Corrosion and Stress Corrosion Crack Initiation in the Machined Surfaces of Austenitic Stainless Steels in Pressurized Water Reactor Primary Water： Research Progress and Perspective

doi:10.11900/0412.1961.2022.00316

Acta Metall Sin

2023, Vol. 59

Issue (2): 191-204 DOI: 10.11900/0412.1961.2022.00316

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Corrosion and Stress Corrosion Crack Initiation in the Machined Surfaces of Austenitic Stainless Steels in Pressurized Water Reactor Primary Water： Research Progress and Perspective

CHANG Litao(

)

Shanghai Institute of Applied Physics, Chinese Academy of Sciences, Shanghai 201800, China

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CHANG Litao. Corrosion and Stress Corrosion Crack Initiation in the Machined Surfaces of Austenitic Stainless Steels in Pressurized Water Reactor Primary Water： Research Progress and Perspective. Acta Metall Sin, 2023, 59(2): 191-204.

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Abstract

Austenitic stainless steels (ASSs) are important materials which are used widely in the primary circuits of pressurized water reactors (PWRs). The performance of the ASSs in PWR primary water has been outstanding. However, stress corrosion cracking cases have been identified in ASS components in the primary loop of PWR nuclear power plants since the end of 20th century. Most stress corrosion cracking cases occurred in low flow or stagnant zones in the dead-leg regions, where the primary water chemistry was contaminated with anionic impurities. Cold work has been identified to be necessary for stress corrosion cracking for components operating in locations where the water is well circulated. Machining and other surface treatments can always introduce cold work to ASS components. Therefore, considerable research efforts have been invested to understand the nature of the surface deformation layer on ASS introduced during machining processes and by other surface treatments, as well as the corrosion and stress corrosion crack initiation behaviors of the machined surfaces in simulated PWR primary water. This paper reviews the research progress on the surface deformation layer on ASSs introduced by various processes, and the effects of surface deformation on the corrosion and stress corrosion crack initiation behavior of ASSs. The key issues that remain to be solved are summarized, and possible solutions are suggested.

Key words: austenitic stainless steel PWR primary water machining stress corrosion crack initiation slow strain rate tensile test

Received: 27 June 2022

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About author: CHANG Litao, professor, Tel: (021)39194096, E-mail: changlitao@sinap.ac.cn

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Fig.1 Back-scattered electron (BSE) image of the machined layer of austenitic stainless steels (ASSs) (a)^[15]; bright field-transmission electron microscopy (BF-TEM) image and corresponding selected area electron diffraction (SAED) pattern (inset) of the topmost ultrafine-grained layer (b)^[32]; BSE image showing the details of the twins-intersected region (c)^[15]; BF-TEM image (d) and dark field-TEM (DF-TEM) image (e) of the deformation twins (Inset in Fig.1e shows the SAED pattern)^[32]

Fig.2 Residual stress distribution in the depth direction of a turned type 316L stainless steel^[38] (σ_∥ and σ_⊥—residual stresses parallel and perpendicular to cutting direction, respectively;v_c—cutting speed, f—cutting feed, a_p—depth of cut)

Fig.3 BSE and BF-TEM images showing the microstructure of the deformation layer on ASSs induced by grinding using 800 grit (a)^[29] and 2400 grit (b)^[43] SiC papers

Fig.4 Surface morphologies (a, b) and cross-sectional microstructures (c, d) of the inner/outer oxide layers formed on the polished surface (a, c) and machined surface (b, d) of an annealed 316L stainless steel in simulated pressurized water reactor (PWR) primary water^[30]

Fig.5 BF-TEM (a) and DF-TEM (b) images of the oxide layers formed in the polished surface, and BF-TEM image of the oxides formed on the machined surface of annealed 316L stainless steel in PWR primary water (d); SAED patterns obtained from the circled regions in Figs.5a and b (c) and Fig.5d (e), respectively; and high angle annular dark field-scanning TEM (HAADF-STEM) image showing intergranular oxidation of the ultrafine-grains in the machined surface (f)^[30]

Fig.6 Main features and influencing factors of the life cycle of a stress corrosion crack (SCC)^[19]

Fig.7 Cracks in the inner oxide layer of an annealed 316L stainless steel (a)^[15], and intergranular stress corrosion crack initiated in cold-rolled 316L stainless steel during slow train rate tensile (SSRT) test (b)^[28]; slip steps at the crack flank in cold-rolled 316L stainless steel sample (c)^[65]

Fig.8 Crack initiated along the machining marks in the machined surface of an annealed 316L stainless steel sample (a) and cross-sectional appearance of the crack (b)^[15]

Fig.9 Stress corrosion crack initiation in the polished (a) and machined (b) surfaces of a warm-forged 304L stainless steel during SSRT test (Inset in Fig.9b shows the magnified image of rectangle area); a crack propagated transgranularly (c) and a crack branched and then propagated both intergranularly and transgranularly after penetrating beyond the topmost ultrafine-grained layer (d)^[32]

Fig.10 HAADF-STEM images of the ultrafine-grains in the machined layer of cold-rolled 316L stainless steel before (a) and after (c) heat treatment, and the surface stress corrosion cracks initiated on the machined surfaces during SSRT test before (b) and after (d) heat treatment (Cracks were colored in red in Figs.10b and d)^[28]

Fig.11 Schematic of the load that material bears during plant operation, constant load testing, and SSRT testing

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