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Corrosion Fatigue

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Corrosion Fatigueis a specific type offatigue failure mechanismthat is caused by a combination of cyclic stress and a corrosive environment. When a crack initiates as a result of fatigue, corrosion typically increases crack propagation.

While corrosion fatigue is commonly associated with rotating equipment, deaerators, and cycling boilers, corrosion fatigue can affect any unit operating in a corrosive environment that has sufficient cyclic stresses and stress raisers. Stress raisers are typically found in concentrated areas of a component such aspits, notches, surface defects, or changes in metallurgy.

Corrosion fatigue usually results in multiple parallel cracks at the surface of the component. However, some corrosion fatigue cracks can also be round, especially when cracking occurs near welded joints. Cracks can be located using effectivenondestructive testingtechniques.Ultrasonic testingandmagnetic particle testingare two of the most common methods in particular to inspect for corrosion fatigue.

Several techniques are available to mitigate corrosion fatigue. Some of these techniques include using more corrosion resistant alloys, usingcoatingsor inhibitors, reducing stress raisers, modifying the corrosive environment, and minimizing residual stresses due to welding by performing apost-weld heat treatment.

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Articles about Corrosion Fatigue
FFS Forum: Fatigue Mitigation Strategies
January/February 2020 Inspectioneering Journal

There are many sources and occurrences of metal fatigue in the chemical and refining industries. They range from low-cycle thermal stresses in an FCCU, to the relentless pressure cycling of a PSA, to the ultra-high cycles of a rotating pump.

Authors: Greg Garic
Failure Analysis in the Oil & Gas Industry
November/December 2013 Inspectioneering Journal

Service failures and safety incidents of machines, structures, and pressure equipment have been experienced in the oil and gas industry for many years without warning, with varying degrees of consequential damages to health, safety,...

Authors: Fernando Vicente
99 Diseases of Pressure Equipment: Corrosion Fatigue (Deaerator Cracking)
2005年1月/ 2月Inspectioneering Journal

Corrosion fatigue is closely related to mechanical and vibration fatigue cracking, except that it is initiated and accelerated by a corrosion mechanism, especially one that gives rise to pitting, from which cracks often initiate. But that...

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Auto-refrigeration can impose low temperatures onto process vessels and piping causing them to be at risk of brittle fracture, the sudden break-before leak phenomena that can result in catastrophic rupture of the equipment.

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