An investigation into the general and pitting corrosion rates of rolled homogeneous armor (RHA) steel in immersion and saltog environments is presented. The mechanical properties of RHA steel have been studied, but the effects of corrosion on RHA have not been analyzed. An immersion environment of 3.5% NaCl was used to induce corrosion for the total testing period of 1500 hours for four immersion samples. A Qog cyclic corrosion tester was used to simulate a saltog/humidity/drying environment for four saltog samples. The different mechanisms of corrosion (general and pitting) and their associated rates were quantified through evolved hydrogen gas measurements, profilometry, Scanning Electron Microscopy (SEM) and Optical Microscopy (OM). The primary corrosion mechanism in the immersion samples was general corrosion, while the primary corrosion mechanism in the saltog samples was pitting corrosion. The immersion samples showed no signs of pitting corrosion.

Nowdays biofuels are becoming a good alternative for petroleum fuels due to environmental issues like high carbon dioxide emission and increasing vehicles population, together with the high price and fast depletion of petroleum oils. This project aims to investigate the corrosive effects of wood Pyrolysis oil on a special grade of nitrogen alloyed tooling steels to be used for injector nozzles in Diesel engines, where high stress and strain encounter high acidity and corrosivity of the Pyrolysis oil and cause breakdown over short periods. Vanax 35 and Vanax 75 manufactured in Uddeholm are two types of powder metallurgy high nitrogen alloyed martensitic stainless steel with a high combination of hardness (over 56HRC), low friction properties, wear resistance, anti-galling and corrosion properties. In this work, the newly developed Vanax material together with the tool steels Elmax and AISI O1 were tempered at various temperatures from 200°Cto 500°C. The tempered steels were then exposed in pyrolysis oil at 4 different temperatures, 20°C, 70°C, 95°Cand 130°C. The materials were investigated by means of corrosion rate measurements, microscopy (LOM, SEM, confocal) and Thermo-Calc calculations. The corrosion rate measurement proved that Vanax tempered at lower ranges (200°C, 400°Cand 450°C) showed the best corrosion resistance while higher tempering temperatures such as 500°C, Elmax and AISI O1 tempered at 200°Csuffered a great deal of general corrosion attack. Thermo-Calc calculations showed the formation of a hard phase, VN as primary nitrides instead of primary chromium carbides at austenizing temperature for the Vanax group. Higher amount of chromium is dissolved in solid solution in Vanax at austenizing temperature hence the martensite matrix has, after quenching, a higher chromium content that helps passivation. The loss in corrosion properties at higher tempering temperatures was due to the formation of CrN secondary phase at around 400˚C which reduces the chromium content of the martensite matrix. The results of light optical and confocal microscopy showed the presence of pits when tempering at 400˚C and 450˚C. No pits were observed at 200˚C. Elmax was not passivated at all which resulted in general corrosion attacks, due to a high chromium loss from the austenite solid solution at the austenizing procedure temperature and also the tempering temperatures. The chromium depletion from the austenite can be explained by a high carbon and a low nitrogen content in the composition which resulted in formation of a high amount of Cr7C3.

<p>Heat exchanger tubes are commonly made from stainless steel.In a heat exchanger both the process fluid and the cooling orheating media can be corrosive. It is therefore important to beable to select materials that do not suffer from corrosion.Current methods in this area, however, suffer from limitationsand shortcomings. This thesis concerns corrosion tests forgeneral corrosion, dewpoint corrosion and stress corrosioncracking, respectively. For evaluation of general corrosion ofsuperduplex stainless steels in hydrochloric acid and sulphuricacid the importance of activation was studied. The results showthat activation has a great influence on the test result.Further the results indicate that experimental differences canbe the explanation for previously reported differences incorrosion resistance of superduplex stainless steel that havebeen attributed to the alloying with Cu and W. Furthermore, asimple test loop for testing stainless steels under dew formingconditions with a formed condensate of 1 % hydrochloric acidhas been developed. In the work constant strain and constantload test result have been compared and the observationsindicate that the differences can be explained by differencesin the relaxation properties of the materials.</p><p><b>Key words:</b>corrosion testing, heat exchanger, stainlesssteel, general corrosion, immersion tests, activation, stresscorrosion cracking, constant load, u-bends, relaxation,dewpoint corrosion</p>

Les enveloppes métalliques en acier non allié choisies par l’Andra comme surconteneurs pour le stockage des déchets radioactifs seront principalement soumises à la corrosion généralisée. L’objectif de ce travail est de démontrer qu’il est possible de simuler sur le long terme cette vitesse de corrosion de façon à bien dimensionner les surconteneurs pour qu’ils restent étanches et confinent la radioactivité des déchets qu’ils contiennent pendant plusieurs siècles.La modélisation par la méthode des éléments finis, basée sur la résolution numérique de l’équation de Nernst-Planck en potentiel libre a donc été utilisée pour prévoir le comportement électrochimique de ces aciers sur des durées inaccessibles à des expériences en laboratoire. A partir d’études paramétriques (influence des constantes de cinétique électrochimique, des constantes cinétiques associées aux réactions chimiques, de la température) et en se basant sur plusieurs comparaisons entre expériences de laboratoire et simulations numériques, il a été possible de déterminer l’ensemble des paramètres et des règles de fonctionnement nécessaires pour construire et utiliser un modèle numérique prédictif le plus complet possible.Dans la simulation à long terme, qui constitue le résultat majeur du travail, on constate qu’après épuisement de l’oxygène dissous initialement piégé, la vitesse de corrosion est contrôlée par le recouvrement de la surface métallique dû à l’apparition de produits de corrosion (magnétite, sidérite). Ce phénomène induit une diminution de la porosité totale, identifiée comme déterminante dans le ralentissement de la vitesse de corrosion. / Unalloyed steels selected by Andra for nuclear waste storage would be mainly affected by general corrosion. The aim of this study is to demonstrate that it is possible to simulate the long term corrosion rate in order to estimate the thickness of the containers expected to maintain the confinement for several centuries. Modeling by the finite element method, based on the resolution of Nernst-Planck equation in free potential conditions has been used to predict the electrochemical behavior of these steels impossible to reach at long time through laboratory experiments. From parametric studies (influence of electrochemical kinetic constants, kinetic constants dealing with chemical reactions, temperature) and in the light of several comparisons between laboratory and numerical experiments, it was possible to determine all the parameters and all the rules to build and use the most completed predictive numerical model.The main result of this study is a long term prediction model. After a first step it was established that dissolved oxygen initially trapped is consumed, whereas the corrosion rate is controlled by the fractional coverage of the surface due to the formation of corrosion products (magnetite, siderite). As a consequence, the decrease of the total porosity can be identified as a key parameter in the reduction of the corrosion rate.

Heat exchanger tubes are commonly made from stainless steel.In a heat exchanger both the process fluid and the cooling orheating media can be corrosive. It is therefore important to beable to select materials that do not suffer from corrosion.Current methods in this area, however, suffer from limitationsand shortcomings. This thesis concerns corrosion tests forgeneral corrosion, dewpoint corrosion and stress corrosioncracking, respectively. For evaluation of general corrosion ofsuperduplex stainless steels in hydrochloric acid and sulphuricacid the importance of activation was studied. The results showthat activation has a great influence on the test result.Further the results indicate that experimental differences canbe the explanation for previously reported differences incorrosion resistance of superduplex stainless steel that havebeen attributed to the alloying with Cu and W. Furthermore, asimple test loop for testing stainless steels under dew formingconditions with a formed condensate of 1 % hydrochloric acidhas been developed. In the work constant strain and constantload test result have been compared and the observationsindicate that the differences can be explained by differencesin the relaxation properties of the materials. <b>Key words:</b>corrosion testing, heat exchanger, stainlesssteel, general corrosion, immersion tests, activation, stresscorrosion cracking, constant load, u-bends, relaxation,dewpoint corrosion / NR 20140805

Cette thèse s’inscrit dans le contexte de la durabilité des structures en acier au carbone envisagées pour le stockage des déchets radioactifs à haute activité et à vie longue. Ce travail porte plus particulièrement sur la simulation numérique de la corrosion généralisée (et de son évolution), principale forme de corrosion susceptible d’affecter ces aciers en phase aqueuse et en condition désaérée.Le processus de corrosion des aciers au carbone est grandement influencé par la formation de couches de produits de corrosion (CPC) dont le rôle sur l’évolution de la vitesse de corrosion a été mis en évidence dans de nombreuses études. Le caractère plus ou moins protecteur d’une CPC dépend de plusieurs paramètres physiques (porosité, épaisseur et propriétés électriques de CPC) et chimiques (pH, PCO2, formations de complexes,…). Le principal objectif de ce travail de thèse est l’étude du rôle d’une CPC de sidérite sur la vitesse de corrosion des aciers au carbone en condition désaérée. Le régime de corrosion est ainsi simulé sur la base de modèles mécanistes en faisant appel à une résolution par la méthode des éléments finis de l’équation de transport réactif en milieu poreux et en potentiel libre.Dans un premier temps, l’étude de la stabilité d’une CPC par expérience numérique est présentée et constitue une étape importante dans la mesure où elle permet de sélectionner les paramètres influençant cette stabilité et par conséquent le processus de corrosion. Cette expérience numérique confirme des résultats expérimentaux obtenus sur des coupons dans un environnement représentatif des conditions de stockage mais sur des durées beaucoup plus courtes (de l’ordre de quelques années). Ces calculs montrent qu’en fonction des conditions chimiques (pH, complexants,…), morphologiques (épaisseur, distribution de porosité dans la CPC, …) et des propriétés électriques de la couche, on obtient soit un dépôt stable pouvant potentiellement entraîner une diminution de la vitesse de corrosion, ou soit un dépôt instable mettant à nu la surface du métal et qui se traduit par une vitesse de corrosion élevée.De manière complémentaire, le transitoire de croissance d’une CPC est également étudié en prenant en compte numériquement le déplacement de l’interface métal – CPC correspondant à la création de vide par la dissolution du métal. Deux approches, la première dite « implicite » et la seconde dite « explicite », de mouvement de cette interface sont présentées. Tous ces modèles numériques sont comparés à différents retours d’expérience. A cet égard, une loi de précipitation de la sidérite, discutée et confrontée aux différentes lois de la littérature, est proposée. Les résultats de simulation d’un transitoire de croissance d’une CPC conductrice sont conformes à certains retours d’expériences, montrant d’abord une phase active de corrosion suivie d’une phase pseudo-passive où la vitesse de corrosion est ralentie par le recouvrement de la surface métallique par la CPC. / This thesis is related to the issue of the sustainability of carbon steel structures intended for the storage of high-level long-lived radioactive waste. This work focuses on the numerical simulation of the uniform corrosion (and on its evolution), representing the main form of corrosion likely to affect these steel components in aqueous and deaerated conditions.The corrosion process of carbon steels is greatly influenced by the formation of corrosion product layers (CPL) whose role on the evolution of the corrosion rate has been demonstrated in numerous studies. The more or less protective nature of a CPL depends on several physical (porosity, thickness and electrical properties of CPL) and chemical parameters (pH, PCO2, complex formations, ...). The main objective of this thesis is the study of the role of a siderite CPL on the corrosion rate of carbon steels in deaerated conditions. The corrosion regime is simulated on the basis of mechanistic models using a finite element method to resolve the reactive transport equation in porous media and in free potential conditions.Firstly, the stability of a CPL is studied by numerical experiment and constitutes an important step that permits to select the key parameters influencing this stability and consequently the corrosion process. This numerical experiment confirms experimental results obtained on coupons in an environment representative of the storage conditions but on much shorter durations (few years). These calculations show that depending on the chemical conditions (pH, complexing medium, ...), morphological (thickness, distribution of porosity in the CPC, ...) and the electrical properties of the layer, we obtain either a stable deposit that could potentially lead to a decrease of the corrosion rate, or an unstable deposit exposing the metal surface and resulting in a high corrosion rate.In a second time, the transient step i.e. the formation and growth process of a CPL, is also studied numerically considering the displacement of the metal-CPC interface corresponding to the creation of voids caused by the dissolution of the metal. Two approaches, the first one called "implicit" and the second "explicit", of the movement of this interface are presented. All these numerical models are compared with different experimental feedbacks. Thus, a kinetics law of precipitation of siderite, discussed and compared with different laws proposed in the literature, is implemented in these models. The results obtained by simulating the growth of a conductive CPL are consistent with some experimental feedbacks, showing firstly a period of active corrosion followed by a pseudo-passive period during which the corrosion rate is significantly decreased resulting from the coverage of the metal surface by the CPL.