Thanks for all the links.  I read every article.  I keep Excel spreadsheets with links in them.  That way I can post up notes on what the links contain.  I will copy the best stuff here into an excel to keep at my office computer.

I better understand some of the testing others are doing on this project now. I think the first cut is a quick and dirty acid weight loss test to flag good/bad material.  Then the witchunt for chemistry will probably begin with the SEM.  The easiest thing to do might be to just switch materials, but it  looks like our only other choices would be 410, or 409 (If available in bar stock from a U.S. Supplier since DOD restricts sources.)  I am not sure people would be happy with the rust color on a 409, but it is not a bad rust.  It is a good rust that "protects", and 409 does not have the problems we are worried about.  At first blush it seems like a junk material since it was invented for auto exhaust systems though.

All this literature got me thinking and I remembered that my employer has a corporate membership at the Edison Welding Institute.

One of the benefits is use of their librarians who do unlimited literature searches and download all the papers for no fee.  We don't even have to pay for the papers - unlike those links like SpringerLink that charge something like $40 a paper.

So, now that I remembered, I have them working on a full up literature search on the keywords 430, Stainless, Embrittlement, Corrosion, and Sigma Phase.