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Up Topic Welding Industry / Inspection & Qualification / Sensitization on Stainless Steel Tp 304
- - By Joey (***) Date 11-03-2007 17:20
Upon inspection of a stainless steel tank (Tp304), we found extensive leaks on weld joints of floor plates using vacuum box test. After repair on leaks, the owner-user of the tank decided to call for metallographic in situ test for those other weld areas not leaking.  The finding was sensitization on HAZ in many weld areas.

My questions are :

1. What could be the possible cause of this sensitization?
2. Should this sensitization on HAZ be repaired even though no sign of leak?
3. How to avoid this sensitization on s/s 304.

thanks for sharing your knowledge on this subject.

Regards
Joey
Parent - - By 803056 (*****) Date 11-04-2007 00:56
It sounds like the damage is done.

Sensitization is the result of the base metal being subjected to the sensitizing temperature range during welding. The carbon combines with the chrome along the grain boundaries thus depleting the HAZ of free chrome that is responsible for corrosion resistance.

You didn't state the tank's use, but SCR is usually associated with an electrolyte containing chlorides. SCR (stress corrosion cracking) is often referred to as IGSCC as well. That is likely to be the source of cracking if it was confined to the heat affected zones (HAZ) along the toes of the welds. You can also get knife line cracking where two welds cross each other. This occurs if the primary weld didn't maintain the high temperatures required to cause sensitization. The combination of the primary weld and the intersecting weld create a situation where the conditions of time and temperature are satisfied and result in localized sensitization only at the intersection where the second weld crosses over the primary weld.

The preventive measure is to use a low carbon grade of stainless, i.e., 304L, with a low carbon stainless filler metal, i.e., 308L. Another measure is to use stabilized grades of stainless, i.e. 321 or 348. These measures must be taken at the design stage of the construction.

Good Luck - Al

Once sensitization has occurred, the only corrective measure I know of is to heat the entire weldment high enough to cause the chromium carbides to dissolve, quench the weldment to prevent the reformation of the chromium carbides. It is unlikely this is a reasonable solution to your problem.
Parent - - By Joey (***) Date 11-05-2007 13:54
Al, It's Acetic Tank. I'm not sure if possible to heat up the entire weldment of 30meter dia bottom plate. Maybe by using blow torch. But who should decide on best solution to adapt? can welding engineer make the decision on what to do or should we get a tank engineer or API 653 inspector? My boss is asking me for solution but I'm just a QC inspector.

help me Al, my Christmas goose is at risk here,,hehehe..

Thanks

Joey
Parent - - By js55 (*****) Date 11-05-2007 14:54
If your tank is leaking you are way beyond doing anything thermally to stop it. Sensitization does not cause leaks. Cracking, or escessive corrosion, that can form from a sensitized microstructure can, given certain service conditions. If your leaking the only remedy is to replace the leaking part, or cut out the damaged portions and reweld.
Parent - By 803056 (*****) Date 11-05-2007 17:24
Your bed is made, i.e., the decision to use a standard grade of stainless rather than a low carbon grade of stainless. You can get some more useful life by repairing the existing welds, but it isn't the welds that are leaking, it is the HAZ beside the welds. Essentially, you have to excavate the HAZ and reweld them. Use a low carbon grade of filler metal and maintain a low interpass temperature to minimize additional sensitization.

When you buy your replacement tanks, remember to specify the low carbon variant or stabilized grades of base metal and filler metal.

Best regards - Al
Parent - - By CWI555 (*****) Date 11-05-2007 18:17 Edited 11-05-2007 21:51
Joey, My advise is let someone else make this decision. What you describe sounds more like an engineering decision. I believe your taking a huge risk of getting your christmas goose cooked prematurely if you try to take this on as a QC inspector.
Parent - - By RANDER (***) Date 11-05-2007 21:20
I second that
Parent - - By 803056 (*****) Date 11-05-2007 23:17
Amen!

Al
Parent - By Joey (***) Date 11-06-2007 13:10 Edited 11-06-2007 16:43
thank you guys, I've learned from you not only the technical aspect but also the proper approach on how to address this problem as QC Inspector. I told my boss what I learned from this forum and he praised me....He said I'm very knowledgeable! brilliant! (hehehe). As a small time contractor, we are only involved mainly on repair maintenance of this tank and we don't have an engineering section, so my boss suggested to the owner-user to contact the tank manufacturer from Japan for advise before any further repair.

Luckily, I raised this issue in this forum, without you guys, I have to eat pigeon instead of goose this Christmas.

oh boy!...I must aim for promotion after Christmas.

Regards
Joey :-)
Up Topic Welding Industry / Inspection & Qualification / Sensitization on Stainless Steel Tp 304

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