{"id":16802,"date":"2016-11-02T15:13:52","date_gmt":"2016-11-02T15:13:52","guid":{"rendered":"https:\/\/www.hawkins.biz\/?post_type=insight&#038;p=16802"},"modified":"2025-07-31T16:50:59","modified_gmt":"2025-07-31T15:50:59","slug":"stress-corrosion-cracking","status":"publish","type":"insight","link":"https:\/\/www.hawkins.biz\/insight\/stress-corrosion-cracking\/","title":{"rendered":"The Cost of Stress Corrosion Cracking"},"content":{"rendered":"\t\t<div data-elementor-type=\"wp-post\" data-elementor-id=\"16802\" class=\"elementor elementor-16802\" data-elementor-post-type=\"insight\">\n\t\t\t\t\t\t<section class=\"has_eae_slider elementor-section elementor-top-section elementor-element elementor-element-96eaca4 elementor-section-boxed elementor-section-height-default elementor-section-height-default\" data-eae-slider=\"19213\" data-id=\"96eaca4\" data-element_type=\"section\">\n\t\t\t\t\t\t<div class=\"elementor-container elementor-column-gap-default\">\n\t\t\t\t\t<div class=\"has_eae_slider elementor-column elementor-col-100 elementor-top-column elementor-element elementor-element-d05bae8\" data-eae-slider=\"53236\" data-id=\"d05bae8\" data-element_type=\"column\">\n\t\t\t<div class=\"elementor-widget-wrap elementor-element-populated\">\n\t\t\t\t\t\t<div class=\"elementor-element elementor-element-a70f84d elementor-widget elementor-widget-text-editor\" data-id=\"a70f84d\" data-element_type=\"widget\" data-widget_type=\"text-editor.default\">\n\t\t\t\t<div class=\"elementor-widget-container\">\n\t\t\t\t\t\t\t\t\t<p>Broad estimates put the cost of corrosion to 1 to 4 % of GNP in the USA.\u00a0 Whilst an accurate figure would be elusive to even the most rigorous rational, it is fair to say that repairing the consequences of corrosion is a costly business. Brass and austenitic stainless steel are widely used in engineering applications to convey liquids, such as water, or for pressurised applications, such as heat exchangers, steam generating equipment and pipework. As such, stress corrosion cracking can result in catastrophic, and costly, failures of this equipment.\u00a0<\/p><h4><span style=\"color: #0a527a;\">WHAT IS STRESS CORROSION CRACKING?<\/span><\/h4><p>Stress corrosion cracking is a specific type of corrosion that often causes failures of engineering components.\u00a0 Stress corrosion cracking occurs over time, with little readily apparent evidence of the degradation of the metal.\u00a0 In addition, it occurs at stresses much lower than those required to produce a spontaneous failure due to overload (i.e. below the yield strength and often at normal service stresses).\u00a0<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-8dde2fb elementor-widget elementor-widget-image\" data-id=\"8dde2fb\" data-element_type=\"widget\" data-widget_type=\"image.default\">\n\t\t\t\t<div class=\"elementor-widget-container\">\n\t\t\t\t\t\t\t\t\t\t\t\t<figure class=\"wp-caption\">\n\t\t\t\t\t\t\t\t\t\t<img fetchpriority=\"high\" decoding=\"async\" width=\"800\" height=\"600\" src=\"https:\/\/www.hawkins.biz\/wp-content\/uploads\/2022\/12\/Stress_Corrosion_Cracking_1-1024x768.jpg\" class=\"attachment-large size-large wp-image-16805\" alt=\"brass plumbing valve that failed due to stress corrosion cracking\" srcset=\"https:\/\/www.hawkins.biz\/wp-content\/uploads\/2022\/12\/Stress_Corrosion_Cracking_1-1024x768.jpg 1024w, https:\/\/www.hawkins.biz\/wp-content\/uploads\/2022\/12\/Stress_Corrosion_Cracking_1-300x225.jpg 300w, https:\/\/www.hawkins.biz\/wp-content\/uploads\/2022\/12\/Stress_Corrosion_Cracking_1-768x576.jpg 768w, https:\/\/www.hawkins.biz\/wp-content\/uploads\/2022\/12\/Stress_Corrosion_Cracking_1.jpg 1329w\" sizes=\"(max-width: 800px) 100vw, 800px\" \/>\t\t\t\t\t\t\t\t\t\t\t<figcaption class=\"widget-image-caption wp-caption-text\">A brass plumbing valve that failed due to stress corrosion cracking.  The failure of the valve resulted in an escape of water and damage to a property. <\/figcaption>\n\t\t\t\t\t\t\t\t\t\t<\/figure>\n\t\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-7ae6ffa elementor-widget elementor-widget-text-editor\" data-id=\"7ae6ffa\" data-element_type=\"widget\" data-widget_type=\"text-editor.default\">\n\t\t\t\t<div class=\"elementor-widget-container\">\n\t\t\t\t\t\t\t\t\t<h4><span style=\"color: #0a527a;\">SIGNS OF STRESS CORROSION CRACKING<\/span><\/h4><p>Branched cracking is a common characteristic of stress corrosion cracking. When viewed at high magnification the fracture surface of a component that has failed due to stress corrosion cracking has a faceted and granular appearance (Photograph 2 below).\u00a0 In contrast to this the fracture surface of a component that has failed due to a ductile overload failure typically has a dimpled appearance (Photograph 3 below). The facets and granular appearance actually reveal the small individual crystals (grains) that comprise the microstructure of the majority of engineering metals.\u00a0<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<section class=\"has_eae_slider elementor-section elementor-inner-section elementor-element elementor-element-bd731ec elementor-section-boxed elementor-section-height-default elementor-section-height-default\" data-eae-slider=\"67061\" data-id=\"bd731ec\" data-element_type=\"section\">\n\t\t\t\t\t\t<div class=\"elementor-container elementor-column-gap-default\">\n\t\t\t\t\t<div class=\"has_eae_slider elementor-column elementor-col-50 elementor-inner-column elementor-element elementor-element-baa8f41\" data-eae-slider=\"15278\" data-id=\"baa8f41\" data-element_type=\"column\">\n\t\t\t<div class=\"elementor-widget-wrap elementor-element-populated\">\n\t\t\t\t\t\t<div class=\"elementor-element elementor-element-00c8f80 elementor-widget elementor-widget-image\" data-id=\"00c8f80\" data-element_type=\"widget\" data-widget_type=\"image.default\">\n\t\t\t\t<div class=\"elementor-widget-container\">\n\t\t\t\t\t\t\t\t\t\t\t\t<figure class=\"wp-caption\">\n\t\t\t\t\t\t\t\t\t\t<img decoding=\"async\" width=\"244\" height=\"186\" src=\"https:\/\/www.hawkins.biz\/wp-content\/uploads\/2022\/12\/Stress-Corrosion-Cracking-2.jpg\" class=\"attachment-large size-large wp-image-16810\" alt=\"\" \/>\t\t\t\t\t\t\t\t\t\t\t<figcaption class=\"widget-image-caption wp-caption-text\">A scanning electron micrograph showing the faceted and granular appearance of the fracture surface of a brass plumbing component that has failed due to stress corrosion cracking.<\/figcaption>\n\t\t\t\t\t\t\t\t\t\t<\/figure>\n\t\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t<div class=\"has_eae_slider elementor-column elementor-col-50 elementor-inner-column elementor-element elementor-element-49e2284\" data-eae-slider=\"46136\" data-id=\"49e2284\" data-element_type=\"column\">\n\t\t\t<div class=\"elementor-widget-wrap elementor-element-populated\">\n\t\t\t\t\t\t<div class=\"elementor-element elementor-element-7945c69 elementor-widget elementor-widget-image\" data-id=\"7945c69\" data-element_type=\"widget\" data-widget_type=\"image.default\">\n\t\t\t\t<div class=\"elementor-widget-container\">\n\t\t\t\t\t\t\t\t\t\t\t\t<figure class=\"wp-caption\">\n\t\t\t\t\t\t\t\t\t\t<img decoding=\"async\" width=\"704\" height=\"600\" src=\"https:\/\/www.hawkins.biz\/wp-content\/uploads\/2022\/12\/Stress-Corrosion-Cracking-3.jpg\" class=\"attachment-large size-large wp-image-16808\" alt=\"\" srcset=\"https:\/\/www.hawkins.biz\/wp-content\/uploads\/2022\/12\/Stress-Corrosion-Cracking-3.jpg 704w, https:\/\/www.hawkins.biz\/wp-content\/uploads\/2022\/12\/Stress-Corrosion-Cracking-3-300x256.jpg 300w\" sizes=\"(max-width: 704px) 100vw, 704px\" \/>\t\t\t\t\t\t\t\t\t\t\t<figcaption class=\"widget-image-caption wp-caption-text\">A scanning electron micrograph showing the dimpled appearance of the fracture surface of a brass component that has failed due to ductile overload.<\/figcaption>\n\t\t\t\t\t\t\t\t\t\t<\/figure>\n\t\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/section>\n\t\t\t\t<div class=\"elementor-element elementor-element-ed7534e elementor-widget elementor-widget-text-editor\" data-id=\"ed7534e\" data-element_type=\"widget\" data-widget_type=\"text-editor.default\">\n\t\t\t\t<div class=\"elementor-widget-container\">\n\t\t\t\t\t\t\t\t\t<h4><span style=\"color: #0a527a;\">SOURCES OF STRESS<\/span><\/h4><p>A susceptible material, a tensile (pulling) stress and a specific corrosive species all need to be present simultaneously for stress corrosion cracking to occur. The stress can be from two sources:<\/p><ol><li>The first source of stress is from<em> an applied stress<\/em>. Applied stresses are those produced by service, such as the water pressure within a pipe, stresses produced by assembly of the item or the weight hanging from a fixture.\u00a0<\/li><li>The second source of stress is from residual stress in the material. To some extent residual stresses are present in all materials and are often produced by relatively rapid cooling from elevated temperatures during manufacture.\u00a0<\/li><\/ol><h4><span style=\"color: #0a527a;\">\u00a0<\/span><\/h4><h4><span style=\"color: #0a527a;\">REDUCING THE LIKELIHOOD OF STRESS CORROSION CRACKING<\/span><\/h4>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-b2f5301 elementor-icon-list--layout-traditional elementor-list-item-link-full_width elementor-widget elementor-widget-icon-list\" data-id=\"b2f5301\" data-element_type=\"widget\" data-widget_type=\"icon-list.default\">\n\t\t\t\t<div class=\"elementor-widget-container\">\n\t\t\t\t\t\t\t<ul class=\"elementor-icon-list-items\">\n\t\t\t\t\t\t\t<li class=\"elementor-icon-list-item\">\n\t\t\t\t\t\t\t\t\t\t\t<span class=\"elementor-icon-list-icon\">\n\t\t\t\t\t\t\t<svg xmlns=\"http:\/\/www.w3.org\/2000\/svg\" width=\"8.305\" height=\"15.142\" viewBox=\"0 0 8.305 15.142\"><path id=\"Path_185\" data-name=\"Path 185\" d=\"M0,0,5.536,7.572,0,15.143H2.768L8.3,7.572,2.768,0Z\" transform=\"translate(0 0)\" fill=\"#007aa3\" opacity=\"0.998\"><\/path><\/svg>\t\t\t\t\t\t<\/span>\n\t\t\t\t\t\t\t\t\t\t<span class=\"elementor-icon-list-text\">Efforts can be made to reduce the stress that the component is subjected to; simply by adding more metal or removing stress raising features.  <\/span>\n\t\t\t\t\t\t\t\t\t<\/li>\n\t\t\t\t\t\t\t\t<li class=\"elementor-icon-list-item\">\n\t\t\t\t\t\t\t\t\t\t\t<span class=\"elementor-icon-list-icon\">\n\t\t\t\t\t\t\t<svg xmlns=\"http:\/\/www.w3.org\/2000\/svg\" width=\"8.305\" height=\"15.142\" viewBox=\"0 0 8.305 15.142\"><path id=\"Path_185\" data-name=\"Path 185\" d=\"M0,0,5.536,7.572,0,15.143H2.768L8.3,7.572,2.768,0Z\" transform=\"translate(0 0)\" fill=\"#007aa3\" opacity=\"0.998\"><\/path><\/svg>\t\t\t\t\t\t<\/span>\n\t\t\t\t\t\t\t\t\t\t<span class=\"elementor-icon-list-text\">Operating stainless steels below 60\u00b0C can also be beneficial in avoiding stress corrosion cracking, but this does not hold true in all circumstances.<\/span>\n\t\t\t\t\t\t\t\t\t<\/li>\n\t\t\t\t\t\t\t\t<li class=\"elementor-icon-list-item\">\n\t\t\t\t\t\t\t\t\t\t\t<span class=\"elementor-icon-list-icon\">\n\t\t\t\t\t\t\t<svg xmlns=\"http:\/\/www.w3.org\/2000\/svg\" width=\"8.305\" height=\"15.142\" viewBox=\"0 0 8.305 15.142\"><path id=\"Path_185\" data-name=\"Path 185\" d=\"M0,0,5.536,7.572,0,15.143H2.768L8.3,7.572,2.768,0Z\" transform=\"translate(0 0)\" fill=\"#007aa3\" opacity=\"0.998\"><\/path><\/svg>\t\t\t\t\t\t<\/span>\n\t\t\t\t\t\t\t\t\t\t<span class=\"elementor-icon-list-text\">Annealing the component post manufacturing. Annealing is a thermal process where the metal is heated to a specific temperature and then cooled slowly.  This relieves the residual stresses in the metal and thus significantly reduces the pre-disposition of a component to fail by stress corrosion cracking.  <\/span>\n\t\t\t\t\t\t\t\t\t<\/li>\n\t\t\t\t\t\t\t\t<li class=\"elementor-icon-list-item\">\n\t\t\t\t\t\t\t\t\t\t\t<span class=\"elementor-icon-list-icon\">\n\t\t\t\t\t\t\t<svg xmlns=\"http:\/\/www.w3.org\/2000\/svg\" width=\"8.305\" height=\"15.142\" viewBox=\"0 0 8.305 15.142\"><path id=\"Path_185\" data-name=\"Path 185\" d=\"M0,0,5.536,7.572,0,15.143H2.768L8.3,7.572,2.768,0Z\" transform=\"translate(0 0)\" fill=\"#007aa3\" opacity=\"0.998\"><\/path><\/svg>\t\t\t\t\t\t<\/span>\n\t\t\t\t\t\t\t\t\t\t<span class=\"elementor-icon-list-text\">Where possible, avoid using alloys that will be exposed to the chemicals known to cause stress corrosion cracking for that alloy type. <\/span>\n\t\t\t\t\t\t\t\t\t<\/li>\n\t\t\t\t\t\t<\/ul>\n\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-dc84365 elementor-widget elementor-widget-text-editor\" data-id=\"dc84365\" data-element_type=\"widget\" data-widget_type=\"text-editor.default\">\n\t\t\t\t<div class=\"elementor-widget-container\">\n\t\t\t\t\t\t\t\t\t<p>Examples, of known species that cause stress corrosion cracking and the metals they affect are:<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<section class=\"has_eae_slider elementor-section elementor-inner-section elementor-element elementor-element-6d862c1 elementor-section-boxed elementor-section-height-default elementor-section-height-default\" data-eae-slider=\"43886\" data-id=\"6d862c1\" data-element_type=\"section\">\n\t\t\t\t\t\t<div class=\"elementor-container elementor-column-gap-default\">\n\t\t\t\t\t<div class=\"has_eae_slider elementor-column elementor-col-50 elementor-inner-column elementor-element elementor-element-d2982b2\" data-eae-slider=\"17191\" data-id=\"d2982b2\" data-element_type=\"column\">\n\t\t\t<div class=\"elementor-widget-wrap elementor-element-populated\">\n\t\t\t\t\t\t<div class=\"elementor-element elementor-element-2b6f9ad elementor-widget elementor-widget-text-editor\" data-id=\"2b6f9ad\" data-element_type=\"widget\" data-widget_type=\"text-editor.default\">\n\t\t\t\t<div class=\"elementor-widget-container\">\n\t\t\t\t\t\t\t\t\t<table width=\"699\"><tbody><tr><td width=\"293\"><p><strong>Specific Chemical Species <\/strong><\/p><\/td><\/tr><tr><td width=\"293\"><p>1.\u00a0 Aqueous (water based) chloride, bromide and iodide solutions<\/p><p>2.\u00a0 Aqueous chloride solutions<\/p><p>3.\u00a0 Nitrate, hydroxide and carbonate\/bicarbonate solutions<\/p><p>4.\u00a0 Ammonia (and ammonia containing chemicals such as urea) and nitrates<\/p><\/td><\/tr><\/tbody><\/table>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t<div class=\"has_eae_slider elementor-column elementor-col-50 elementor-inner-column elementor-element elementor-element-f185569\" data-eae-slider=\"30040\" data-id=\"f185569\" data-element_type=\"column\">\n\t\t\t<div class=\"elementor-widget-wrap elementor-element-populated\">\n\t\t\t\t\t\t<div class=\"elementor-element elementor-element-6283b15 elementor-widget elementor-widget-text-editor\" data-id=\"6283b15\" data-element_type=\"widget\" data-widget_type=\"text-editor.default\">\n\t\t\t\t<div class=\"elementor-widget-container\">\n\t\t\t\t\t\t\t\t\t<table width=\"699\"><tbody><tr><td width=\"406\"><p><strong>Affected Metal(s)<\/strong><\/p><\/td><\/tr><tr><td width=\"406\"><p>1.\u00a0 Aluminium and titanium alloys<\/p><p>2.\u00a0 Austenitic stainless steels and magnesium alloys<\/p><p>3.\u00a0 Carbon steels<\/p><p>4.\u00a0 Brasses.\u00a0 Brass is principally an alloy of copper and zinc<\/p><p>\u00a0<\/p><\/td><\/tr><\/tbody><\/table>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/section>\n\t\t\t\t<div class=\"elementor-element elementor-element-b6449c0 elementor-widget elementor-widget-text-editor\" data-id=\"b6449c0\" data-element_type=\"widget\" data-widget_type=\"text-editor.default\">\n\t\t\t\t<div class=\"elementor-widget-container\">\n\t\t\t\t\t\t\t\t\t<h4><span style=\"color: #0a527a;\">ABOUT THE AUTHOR<\/span><\/h4><p><em><a href=\"https:\/\/www.hawkins.biz\/experts\/neville-tranter\/\">Neville Tranter<\/a> started investigating mechanical failures in 2005.\u00a0 Since then he has investigated the failure of a wide range of components, systems and structures; from medical devices such as stents and prosthesis, to bulk storage tanks, drilling Derrick and oil well drilling equipment, through aerospace and rail components, plumbing systems and many things in between. <\/em><em>His background in Metallurgy makes him ideally placed to understand the design of equipment, the materials they are made out of, manufacturing processes used to produce them, service life and how these factors can result in failure.\u00a0 <\/em><\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/section>\n\t\t\t\t<\/div>\n\t\t","protected":false},"excerpt":{"rendered":"<p>Broad estimates put the cost of corrosion to 1 to 4 % of GNP in the USA.  Whilst an accurate figure would be elusive to even the most rigorous rational, it is fair to say that repairing the consequences of corrosion is a costly business. Brass and austenitic stainless steel are widely used in engineering applications to convey liquids, such as water, or for pressurised applications, such as heat exchangers, steam generating equipment and pipework. As such, stress corrosion cracking can result in catastrophic, and costly, failures of this equipment.  <\/p>\n","protected":false},"featured_media":16803,"parent":0,"template":"","insight_category":[],"experties":[68],"class_list":["post-16802","insight","type-insight","status-publish","has-post-thumbnail","hentry","experties-materials-chemistry-biology"],"acf":[],"yoast_head":"<!-- This site is optimized with the Yoast SEO plugin v25.5 - https:\/\/yoast.com\/wordpress\/plugins\/seo\/ -->\n<title>Stress Corrosion Cracking: Hidden Costs &amp; Risks<\/title>\n<meta name=\"description\" content=\"Explore the causes and consequences of stress corrosion cracking in metals, and how forensic analysis helps mitigate costly failures.\" \/>\n<meta name=\"robots\" content=\"index, follow, max-snippet:-1, max-image-preview:large, max-video-preview:-1\" \/>\n<link rel=\"canonical\" href=\"https:\/\/www.hawkins.biz\/insight\/stress-corrosion-cracking\/\" \/>\n<meta property=\"og:locale\" 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