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Stress corrosion cracking caused by tension developed in an unsuitably welded reinforcement collarA close-up of the surface of a steel pipeline showing stress corrosion cracking (two clusters of small black lines) revealed by magnetic particle inspection. Cracks which would normally have been invisible are detectable due to the magnetic particles clustering at the crack openings. The scale at the bottom is in centimeters (each division indicates a millimeter).
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Mechanical failure modes
Buckling
Corrosion
Corrosion fatigue
Creep
Fatigue
Fouling
Fracture
Hydrogen embrittlement
Impact
Liquid metal embrittlement
Mechanical overload
Metal-induced embrittlement
Stress corrosion cracking
Sulfide stress cracking
Thermal shock
Wear
Yielding
Stress corrosion cracking (SCC) is the growth of crack formation in a corrosive environment. It can lead to unexpected and sudden failure of normally ductile metal alloys subjected to a tensile stress, especially at elevated temperature. SCC is highly chemically specific in that certain alloys are likely to undergo SCC only when exposed to a small number of chemical environments. The chemical environment that causes SCC for a given alloy is often one which is only mildly corrosive to the metal. Hence, metal parts with severe SCC can appear bright and shiny, while being filled with microscopic cracks. This factor makes it common for SCC to go undetected prior to failure. SCC often progresses rapidly, and is more common among alloys than pure metals. The specific environment is of crucial importance, and only very small concentrations of certain highly active chemicals are needed to produce catastrophic cracking, often leading to devastating and unexpected failure.[1]
The stresses can be the result of the crevice loads due to stress concentration, or can be caused by the type of assembly or residual stresses from fabrication (e.g. cold working); the residual stresses can be relieved by annealing or other surface treatments. Unexpected and premature failure of chemical process equipment, for example, due to stress corrosion cracking constitutes a serious hazard in terms of safety of personnel, operating facilities and the environment. By weakening the reliability of these types of equipment, such failures also adversely affect productivity and profitability.
^"Chapter 32: Failure Analysis". Metals Handbook (Desk ed.). American Society for Metals.
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