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Fig. 1 Corrosion rates of various cast steels in a marine atmosphere. Nonmachined specimens were exposed 24 m (80 ft) from the ocean at Kure Beach, NC. Source: Ref 1 Fig. 2 Corrosion rates of various cast steels exposed at the 240-m (800-ft) site at Kure Beach, NC. Specimens were not machined. Source: Ref 1 Fig. 3 Corrosion rates for ca st steels in an industrial atmosphere. Nonmachined specimens were exposed at East Chicago, IN. Source: Ref 1 Fig. 4 Corrosion rates of machined and non- machined specimens of cast steels after 7 years in three environments. The effect of surface finish on corrosion rates is negligible. Source: Ref 1 Figure 5 shows the results of another portion of this project. Corrosion rates for a 3-year exposure of various cast steels, wrought steels, and malleable iron in both atmospheres are compared. The following conclusions can be drawn from these tests: • The condition of the specimen surface has no significant effect on the corrosion resistance of cast steels. Unmachined surfaces with the casting skin intact have corrosion rates simi lar to those of machined surfaces regardless of the atmospheric environment • The highest corrosion rate occurs in the marine atmosphere 24 m (80 ft) from the ocean, with lower but similar corrosion rates occurring in the industrial atmosphere and the marin e atmosphere 240 m (800 ft) from the ocean • The corrosion rate of cast steel decreases as a function of time, because corrosion products (scale and rust coating) build up and act as a protective coating on the cast steel surface. However, the corrosion rate of the most resistant cast steel (2% Ni) is always less than that of lesser corrosion- resistant cast steels • Cast steels containing small percentages of nickel, copper, or chromium as alloying elements have corrosion resistance superior to that of cast c arbon steels and those containing manganese when exposed to atmospheric environments • Increasing the nickel and the chromium contents of cast steel increases the corrosion resistance in all three of the atmospheric environments • All cast steels have greate r corrosion resistance than malleable iron in industrial atmospheres and are superior or equivalent to the wrought steels in this environment. The corrosion rate in the marine atmosphere depends primarily on the alloy content. The cast carbon steel is much superior to the AISI 1020 wrought steel, but is slightly inferior to malleable iron (Ref 1) Fig. 5 Comparison of corrosion rates of cast steels, malleable cast iron, and wrought steel after 3 years of exposure in two atmospheres. Source: Ref 1 Other Environments. Several low- and high-alloy cast steels have been studied regarding their corrosion resistance to high-temperature steam. Test specimens 150 mm (6 in.) in length and 13 mm ( -in.) in diameter were machined from test coupons and then exposed to steam at 650 °C (1200 °F) for 570 h. The steel compositions and test results are given in Table 2. Table 3 shows the resistance of cast steels to petroleum corrosion, and Tables 4 and 5 supply similar data relating to water and acid attack. These data show the value of higher chromium content for improved corrosion resistance. Table 2 Corrosion of cast carbon and alloy steels in steam at 650 °C (1200 °F) for 570 h Composition, % Average penetration rate Type of steel C Cr Ni Mo mm/yr mils/yr Carbon 0.24 . . . . . . . . . 0.3 12 Carbon 0.25 . . . . . . . . . 0.28 11 Carbon-molybdenum 0.21 . . . . . . 0.49 0.3 12 Carbon-molybdenum 0.20 . . . . . . 0.49 0.25 10 Nickel-chromium-molybdenum 0.35 0.64 2.13 0.26 0.25 10 Nickel-chromium-molybdenum 0.28 0.73 2.25 0.26 0.25 10 5Cr-molybdenum 0.22 5.07 . . . 0.47 0.1 4 5Cr-molybdenum 0.27 5.49 . . . 0.43 0.1 4 7Cr-molybdenum (a) 0.11 7.33 . . . 0.59 0.05 2 9Cr-1.5Mo 0.23 9.09 . . . 1.56 0.025 1 Source: Ref 1 (a) Not a cast steel. Table 3 Petroleum corrosion resistance of cast steels 1000-h test in petroleum vapor under 780 N (175 lb) of pressure at 345 °C (650 °F) Weight loss Type of material mg/cm 2 mg/in. 2 Cast carbon steel 3040 196 Cast steel, 2Ni-0.75Cr 2370 153 Seamless tubing, 5% Cr 1540 99.2 Cast steel, 5Cr-1W 950 61.5 Cast steel, 5Cr-0.5Mo 730 47 Cast steel, 12% Cr 6.4 100 Stainless steel, 18Cr-8Ni 2.1 30 Source: Ref 1 Table 4 Corrosion of cast steels in waters Corrosion factor (a) Corrosive medium Exposure time, months Fe-0.29C-0.69Mn-0.44Si Fe-0.32C-0.66Mn-1.12Cr Fe-0.11C-0.41Mn-3.58Cr 2 100 85 58 Tap water 6 100 73 61 2 100 60 26 Seawater 6 100 80 40 2 100 93 30 Alternate immersion and drying 6 100 109 25 Hot water 1 100 100 64 2 100 71 68 0.05% H 2 SO 4 6 100 89 102 0.50% H 2 SO 4 2 100 223 61 Source: Ref 1 (a) Corrosion factor is the ratio of average penetration rate of the alloy in question to Fe-0.29C-0.69Mn-0.44Si steel. Table 5 Corrosion of cast chromium and carbon steels in mineral acids Weight loss in 5 h 5% H 2 SO 4 5% HCl 5% HNO 3 Steel mg/cm 2 mg/in. 2 mg/cm 2 mg/in. 2 mg/cm 2 mg/in. 2 Carbon steel, 0.31% C 2.7 17.42 2.1 13.55 80.79 521.1 Chromium steel, 0.30C-2.42Cr 4.9 31.6 5.41 34.9 47.36 305.5 Corrosion of Cast Stainless Steels Cast stainless steels are usually specified on the basis of composition by using the alloy designation system established by the Alloy Casting Institute (ACI). The ACI designations, such as CF-8M, have been adopted by the American Society for Testing and Materials (ASTM) and are preferred for cast alloys over the designations used by the American Iron and Steel Institute (AISI) for similar wrought steels. The first letter of the ACI designation indicates whether the alloy is intended primarily for liquid corrosion service (C) or heat-resistant service (H). The second letter denotes the nominal chromium-nickel type, as shown in Fig. 6. As the nickel content increases, the second letter in the ACI designation increases from A to Z. The numerals following the two letters refer to the maximum carbon content (percent × 100) of the alloy. If additional alloying elements are included, they can be denoted by the addition of one or more letters after the maximum carbon content. Thus, the designation CF-8M refers to an alloy for corrosion-resistant service (C) of the 19Cr-9Ni (F) type, with a maximum carbon content of 0.08% and containing molybdenum (M). Fig. 6 Chromium and nickel contents in ACl standard grades of heat- and corrosion-resistant castings. See text for details. Source: Ref 2 Corrosion-resistant cast steels are also often classified on the basis of microstructure. The classifications are not completely independent, and a classification by composition often involves microstructural distinctions. Cast corrosion- resistant alloy compositions are listed in Table 6. Table 6 Compositions of ACI heat- and corrosion-resistant casting alloys Composition, % (balance iron) (b) ACI designation Wrought alloy type (a) C Mn Si P S Cr Ni Other elements CA-15 410 0.15 1.00 1.50 0.04 0.04 11.5-14 1 0.5Mo (c) CA-15M . . . 0.15 1.00 0.65 0.04 0.04 11.50- 14.0 1.00 0.15-1.00Mo CA-40 420 0.20- 0.40 1.00 1.50 0.04 0.04 11.5-14 1 0.5Mo (c) CA-6NM . . . 0.06 1.00 1.00 0.04 0.03 11.5-14.0 3.5-4.5 0.4-1.0Mo CA-6N . . . 0.06 0.50 1.00 0.02 0.02 10.5-12.0 6.0-8.0 CB-30 431 0.30 1.00 1.50 0.04 0.04 18-21 2 . . . CB-7Cu-1 . . . 0.07 0.70 1.00 0.035 0.03 14.0-15.5 4.5-5.5 0.15-0.35Nb, 0.05N, 2.5-3.2Cu CB-7Cu-2 . . . 0.07 0.70 1.00 0.035 0.03 14.0-15.5 4.5-5.5 0.15-0.35Nb, 0.05N, 2.5-3.2Cu CC-50 446 0.50 1.00 1.50 0.04 0.04 26-30 4 CD-4MCu . . . 0.04 1.00 1.00 0.04 0.04 24.5-26.5 4.75- 6.00 1.75-2.25Mo, 2.75-3.25Cu CE-30 . . . 0.30 1.50 2.00 0.04 0.04 26-30 8-11 . . . CF-3 304L 0.03 1.50 2.00 0.04 0.04 17-21 8-21 . . . CF-8 304 0.08 1.50 2.00 0.04 0.04 18-21 8-11 . . . CF-20 302 0.20 1.50 2.00 0.04 0.04 18-21 8-11 . . . CF-3M 316L 0.03 1.50 1.50 0.04 0.04 17-21 9-13 2.0-3.0Mo CF-8M 316 0.08 1.50 2.00 0.04 0.04 18-21 9-12 2.0-3.0Mo CF-8C 347 0.08 1.50 2.00 0.04 0.04 18-21 9-12 3 × C min, 1.0 max Nb CF-16F 303 0.16 1.50 2.00 0.17 0.04 18-21 9-12 1.5Mo, 0.2-0.35Se CG-12 . . . 0.12 1.50 2.00 0.04 0.04 20-23 10-13 CG-8M 317 0.08 1.50 1.50 0.04 0.04 18-21 9-13 3.0-4.0Mo CH-20 309 0.20 1.50 2.00 0.04 0.04 22-26 12-15 . . . CK-20 310 0.20 2.00 2.00 0.04 0.04 23-27 19-22 . . . CN-7M . . . 0.07 1.50 1.50 0.04 0.04 19-22 27.5- 30.5 2.0-3.0Mo, 3.0-4.0Cu CN-7MS . . . 0.07 1.00 2.50- 3.50 0.04 0.03 18-20 22-25 2.0-3.0Mo, 1.5-2.0Cu CW-12M . . . 0.12 1.00 1.50 0.04 0.03 15.5-20 bal 7.5Fe CY-40 . . . 0.40 1.50 3.00 0.03 0.03 14-17 bal 11.0Fe CZ-100 . . . 1.00 1.50 2.00 0.03 0.03 . . . bal 3.0Fe, 1.25Cu N-12M . . . 0.12 1.00 1.00 0.04 0.03 1.0 bal 0.26-0.33Mo, 0.60V, 2.50Co, 6.0Fe M-35 . . . 0.35 1.50 2.00 0.03 0.03 . . . bal 28-33Cu, 3.5Fe HA . . . 0.20 0.35- 0.65 1.00 0.04 0.04 8-10 . . . 0.90-1.20Mo HC 446 0.50 1.00 2.00 0.04 0.04 26-30 4 0.5Mo (c) HD 327 0.50 1.50 2.00 0.04 0.04 26-30 4-7 0.5Mo (c) HE . . . 0.20- 0.50 2.00 2.00 0.04 0.04 26-30 8-11 0.5Mo (c) HF 302B 0.20- 0.40 2.00 2.00 0.04 0.04 18-23 8-12 0.5Mo (c) HH 309 0.20-2.00 2.00 0.04 0.04 24-28 11-14 0.5Mo (c) , 0.2N 0.50 HI . . . 0.20- 0.50 2.00 2.00 0.04 0.04 26-30 14-18 0.5Mo (c) HK 310 0.20- 0.60 2.00 2.00 0.04 0.04 24-28 18-22 0.5Mo (c) HL . . . 0.20- 0.60 2.00 2.00 0.04 0.04 28-32 18-22 0.5Mo (c) HN . . . 0.20- 0.50 2.00 2.00 0.04 0.04 19-23 23-27 0.5Mo (c) HP . . . 0.35- 0.75 2.00 2.50 0.04 0.04 24-28 33-37 0.5Mo (c) HP-50WZ . . . 0.45- 0.55 2.00 2.00 0.04 0.04 24-28 33-37 4.0-6.0W, 0.2-1.0Zr HT 330 0.35- 0.75 2.00 2.50 0.04 0.04 15-19 33-37 0.5Mo (c) HU . . . 0.35- 0.75 2.00 2.50 0.04 0.04 17-21 37-41 0.5Mo (c) HW . . . 0.35- 0.75 2.00 2.50 0.04 0.04 10-14 58-62 0.5Mo (c) HX . . . 0.35- 0.75 2.00 2.50 0.04 0.04 15-19 64-68 0.5Mo (c) Source: Ref 3 (a) Cast alloy chemical composition ranges are not the same as the wrought composition ranges; buyers should use cast alloy designations for proper identification of castings. (b) Maximum, unless range is given. (c) Molybdenum not intentionally added. Composition and Microstructure The principal alloying element in the high-alloy family is usually chromium, which, through the formation of protective oxide films, is the first step for these alloys in achieving stainless quality. For all practical purposes, stainless behavior requires at least 12% Cr. As will be discussed later, corrosion resistance further improves with additions of chromium to at least the 30% level. As shown in Table 5, nickel and lesser amounts of molybdenum and other elements are often added to the iron-chromium matrix. [...]... T4 -0 .69(b) T6 -0 . 78 T3 -0 .64(b) T4 -0 .64(b) T6 -0 .80 T8 -0 .82 T3 -0 .69(b) 2219 2024 T4 -0 .69(b) T6 -0 .81 T8 -0 .82 2036 T4 -0 .72 2090 T8E41 -0 .83 6009 T4 -0 .80 6010 T4 -0 .79 6151 T6 -0 .83 6351 T5 -0 .83 6061 T4 -0 .80 T6 -0 .83 T5 -0 .83 T6 -0 .83 7005 T6 -0 .94 X7016 T6 -0 .86 X7021 T6 -0 .99 X7029 T6 -0 .85 X7146 T6 -1 .02 7049 T73 -0 .84 (c) T76 -0 .84 (c) T73 -0 .84 (c) 6063 7050 T76 -0 .84 (c) -0 .84 (c) T6 -0 .83 (c)... potentials of nonheat-treatable commercial wrought aluminum alloys Values are the same for all tempers of each alloy Alloy Potential(a), V 1060 -0 .84 1100 -0 .83 3003 -0 .83 3004 -0 .84 5050 -0 .84 5052 -0 .85 5154 -0 .86 5454 -0 .86 5056 -0 .87 5456 -0 .87 5 182 -0 .87 5 083 -0 .87 5 086 -0 .85 7072 -0 .96 (a) Potential versus standard calomel electrode Table 1(b) Solution potentials of heat-treatable commercial... CF -8 LO 4 0.0 58 0.60 1.52 0.012 0. 013 18. 53 9. 98 0.02 0.02 CF -8 INT 11 0. 086 0. 084 1.10 0.031 0.012 19.90 8. 73 0.50 0.02 CF -8 HI 20 0.066 0.79 1.25 0.031 0.011 20 .81 8. 85 0.45 0.02 CF-8M LO 5 0.063 0.94 1.21 0.011 0.014 18. 26 11.17 2. 28 0.02 CF-8M INT 11 0. 083 1.20 1.20 0.030 0. 013 19. 78 9.53 2.21 0.02 CF-8M HI 20 0.071 1.19 1.16 0.030 0.011 19.92 9.40 1.95 0.02 CF-3 LO 2 0.016 0. 98 1.12 0.010 0.0 08. .. T4 S or P -0 .71 3 08. 0 F P -0 .75 F S -0 .81 F P -0 .76 T4 S or P -0 . 78 T6 S or P -0 .79 356.0 T6 S or P -0 .82 443.0 F S -0 .83 F P -0 .82 514.0 F S -0 .87 520.0 T4 S or P -0 .89 710.0 F S -0 .99 319.0 355.0 (a) S, sand; P, permanent (b) Potential versus standard calomel electrode Table 1(d) Solution potentials of some nonaluminum base metals Metal Potential(a), V Magnesium -1 .73 Zinc -1 .10 Cadmium -0 .82 Mild... -0 .83 (c) T73 -0 .84 (c) T76 71 78 -0 .83 (c) T76 7475 T6 T73 7075 -0 .84 (c) -0 .84 (c) T6 -0 .83 (c) (a) Potential versus standard calomel electrode (b) Varies ±0.01 V with quenching rate (c) Varies ±0.02 V with quenching rate Table 1(c) Solution potentials of cast aluminum alloys Alloy Temper Type of mold(a) Potential(b), V 2 08. 0 F S -0 .77 2 38. 0 F P -0 .74 295.0 T4 S or P -0 .70 T6 S or P -0 .71 T62 S or P -0 .73 296.0... 17.36 10.10 0.10 0.04 CF-3 INT 5 0.023 0. 68 1.24 0.011 0.009 19.35 10.27 0.10 0.06 CF-3 HI 8 0.015 0.67 1.09 0. 013 0.006 19 .82 8. 73 0.10 0.04 CF-3M LO 5 0.027 0.96 0 .85 0.011 0.010 17.55 12.00 2. 18 0.04 CF-3M INT 9 0.027 1.04 1.02 0.009 0.009 18. 78 10.79 2.12 0.03 CF-3M HI 16 0.022 0.94 1.14 0.012 0.007 19 .85 10. 08 2.26 0.02 (a) This value is the percentage of ferrite Intergranular Corrosion of Ferritic... general corrosion, intergranular corrosion, localized corrosion, corrosion fatigue, and stress corrosion General Corrosion of Martensitic Alloys The martensitic grades include CA-15, CA-15M, CA-6NM, CA-6NM-B, CA-40, CB-7Cu-1 and CB-7Cu-2 These alloys are generally used in applications requiring high strength and some corrosion resistance Alloy CA-15 typically exhibits a microstructure of martensite... intergranular corrosion resistance in applications involving relatively high service temperatures Alloys CF-8M, CF-3M, CF-8MA, and CF-3MA are molybdenum-bearing (2 to 3%) versions of the CF -8 and CF-3 alloys The addition of 2 to 3% Mo increases resistance to corrosion by seawater and improves resistance to many chloride-bearing environments The presence of 2 to 3% Mo also improves crevice corrosion and... wholly austenitic counterparts Alloy CF-3 is a reduced-carbon version of CF -8 with essentially identical corrosion resistance except that CF-3 is much less susceptible to sensitization (Fig 14) For applications in which the corrosion resistance of the weld heat-affected zone (HAZ) may be critical, CF-3 is a common material selection Fig 13 Isocorrosion diagrams for ACI CF -8 in HNO3 (a), H3PO4 (b and... pressure Fig 14 Isocorrosion diagram for solution-treated quenched and sensitized ACI CF-3 in HNO3 Alloys CF-8A and CF-3A contain more ferrite than their CF -8 and CF-3 counterparts Because the higher ferrite content is achieved by increasing the chromium/nickel equivalent ratio, the CF-8A and CF-3A alloys may have slightly higher chromium or slightly lower nickel contents than the low-ferrite equivalents . 1 7-2 1 8- 2 1 . . . CF -8 304 0. 08 1.50 2.00 0.04 0.04 1 8- 2 1 8- 1 1 . . . CF-20 302 0.20 1.50 2.00 0.04 0.04 1 8- 2 1 8- 1 1 . . . CF-3M 316L 0.03 1.50 1.50 0.04 0.04 1 7-2 1 9 -1 3 2. 0-3 .0Mo. 2. 0-3 .0Mo CF-8M 316 0. 08 1.50 2.00 0.04 0.04 1 8- 2 1 9-1 2 2. 0-3 .0Mo CF-8C 347 0. 08 1.50 2.00 0.04 0.04 1 8- 2 1 9-1 2 3 × C min, 1.0 max Nb CF-16F 303 0.16 1.50 2.00 0.17 0.04 1 8- 2 1 9-1 2 1.5Mo,. 0. 2-0 .35Se CG-12 . . . 0.12 1.50 2.00 0.04 0.04 2 0-2 3 10 -1 3 CG-8M 317 0. 08 1.50 1.50 0.04 0.04 1 8- 2 1 9 -1 3 3. 0-4 .0Mo CH-20 309 0.20 1.50 2.00 0.04 0.04 2 2-2 6 1 2-1 5 . . . CK-20