Evaluation of sensitization in stainless steel 304 and 304L using nonlinear Rayleigh waves

Austenitic stainless steels have a wide range of applications in the energy industry, but the corrosion resistance of these stainless steels can be reduced by sensitization, particularly in the heat affected zones in welds. Sensitization is the formation of chromium carbide precipitates along the grain boundaries, causing the formation of a zone of chromium depletion around the grain boundary. Since chromium is the primary alloying element that makes stainless steel corrosion resistant, this chromium depleted zone is susceptible to intergranular stress corrosion cracking (IGSCC). Sensitization occurs when a stainless steel is exposed to a high temperature for an extended time period, such as during welding. The objective of this research is to determine the sensitivity of nonlinear ultrasound to the presence of sensitization by using nonlinear Rayleigh waves to quantitatively track the sensitization of 304 and 304L stainless steels as a function of holding time at 675 °C. The effect of the carbon content of the alloys (304 versus 304L) to the sensitization process and the measured nonlinearity parameter, β are investigated. Annealing of these specimens isolates the effect of just sensitization, removing the presence of cold work which can also affect the material nonlinearity. Complementary electrochemical potentiodynamic reactivation (EPR) measurements and microscopy are used to confirm the absence or presence of sensitization. The results show that the acoustic nonlinearity parameter is sensitive to the presence of chromium carbide precipitates in sensitized austenitic stainless steels.