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Report Issued: MQP ] $ 1973 Report 7333.56-73

PACIFIC GAS AND ELECTRIC COMPANY DEPARTMENT OF ENGINEERING RESEARCH

RUSTING OF WELDED JOINTS IN STAINLESS PIPING DIABLO CANYON

F. J D DD, En sneer W.. HAYi, metallurgical Engineer

Di ibution: WJLindbl ad Enclosures: Figures 1 through 10 sm/t RSBain Appendix A, AGWalther GVRichards WRForbes l 1

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I Report 7333.56-73

I NTRODUCT

Concern has recently been shown over rusting observed on welded joints in piping for the Diablo Canyon project. The material has been stored in a coastal environment at the plant site. The appearance of the rusting ranges from a thin, light brown film over the weld area to darker, uneven streaks. Some examples of this condition are shown in Fioures 1 and 2.

In all cases observed, rusting was limited to the area of postweld cleaning.

CORROSION RESISTANCE OF STAINLESS

Corrosion phenomena consist of electrochemical reactions between an and a surface. base alloys generally show a tendency to corrode in the environments encountered in most engineering applications. The surface condition which inhibits the corrosion reaction of stainless steels is called passivity.

Chromium, in a minimum proportion of 12 to 15 percent, confers a state of passivity on the iron based alloys called stainless steels. Steels with a content exceeding this limit will form a protective surface film when exposed to under the proper conditions. The film is believed to be formed by a complex process called chemisorption, and to be responsible for the passivity of the stainless steels.

'he passivity exhibited by the stainless steels is 'generally metastable.

The metal will remain in the passive state until some chemical, thermal, or mechanical condition destroys its passivity. If the passivity of the metal is destroyed, it can rust. Rusting progresses at a rate dependent upon the envi ronment. The corrosion can be arrested by cleaning the surface and repassi vating it by chemical or chemical arid thermal treatments . ,If Report 7333.56-73

SENSITIZATION

Sensitization is a localized reduction in chromium content which occurs when the stainless steel is heated to temperatures between 400'C and 900'C

(750'F and 1250'F) and results in a loss of passi vity. Solution-treated,

Type 304 stainless steel is a supersaturated solid solution of carbon in . At temperatures above 400'C, the carbon atoms have sufficient mobility to allow a si gni ficant diffusion rate. Above this temperature, carbon atoms migrate to areas of high internal energy, primarily grain boundaries, and combine with chromium to form chromium carbide precipitates such as (CrFe)23C6 Chromium carbide precipitation removes chromi um from solution resulting in narrow regions adjacent to the grain boundaries with chromium concentrations below the minimum necessary for passi vity. This cond ion is illus i a ed in igure 3 ~ Since sensitization is diffusion controlled, the degree of sensitization is a function of both time and temperature. The time necessary to obtain a given degree of corrosion susceptibility decreases with increasing tempera- ture up to approximately 750'C (1380'F). A temperature-time-sensitivity diagram demonstrating this relationship is shown in Figure 4. At tempera- tures above 1000'C (1830'F), the carbon solubility limit exceeds the carbon content of Type 304 stainless steel. Holding the steel at temperatures above 1000'C until the precipitates are dissolved and quenching to below

400'C eliminates sensitization and is called solution annealing or solution heat treating. The quench must result in cooling through the range of sensi- tizing temperatures in. less than the minimum time for sensitization. S' Report 7333.56-73

The relationship between carbon content and sensitization time is also demonstrated by Figure 4, and the influence of carbon content on degree of sensitization is shown in Figure 5. As the carbon content is increased, the time to produce a given degree of sensitization decreases. Type 304 stain- less steel has a maximum carbon content of ,08 percent. Welding 304 stain- less steel always results in some sensitization since the metal adjacent to the weld is subjected to a thermal cycle in the sensitizing range (400-900'C).

Two methods of controlling sensitization by controlling carbon are possible: (1) The carbon content of the stainless steel can be reduced so that the amount present is insufficient to reduce the local chromium concen- tration below the minimum level for corrosion resistance. This is attempted in the "L" grades of austenitic stainless steel. (2) The other method involves the addition of stabilizers. These are elements such as columbium, tantalum, and which form insoluble carbides. The formation of these carbi des removes the carbon from solution and prevents it from com- bining with the chromium. These changes also affect mechanical properties and welding characteristics,

The principal reason for avoiding severe sensitization is to prevent intergranular corrosion, a phenomenon in which grain boundaries are selec- tively attacked. This introduces cracks into the structure or may result in failure by disintegration in cases of very severe attack. Diverse media are reported to have produced intergranular corrosion in sensitized stain- less steel, including sulfuric, hydrofluoric, acetic, and other acids of varying temperatures and concentrations, , crude petroleum, chlori- nated solvents, and food products. Severity of attack is governed both by

Report 7333,56-73 the degree of sensitization and the corrosi veness of the media. 'llhere media are involved which have potential for severe intergranular attack at operating temperatures, welded Type 304 stainless steel is not used.

The elimination of sensitization by solution treatment of welded assemblies is not usually employed. The cooling rate required for solution treatment can only be obtained in small components and can result in distor- tion and high thermal stresses. However, several methods of reducing the degree of sensitization in components for use at the Diablo Canyon project are presently being used. These include improving heat removal by clamping liquid-cooled heat sinks near the weld, and limiting heat input by control- ling machine settings, electrode size, pass size, interpass temperature, preheating, postheating, and weaving.

SURFACE ACTIVATION

Since passivity is a surface phenomenon, it is logical that the corrosion resistance of stainless steels is quite sensiti ve to surface con- ditions, Deposits of scale and other contaminants on the surface, particles of contaminants imbedded in the surface by forming or cleaning operations, and loss of passivity due to grinding, brushing, or buffing can be detri- mental to the corrosion resistance of stainless steel and may lead to surface rusting.

Deposits of scale or other contaminants on the surface may result in corrosion for several reasons. Maintenance of the chemisorbed passive layer is dependent on sufficient access of oxygen. Surface deposits may block 1 1

~ H Report 7333,56-73 oxygen access resulting in oxygen concentration corrosion or a general loss of passivity. The contaminants may also be electropositive to stainless steel so that when an electrolyte such as spray or dew is present, gal- vanic corrosion oiay occur, Surface deposits provide sites for the collection and concentration (by precipitation and evaporation) of chemical species, such as the halogen , which are deleterious to passi vity.

Contaminant particles imbedded in the surface may be such things as scale embedded by grit blasting or improper wire bkushing, or / particles from grinding wheels used on carbon steel parts. These provide an interruption in the passivating film and introduce galvanic action between the stainless steel and the particle. The corrosion products resulting from this interaction form as surface'eposi ts leading to the complications described above. When the imbedded contam-inants are inclusionis in thie s.ee', this type of corrosion is often referred to as end grain corrosion. Corro- sion at embedded contaminant particles often results in pitting. Grinding, buffing, and wire brushing mechanically remove the passivating surface layer. In an environment of dry air, this layer normally reforms within 24 to 48 hours. However, these operations may imbed contaminants as discussed previously, plasticly deform the surface structure, and generate a considerable amount of heat. t1oderate to high degrees of plastic deformation significantly decrease the tendency of stainless steels to passivate. Improperly applied mechanical cleaning techniques can introduce severe plastic deformation in the surface of the material. Repassivation may not then occur in time to prevent corrosion or may be incomplete. 'h Report 7333.56-73

Because stainless steels have low thermal conductivity, the heat introduced by power grinding or wire brushing is concentrated near the sur- face being worked. Improper grinding can result in surface temperatures in the sensitizing range. Although the sensitized layer produced is very thin, it is an area susceptible to surface corrosion.

Four conditions have been described that result in a loss of passivity or corrosion resistance in austenitic stainless steels such as Type 304.

These are grouped as volumetric (sensitization from u!elding or heat treatment) or surface (surface contamination, embedded contamination, improper cleaning or finishing) conditions. This grouping also applies to the ways these conditions can be corrected. The surface conditions can be corrected by cleaning away the corrosion products and repassivating the surface by

";ckl;ng, Sensi+iza+ion through the volume of +he material can only be prevented by metallurgical methods, and can be removed only by heat treatment.

INVESTIGATIONS

Because of the "brush mark" appearance of much of the rusting around stainless steel welds, it was suspected that the welds had been cleaned with carbon steel wire brushes, contrary to Company specification. Several tests were conducted by the vendor, M. M. Kellogg, under the supervision of a metallurgical engineer. employed by the Company.* These tests demonstrated that the surface rusting found on the stainless steel components could be

*Prof. H. H. Honegger of the lletallurgical Engineering Department, California State Polytechnic University, San Luis Obispo. P Report 7333.56-73

induced by cleaning the welds and adjacent base metal wi th a power stainless

steel brush per standard construction practice, and then exposing the com- ponent to the marine environment of the construction site. Postweld cleaning

= by hand wire brushing eliminated nearly all rusting. Cleaning rusted or wire brushed components with Pelox, a commercially available phosphoric acid based cleaner for stainless steel, usually reduced the amount of rusting.

On February 1, 1973, several stainless steel pipes in open storage were inspected by a metallurgist from the Department of Engineering Research.

Welds at which rusting was not observed appeared to have been chemically

cleaned. The two upper quadrants of the weld shown in Figure 6 were cleaned, one with Pelox and one with a 20 percent nitric acid solution. All rust was

removed except at the boundary between the quadrants and a small area in the nitric acid cleaned quadrant where surface roughness h'.nde. d o...p,". t removal. After 14 days'xposure, the rust not removed by the cleaning operation had spread slightly and some small rust spots had reappeared on the cleaned areas adjacent to the weld bead. Host of the cleaned area remained free of rust.

A pipe'section with rusting at a socket weld was removed for metallographic examination. It was Sh Held D, Spool F-321 from pipe heat '7 Iio. l1-5723, and is shown in Figure~ Documentation applicable to this weld is contained in Appendix A. Parts of this sample had been protected from the environment by plastic tape and are free of rust. I Report 7333.56-73

A longitudinal cross section of the pipe wall containing weld metal, rusted pipe metal, pipe metal unrusted due to the plastic tape, and pipe metal outside the wire brushed region were examined metallographically. The bulk of the material exhibited a normal austenitic structure. Electrolytic oxalic acid etching revealed a structure in the heat-affected zone with steps and light ditching at grain boundaries with a few grains completely surrounded. The severity of ditching is indi cative of the degree of sensi- tization. Figure 9 shows some of the most severe ditching observed. This I structure was limited to a band having a maximum width of approximately three millimeters. Outside this band no ditching was observed. It is felt that this narrow band of light sensitization reflects acceptable welding practice.

A heavily cold worked layer of smeared metal and laps approximately

.001-'nch tt ick was observed on the outs',de surface of the pipe. This ccn- dition was limited to regions that had been power wire brushed and appeared to be the result of the wire brushing. Such laps provide sites for crevice attack. On laps not protected by tape, corrosion products were very often apparent; corrosion products were not found at other locations. This sur- face condition is shown in Figures 10 and ll. The cold worked surface layer etched very rapidly, as seen in Figure 9, indicating that it was much more active than the base material. Iron printing with potassium ferri- cyanide in areas protected from rusting by tape showed that the cold worked surface and laps were stainless steel with no carbon steel contamination present.

Report 7333.56-73

The positive correlation between the configuration of the cold worked

s'urface and the location of corrosion products, as well as the lack of carbon . steel contamination, indicate that the surface rusting is probably due to

reduced passi vation caused by cold work and by crevice conditions at the surface laps. These conditions were aggrevated by coastal exposure. The surface laps are limited to the outside of the pipe wi thi n two inches of the weld, and to a depth of approximately .001 inch. The corrosion does not appear to have penetrated to any significant depth. The primary reason for the use of stainless steels in the cooling system of pressurized reactors is to limit the amount of crud accumu- lated in the system. The conditions causing the rusting are limited to the outside surface of the pipe. In light of industry experience wi th PMR "eactor coolant systems and experiments simulating operating conditions, failure by intergranular corrosion or stress corrosion cracking is extremely unlikely. i

This is because these cleaning methods could not entirely remove the

surface layer. I'ffected In order to completely remove all the effects of \ the power wire brushing observed in the metallographic investigation a hot nitric acid pickle would be required. This operation would require careful controls to avoid overpickling and pitting, and might result in some inter- granular penetration in the heat-affected zone of the weld. Since the '1

1 10 Report 7333.56"73 rusting is limited to the outside surface and has not progressed to pitting or intergranular penetration in the salt mist environment, it does not seem probable that this surface condition will lead to any problems in., the environ- ment inside the plant. The risks introduced by , therefore, do not seem warranted.

SUMMARY

Some sensitization always occurs adjacent to welds in nonstabilized austenitic stainless steels. The degree of sensitization produced by a given weld is primarily dependent upon temperature, time at temperature, and the carbon content of the base metal. The degree of sensitization in components at Diablo Canyon is minimized by controlling the first two fac- tors in specifying welding procedures. Sensitized stainless steel is not susceptible to intergranular corrosion and stress corrosion cracking under the conditions normally found in the PHR coolant system.

The rusting of Type 304 stainless steel piping encountered has been I associated primarily with heavy cold working of the surface caused by power wire brushing. The decreased tendency to passivate and the crevice condi- tions which were caused by power wire brushing, combined with the marine environment in which the piping is stored, are responsible for most of the rusting. These conditions appear to be limited to a depth of .001 inch, and the corrosion appears much shallower.

The rusting could be prevented by pickling; however, the complications which this could introduce make it undesirable. The rusting observed was superficial, and although it could be removed by mild localized cleaning I ll Report 7333 56-73

(such as Pelox), this does not seem essential to the integrity of the components. However, if pitting-type corrosion occurs, it should be arrested. The piping should be thoroughly rinsed with demineralized water before installation in order to remove any contaminants which may have accumulated on it during storage.

Report 7333,56-73

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Figure j. A e')bow pipe with some of the heaviest observed rusting is shown.

7333.56-73

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Figure 2. Typical rusting at a welded joint is shown.

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kb'nimuln i'eve/ For corrosion resi'stance I2% Cr

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Diagram indicating the carbon and chromium concentrations around a carbide particle. (Bain)

Figure 8

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Report 7333.56-73

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Figure 6. Three welded joints are shown. The upper two quadrants of the weld indicated by the arrow have been cleaned.

Report 7333.56-73

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Figure 7. A specimen removed from Spool F-321 is shown. Varying degrees of rusting are evident on and around the weld. The somewhat rectangular areas free of rust were protected by plastic tape.

Report 7333.56-73

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Figure 8. Grain boundary ditching in the heat-affected zone and the outside surface of the component shown in Figure 7 is shown. This was the most severe ditching observed, and light to moderate in comparison to that often found. in welded stainless steel. The unevenness of the surface is the result of the rapid etching of the cold worked layer. The remains of a lap is marked by the arrows. Etchant: Electrolytic oxalic acid Magnification: 400X

Report 7333.56-73

Figure 9. The outside surface of the pipe is shown in this view of a longitudinal cross section of the component shown in Figure 7. Three surface laps are marked by arrows. magnification: 100X

Figure 10. The center most lap of Figure 9 is shown at higher magnification. Some evidence of a corrosion product is visible just to the right of the lap.

t1agnification: 400X

Report 7333.56-73

APPENDIX A

Documentation applicable to Shop Weld D, Spool F-321, Pipe Heat

No. tl-5723, Meld Rod ER-308-85813, Welding Procedure 125. Spool completed

June 13, 1972.

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NL) 11.'ny <@set>n sd Ii«vr sh~jj ac.f in Il.<.h. f1 1/nbratI:" film chc .

I , . Tubular Products''lDivision ALUA'!CE. OIIIO-I BEAVER FALLS. IFA.-2 ILIVAUKEE.IVISCPNSIH -3 Sl IIicPIIIG CVSTOIRCR OROCR RO. - ~ OAT -1-lf--1-»52-SO— I I 1OhSl711 1014125 I

. TUBESALES. NO. 9O249'5 Ml LL TEST APPLIES TO: Ts 22! 1 TLIBEVAY o LOS ANGELES, CALIFORNIA 900ZP. . M. W. KELLOGG CO. I- P.O. 2)08-5IO 5 H I P T 0 L - ~ SI'MLS BEAKED-". AL, TP 304. - CARBON .04-,08, EF AM PIPE TO c ~ KA~M t~ , '~)AS1'M A-312-70A AND A SI B31,'7 CLASS 2 PAR, 2-724 ~ 6 APPLIES CccccIJLISF cc/ 5h TI C NO OIL IcI5P.

~ "P" "C COMPLETE OOc hAll PACVc IC CODD HO PARTIAL ~ IIYDRO TFST LOS ITKM O.D WALI LCNCTH SRECIAt AFARKS Ic PCS' FOOTACL PCR SO cINCH TESTS A'IADf I 1 350 0828835091 10000 KTCH 8,690 I I I I

01 ! 050 ii 13 PL; 17/24 ITEM O2 C 55 1228 69 2000' SKNO I gr 'Li !i05 0 13 FLATTENING ply 02'3 ii 17/24 ITEN f2 3o8 68

1050 il 13 RLi f7/24 ITEN 17 C 2 46 f15 FLANGE I I I 04 f 05O ii 13 RLi 17/24 ITEN 20 157 88 KTPANSION I

05 fi05 0 il 13 RLi 17/24 ITEM 27 114 09 flARE,

1,:050 il 13 RLi 17/24 ITEN 32 C 1 23 b1 CORROSION I I 0 1,'05 0 Il 13 RL» 17/24 ITEN 35 C 1 S9 I F I I I I ULTRASONIC ri I I I I I OTE I I PKNKiRAN'I

c cI THI S IS TO CERTIFY THE ABOVE TUBES r.hcD PIPE+iAVE ~ I M C c D iN ACCORDAICCE LYITH AND HAY MET ALL THE REOUIREMENTS OF THE SPECIFICATIONS. I T E DAD K & WILCOX COMPANY I q Ei S VEI'IOOA:3F l JPVin G, SL,afjar ITCM HCA'I AO CARO MANO SV L. PHOS. SIL CHROM. IrO CV CO CP H C I'5723 , 0'l3 1.59 .015 .023 .57 10,>>3 10. 31 .048

II5097 OM 1. 67 , 021I .021 .53 18. 96 10 73 .10

V'IMA C CI.O' RCDVCT I5CI I HCAT ND 0 >OI cT HARDRCSS 5 Rccc Tcc 'IC IN 2 IN ARCA SWORN TO AND SUOSCRIOCD REF'ORC Mf . . 3uoli15KI ~ 'c H5723 7 J'>305'OD9a 65 tl50$ 7 IT03 '9 M 61

'c 0 CQM5IISSIO'c CXc+AI 5+~I+fi

7/2/71 7/12/71 " i9KNDFD

WELDING PRODUCTS DIVISION HOME OFFICES P.O. Box 1609 Fcdcratcd Investmcnt Building York, Pennsylvania 17405 421 Scvcnth Avenue Telephonct 717 845 7501 Pittsburgh, Pa. 16219 Telcphonc: 412.281.6380 Coast Melding Supply Company Yovr Order No 20260-3 916 Hest Betteravia Road Marked For: M. H. Kellogg Co. - 7177-42 Santa Maria, California 93456 Ovr Order No. 05602-1 Attn: Stan Louis Dote Shipped: MATERIAL DESCRIPTION AND SPECIFICATIONS Weight, lb, Size. in. Type or Grode Cooting 450 6- 1/16" z 36" ER308 Bare Hire 4 i.

Item Hoot No. Lot No. 5 pecificotions I; 85813 26151 AHS A5.9-69; ASME SPA"5.9 2 3/10%

CH EMICAL ANALYSIS: Colcvlotcd Weld Mctol: Typicol Weld Motel~. Actvol Wold Metal: Hoot'ther- oC /I oMn ooP oS ooSi ooCI ooNi XMo (oCb .04 1.66 .023 .012 .97 20.44 9.60

IhECHANICAI. PROPERTIES: Typical We!d Metal:~Actvof Weld Metol: Other ,'tem Tensile, psi Yield. psi ',El. 'oR.A. Chorpy V Notch Impoct. It. lb. As Welded Brinell As Welded Rockwell C Wo k Hardened Rockwell C 89,400 53,000 46 68.4

We hereby certify thot thc obovc motorial hos been tested in occordonce with thc listed spccilicotions ond conlotrns to oil cpplicoblc requirements. a] g

Swoin ond Svhscr:bed before me t iis /~~'f gjQ.c Authttetrod Sianototo feim IIO.A a' Report 7333.56-73

REFERENCES

ASTM Standards. American Society for Testing and Materials, Part 3, A262 and A380, 1972.

, Bain, E. C., R. H. Aborn, and J. J. B. Rutherford. Transactions of the American Societ for Steel Treatin . Volume 21, p. 481, 1933.

Binder, W. 0., C. M. Brown, and R. franks. Transaction of the American Societ for . Volume 41, pp. 1301-1346, 1949.

Colombier, L. and J. Hochmann. Stainless and Heat Resistin Steels. St. Martins Press, 1968

K., P. K. De, and'layaperamal, J. Balachandra. Corrosion. Volume 28, p. 269, 1972.

Gold, I.. Journal of Materials. Volume 7, p. 326, 1972.

Joinin of Stainless Steels. American Society for Metals, 1967.

M. W. Kellogg Co. Material Review Board Report No. 234.

Ryabchenkov, A. V., and V. M. Nikiforava, Intercr stalline Corrosion and Corrosion of Metals Under Stress . Leonar Hi 11, 1963.

Staehle, R. W. Proceedin s of the Conference on Fundamental As ects of Stress Corrosion Crackin . National Association of Corrosion Engineers, 1969.

Stainless Steel Information Manual for the Savannah River Plant, U.S, Atomic Energy Commission, 1964.

Thum, E. E. The Book of Stainless Steels. American Society for Metals, 1935.

Uhlig, H. H. The Corrosion Handbook. Chapman, 1948.

Ward, C. T., D. L, Mathis, and R. W. Staehle. Corrosion. Volume 25, p. 394, 1969.

Weldin Handbook. American Welding Society, Part 4, 1960. 'I

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