did not develop
during corrosion test. The precipitates were identied as TiC or
TiN in the matrix, and there was no precipitation along the grain
boundaries.
The grain boundary of 11Cr FSS aged for 10 h at 500 C, which
developed IGC, was analyzed with TEM and EDS and the results
are presented in Fig. 5. Lots of ne precipitates were formed along
Fig. 2. DL-EPR curves of type 409L grade FSS aged at 500 C for various aging times the grain boundary. EDS spectra in Fig. 5(b) show peaks for Ti, Cr
[21].
and C. The electron diffraction analysis on the precipitate shown in
Fig. 5(c) veries that the precipitates are TiC carbides with a face
for low Cr FSS (1013 wt% Cr) [3,16,17]. Rectangular test coupons centered cubic structure having the lattice parameter of 0.433 nm.
(12 mm 12 mm 1.2 mm) with surface grinded with abrasive But, no second phase such as Cr-carbides or intermetallic phases of
paper to #2000 were immersed in the boiling solution of 300 ml Cr was detected at all from this analysis. Then, the question is the
for 20 h, with electrochemical contact with copper balls in the origin of EDS peak for Cr, and this question is solved by the critical
solution. Metallographic observation was performed on the no- evaluations which will be explained below.
etched specimens after corrosion test. Analysis on the precipitates
was carried out with carbon replica of all stainless steels using 3.2. New ndings on IGC mechanism
TEM with EDS, Philips CM-200, operated at 200 kV. The atomic
distribution around the grain boundary was analyzed using 3DAP, From TEM and EDS analysis on the intergranular precipitates of
Cameca LA-WATAPTM , which was particularly useful to analyze 10 h-aged 11Cr FSS, it is clearly evidenced that IGC has not been
elemental distribution with near-atomic resolution [18]. induced by formation of Cr-carbide which results in Cr-depletion
in the grain boundary area according to the conventional theory
3. Result and discussion of IGC. There should be a new mechanism operating in this steel
system, which may explain clearly the cause of Cr-depletion in the
3.1. IGC characteristics of Ti-stabilized 11 wt% Cr FSS grain boundary area.
To understand this new IGC mechanism of this steel, the rst
The Ti-stabilized 11Cr FSS were heat-treated in various condi- work is to identify where Cr peak comes from. It may come from Cr
tions and subjected to the chemical corrosion test. Fig. 1 presents dissolved in TiC, Cr precipitates (i.e., Cr-carbonitride) or Cr segrega-
the no-etched surfaces of 11Cr FSS after corrosion test and tion. A thermodynamic calculation using the Thermo-Calc program
timetemperaturesensitization (TTS) curve plotted on the basis [22] was performed. Fig. 6 is the calculated fraction of individual
of the result. The surface of 1 h-aged specimen at 500 C shows phases for the elements of Ti-stabilized 11Cr FSS listed in Table 1.
dark regions (indicated as A in Fig. 1(c)) and these are the evi- Any kind of Cr compounds such as Cr carbides was not predicted to
dence of IGC called grain dropout according to some literature be formed in the temperature range of 01500 C, moreover the sol-
[19,20]. But, the grain dropouts are not observed from the surfaces ubility of Cr in Ti(C, N) was calculated to be about 107 at% at aging
of as-annealed and solution treated ones. TTS curve implies that IGC temperature of 500 C. This result means that Cr atoms would not
occurs in the specimen aged at the temperature range of 400600 C precipitate any new second phase and also would not be dissolved
(gray region). Except this temperature range, IGC does not occur. in the intergranular TiC at the aging temperature. Therefore, it is
The sensitization nose is around 600 C. believed that the Cr peak detected from the EDS analysis is most
We have reported previously a similar result after IGC tests probably due to the Cr segregation adjacent to the intergranular TiC
for type 409L grade FSS (11.1 wt% Cr0.0048 wt% C-0.23 wt% Ti- carbides.
0.0055 wt% N, Ti/(C + N) = 22.3) by both the chemical corrosion test 3DAP characterization is carried out with 10 h-aged 11Cr FSS for
and double loop electrochemical potentiokinetic reactivation (DL- further investigation of Cr segregation around TiC and is shown in
EPR) test [21]. For both the chemical corrosion and DL-EPR tests of Fig. 7. Segregations of Cr as well as Ti and C is clearly observed along
this steel, the as-annealed specimen was solution treated at 1300 C the grain boundary in the atom map of Fig. 7(a), although TiC pre-
for 10 min. Fig. 2 and Table 2 are cited from our previous report. cipitate itself is unfortunately missed out of the specimen for 3DAP.
Fig. 2 presents the DL-EPR test result and Table 2 lists the sum- In the concentration-depth prole across the grain boundary, it is
mary of Ir , Ia , and Ir /Ia , which indicates the degree of sensitization, also veried that Cr atoms extensively segregates up to 18 at% on
the grain boundary and a consequent Cr-depletion zone is resulted
Table 2 inevitably in the vicinity of the Cr segregation. The Cr content of the
Summary of Ia , Ir and Ir /Ia determined by the DL-EPR test [21]. depletion zone is only around 7 at%.
Aging time/h Ir (A cm2 ) Ia (A cm2 ) Ir /Ia Fig. 8 illustrates schematically a new IGC mechanism operat-
ing in Ti-stabilized 11Cr FSS on the basis of TEM, EDS and 3DAP
As-annealed 1.37 104 9.29 103 0.015
Solution treated 1.39 104 11.20 103 0.012
analysis. At rst, the solution treatment at 1300 C dissolves TiC
0.5 1.78 104 9.32 103 0.018 carbides (not TiN which is stable even at this temperature [7]) in
1 2.97 104 9.56 103 0.033 the matrix and the dissolution of TiC produce soluble carbon atoms
4 3.31 104 9.28 103 0.036 as illustrated in Fig. 8(a). During aging the solution-treated speci-
10 7.14 104 9.36 103 0.076
men, the soluble C atoms would diffuse to the grain boundary as
1704 J.K. Kim et al. / Electrochimica Acta 56 (2011) 17011710

Fig. 3. Comparison of no-etched surfaces of type 409L grade FSS aged at 500 C for various aging times after the chemical corrosion and the DL-EPR test [21].

shown in Fig. 8(b). This diffusion of C atoms induces the segrega- may be summarized as illustrated in Fig. 8(d) which shows distri-
tion of Cr and Ti atoms both of which have a strong afnity for butions of Ti-carbide, Cr-segregation and Cr-depletion in the grain
carbon. However, C atoms preferentially react with Ti, leaving the boundary area.
un-reacted Cr to be segregated along the grain boundaries, since
Ti atoms have much stronger afnity for C than Cr atoms. Fig. 8(c) 3.3. Prevention methods for IGC in stabilized stainless steel
illustrates development of Cr-depletion zone due to the segrega-
tion of the un-reacted Cr atoms in the grain boundary area. The As discussed previously, it was conrmed that IGC in Ti-
newly proposed IGC mechanism operating in Ti-stabilized 11Cr FSS stabilized 11Cr FSS was induced by Cr-depletion not due to
J.K. Kim et al. / Electrochimica Acta 56 (2011) 17011710 1705

Fig. 4. TEM characterization of the precipitates in the matrix and grain boundaries of as-annealed 11 wt% Cr FSS: (a) carbon replica of the precipitates in the matrix, (b)
carbon replica around the grain boundary, (c) EDS spectra of TiC in the matrix, and (d) EDS spectra of TiN in the matrix.

formation of the intergranular Cr carbides or Cr carbonitrides, but regardless Cr content, the intergranular precipitates in all the tested
due to the intergranular Cr segregation around TiC carbides. Since specimens are TiC precipitates with Cr peak as those observed
the IGC mechanism in the Ti-stabilized FSS is reasonably well previously from 11 wt% Cr specimen as presented in Fig. 10. There-
understood, the effects of several factors such as the content of fore, with these results, it can be made clear that in Ti-stabilized
Cr and C, type of matrix and kind of stabilizers were examined to 1118 wt% Cr FSS, IGC is induced by the same mechanism; i.e., by
conrm the newly proposed IGC mechanism and to nd a way to Cr-depletion due to segregation of the un-reacted Cr atoms around
prevent IGC occurring in the stabilized stainless steels. the intergranular TiC precipitates. Furthermore, increase in the Cr
Since Cr is the most important element to improve the cor- content cannot be a practical solution to prevent IGC (Fig. 11).
rosion resistance in stainless steels, rst of all, the effect of Cr In the new IGC mechanism by Cr segregation, carbon plays the
content on IGC and intergranular precipitation were evaluated with critical role to induce the segregation of Cr and Ti. A low carbon 11Cr
Ti-stabilized 1118 wt% Cr FSS. Fig. 9 is TTS curves plotted accord- FSS with 0.002 wt% C was used to investigate the effect of C con-
ing to the results of the chemical corrosion test carried out with tent on the intergranular precipitation. The precipitation analysis
1113 wt% Cr FSS which were aged in various conditions. The TTS results on this steel aged for 10 h at 500 C is presented in Fig. 10. It
curve clearly explains that increase in Cr content improves IGC can be noticed that this steel shows different precipitation charac-
resistance of the steel, but it cannot prevent IGC. In TEM and EDS teristics from other Ti-stabilized FSS with about 0.005 wt% C. Along
analysis on 1218 Cr FSS aged at 500 C for 14 h means that, the grain boundary, neither TiC precipitates with Cr nor any other

Fig. 5. TEM characterization of the grain boundary of 11 wt% Cr FSS aged at 500 C for 10 h: (a) carbon replica of intergranular precipitates, (b) EDS spectra of the intergranular
precipitates, and (c) electron diffraction pattern analyzed on the intergranular precipitates.
1706 J.K. Kim et al. / Electrochimica Acta 56 (2011) 17011710

Fig. 9. Timetemperaturesensitization curve of 1113 wt% Cr FSS.

Fig. 6. Calculated fraction of individual phase in 11 wt% Cr FSS by Thermo-Calc.

Fig. 7. 3DAP characterization around the grain boundary of 11 wt% Cr FSS aged at 500 C for 10 h. (a) 3DAP element maps, and (b) Concentration prole across the grain
boundary.

Fig. 8. Schematic illustration of newly proposed IGC mechanism developed by Cr-depletion due to segregation of the un-reacted Cr atoms in the grain boundary area.
J.K. Kim et al. / Electrochimica Acta 56 (2011) 17011710 1707

Fig. 10. TEM characterization of the grain boundary of 12, 13 and 18 wt% Cr FSS aged at 500 C for 10 various aging times.

kinds of precipitates are observed, although the specimen was aged suldes in low C11Cr specimen. As shown in Fig. 12, this specimen
for the longest time in the study. In addition, Ti suldes are detected actually shows good resistance to IGC in the chemical corrosion test.
from the matrix instead of TiC and TiN observed in the matrices It means that reducing C content to extremely low level could be a
of other Ti-stabilized stainless steels. Sulfur was not intentionally method to prevent IGC.
added in all the specimens used in this study. However, the S con- Fig. 13 indicates the corrosion test result performed on Nb- and
tent in all specimens was around 0.003 wt% and it resulted in Ti TiNb-stabilized 11Cr FSS aged for 2 h at 500 C. The grain dropouts

Fig. 11. TEM characterization of low carbon 11 wt% Cr FSS aged at 500 C for 10 h. (a) Carbon extraction replica around the grain boundary, (b) Higher magnication of A
marked in (a), and (c) EDS spectra of Ti suldes in the matrix.
1708 J.K. Kim et al. / Electrochimica Acta 56 (2011) 17011710

Fig. 12. No-etched surface of low carbon 11 wt% Cr FSS after the chemical corrosion
test.

Fig. 14. TEM characterization of Nb-stabilized 11 wt% Cr FSS and TiNb-stabilized


11 wt% Cr FSS aged at 500 C for 4 h: (a) carbon extraction replica around the grain
boundary of Nb-stabilized 11 wt%Cr FSS, (b) EDS spectra of intergranular precipitates
of Nb-stabilized 11 wt% Cr FSS, (c) carbon extraction replica around the grain bound-
ary of TiNb-stabilized 11 wt% Cr FSS, (d) EDS spectra of intergranular precipitates
Fig. 13. No-etched surfaces of (a) Nb-stabilized 11 wt% Cr FSS and (b) TiNb-
of TiNb-stabilized 11 wt% Cr FSS.
stabilized 11 wt% Cr FSS aged at 500 C for 4 h after the chemical corrosion test.
J.K. Kim et al. / Electrochimica Acta 56 (2011) 17011710 1709

are found in the no-etched surface of Nb-stabilized FSS, while no segregation around the intergranular carbides, and it is the cause
grain dropout was observed from the no-etched surface of the spec- of IGC in the ferritic stainless steel stabilized with Nb and TiNb.
imen stabilized with TiNb after corrosion test. Nevertheless, in the Now, the question is whether the new IGC mechanism is oper-
TiNb-stabilized FSS, a sign of grain boundary attack is detected ated in the stabilized austenitic stainless steel (ASS), or not. It is
as indicated as A in Fig. 13(b). The authors in the study thought generally known that IGC occurs much slower in ASS than in FSS
that the specimen did already undergo IGC. Fig. 14 presents TEM due to difference in the solubility limit of C and N [2326]. Further
and EDS analysis on the intergranular precipitates in Nb11Cr and investigation with TEM and EDS analysis was carried out with the
TiNb11Cr FSS, in which IGC is clearly developed. NbC carbides replicas of 1 and 4 h-aged 18Cr9Ni ASS specimens stabilized with
and (Ti, Nb) C carbides are observed in NbFSS and in TiNbFSS, Ti to compare the precipitation and segregation behaviors of ASS
respectively, and Cr peak is also detected in both kinds of carbides with those of FSS. The analysis on the 1 h-aged ASS indicates that
in EDS analysis. It is clear again that the Cr peak is due to the Cr no precipitation was formed along the grain boundary as shown in

Fig. 15. TEM characterization of 18 wt% Cr-9 wt% Ni ASS aged at 500 C for 1 h: (a) Carbon extraction replica around the grain boundary and (b) higher magnication of A
marked in (a).

Fig. 16. TEM characterization of 18 wt% Cr-9 wt% Ni ASS aged at 500 C for 4 h. (a) Carbon extraction replica around the grain boundary, (b) Higher magnication of A marked
in (a), (c) EDS spectra of intergranular precipitates, and (d) Electron diffraction pattern analyzed on the intergranular precipitates.
1710 J.K. Kim et al. / Electrochimica Acta 56 (2011) 17011710

Fig. 15. However, along the grain boundaries of 4 h-aged ASS spec- References
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