International Conference on Recent Advances in Mechanical Engineering and Interdisciplinary Developments [ICRAMID - 2014]

Measures of Corrosion Properties in 316L

Stainless Steel Welds on Cast Iron
G.Krishna Kumar #1,

A.Vivekananthan*2,

G.Pradeep Kumar #3

1Department of Mechanical engineering, SVS College of Engineering, Coimbatore, India

642109. 2Department of Mechanical engineering, SVS College of Engineering, Coimbatore,

India 642109. 3Department of Mechanical engineering, SVS College of Engineering,
Coimbatore, India 642109.
1krishnakumark555@gmail.com 2vivekautomech232@gmail.com 3
pradeepgpk92@gmail.com
threefold includes economic losses, improved
safety and conservation.
Lietai Yang et al [3], explores corrosion rates
of type 1010 carbon steel, and types 304 and
316 stainless steels in saturated solutions under
salt deposits were measured using coupled multi
electrode sensors. For comparison, many of the
measurements also were conducted using
sensors made of type 304 and type 316 stainless
steels. [3].
Ukobal, O.K et al [4], focuses on the
corrosion rate of ductile iron in different
corresponding to areas of usage and storage for
a period of six (6) months. The environments
are outside, air conditioned, brackish (salty) and
alkaline. As the period increases the corrosion
rate decreases.
Qi Beimeng et al [5], focuses on
investigation Electrochemical behavior and
corrosion of cast iron in the presence of
sulphate. Laurie S. McNeill et al [6],
synthesizes nearly 100 years of corrosion
studies in an attempt to provide the water
industry with an updated understanding of
factors that influence iron pipe corrosion.
F.O. Aramide et al [7], samples were
immersed in freshly extracted lime juice for a
period of four weeks. Microstructure and tensile
properties It was concluded that corrosion rate
can be kept to the minimum by controlling the
pH of the media within the range 2.0 to 3.05.
C.A. Cooper et al [8], found that the Raman
peak position shifted to a lower wave number
upon application of a tensile strain, and to a
higher wave number upon application of a
compressive strain. Ju-lin Wang et al [9], the
effectiveness of different corrosion inhibitors
on bare bronze and cast iron, patina bronze and
rusty cast iron with immersion treatment,
showed that the prefilming treatment cannot
protect the cultural heritage from the corrosion
of the environment medium.The kinetics of
mild steel corrosion S.K. Singh et al [10], in

AbstractCast Iron is having a wide range of

applications in various engineering fields like
Aerospace, Automotive sector, Piping, etc. It is
necessary to study about the weld quality, corrosive
resistance, metallurgical and mechanical properties of
Cast Iron welds. It will be useful for repair works in
Cast Iron products. The combination between
stainless steel and cast iron has never been
commercialized. Thus a research on this area of
Stainless Steel and Cast Iron will be an eye opening
for the possibility of further research. For this
research work the 25 grade Cast Iron is selected and
316L Stainless Steel is used as a filler rod. Welding is
done by using Gas Metal Arc Welding process. The
various measures of corrosion have been done against
the different types of corrosive mediums.
Keywords Gas Metal Arc Welding process
(GMAW), Cast Iron, 316L Stainless Steel, corrosive
acids, weld bead, microscopic view.

I.INTRODUCTION
Corrosion failures of welds occur in spite of
the fact that the proper base metal and filler
metal have been selected, industry codes and
standards have been followed, and welds have
been deposited that possess full weld
penetration and have proper shape and contour.
It is not unusual to find that, although the
wrought form of a metal or alloy is resistant to
corrosion in a particular environment, the
welded counterpart is not.
The large number of researches has done on
corrosive properties of welds. T. Charng et al
[1], focuses on a general review of causes of
corrosion of metals and their alloys. The
corrosion mechanism is explained using the
concept of electrochemical reaction theory.
Corrosion control of metals is of technical,
economical, environmental and aesthetical
importance. Satya Vani Yadla et al [2], focuses
on complex series of reactions between
different environmental conditions and metal
surfaces. The importance of corrosion studies is

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773

International Conference on Recent Advances in Mechanical Engineering and Interdisciplinary Developments [ICRAMID - 2014]

aqueous acetic acid conclusions drawn from the

weight loss method.
S.K. Singh et al [11], analyses the kinetics of
mild steel corrosion in 20:0, 19:1, 18:2 and 15:5
(v/v %) aqueous mixture of acetic and formic
acid has been by weight loss and potentiostatic
polarization techniques.
Microstructure characteristics and chemical
analysis Sami A. Ajeel et al [12], highlights the
study of for both materials results indicate that
the corrosion resistance of both types of cast
irons is excellent and ductile iron is better than
gray cast iron and the reduction in corrosion
rates for both materials. A.U. Malik et al [13],
investigations on the failure of a Ni-Resist cast
discharge column of brine recycle pump from a
desalination plant and laboratory tests on two
types of Ni-Resist irons.
Neculai Aelenei et al [14], analyzed
corrosion products of high strength low-alloyed
steel and of cast iron, maintained a prolonged
period in natural seawater. W.B. Wan Nik et al
[15]and H. Moller et al [16], concluded that
small differences of seawater parameters causes
the corrosion behavior of mild steel.
Rita Mehra et al [17], explores that the
corrosion rate should be decreased so as to
provide protection. H. Mohebbi et al [18],
showed that cast iron pipes behave over a
longer time scale than hours, days, or weeks.
The effect of the MIG weld towards the
combination of different metals, Erhi Zahani et
al [19], investigates martensitic custom 450 SS
to white cast iron, welded using metal inert gas
welding or MIG.

shows the solving methodology of the defined

problem.

Fig. 1 Solving methodology

A. Experimental Setup
The base metal employed was Cast Iron (100
x 76 x 25 mm). The samples were mechanically
polished using 400, 800, 1200 emery paper
respectively. After that the metals were
lubricated using distilled water. The polished
samples were cleaned with acetone, washed
using distilled water, dried in air and stored in
desiccators. They were weighed for the original
weight. After that the metal was welded using
GMAW process with SS 316L filler rod along
the centre of the work piece as shown in Fig.2.
The weight of the sample after welding was also
observed.

II. EXPERIMENTAL PROCEDURE

This research studies have been carried out
for determination of corrosive behavior of weld
bead on cast iron in different concentrations of
four different aqueous solutions, which include
acetic acid, citric acid, ammonium chloride and
sodium chloride. The various concentrations
were 15%, 25%, 35% and 50%. Concentration
above 50% was not considered as the solutions
tend to be saturated and salts failed to dissolve
further. Also, Sea water and tap water samples
were taken along with the aqueous solutions.
The Mechanical and corrosion resistant
properties of welded components depend on the
weld bead geometries. Therefore it is essential
to study the effect of corrosion on the bead
geometry.
III. PLAN OF INVESTIGATION
The objective is to study the corrosive
behavior of Cast Iron and the weld bead
geometry deviations due to corrosion. Thus the
necessary observations of test specimen were
observed before and after corrosion. The Fig. 1

Fig.2 Sample Work Piece

The Compositions of Cast Iron shown in TABLE I.

TABLE I
COMPOSITIONS OF CAST IRON

C%

Si %

Mn%

S%

P%

CE%

3.203.50

1.602.40

0.600.90

0.15

0.20

4.004.25

The Nomenclature of the Test Samples are

shown in TABLE II
.

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International Conference on Recent Advances in Mechanical Engineering and Interdisciplinary Developments [ICRAMID - 2014]

TABLE II
NOMENCLATURE OF THE TEST SAMPLES

Category

Ammonium
chloride

Sodium
chloride

Acetic
acid

Citric
acid

A1
A2
A3
A4
(15%)
B1
B2
B3
B4
(25%)
C1
C2
C3
C4
(35%)
D1
D2
D3
D4
(50%)
E- Hard Water F- Distilled Water G- Sea Water HAmmonium Chloride + Sodium Chloride

Fig. 6 Work Piece in 35% Concentration

B. Aqueous Solution Preparation

Seawater as corrosive medium was taken
from Fort Kochi coastal area, as a pipe line
project was to be implemented in future shown
in Fig. 3. Aqueous solution of Acetic Acid,
Citric Acid, Ammonium Chloride and Sodium
Chloride were to be prepared in different
concentrations. For preparation of different
concentrations the knowledge of preparation of
percentage solution was important.

Fig. 7 Work Piece in 50% Concentration

Fig. 8 Work Piece A3

Fig. 9 Work Piece B4

Fig. 3 Seawater Collected Location

For preparation of a 25% solution, 25 ml of

acid was to be dissolved in 100 ml of distilled
water, viz. Thus aqueous solutions of Acetic
Acid, Citric Acid, Ammonium Chloride and
Sodium Chloride were prepared in different
concentrations of 15%, 25%, 35%, and 50%.
Also Tap water & Distilled water were
collected as a test solution. Fig. 4 to 7 shows the
Welded CI samples immersed in the
experimental setup of corrosion test and Fig. 8
to 12 shows the samples after 6 days.

Fig. 10 Work Piece C2

Fig. 11 Work Piece D1

Fig. 4 Work Piece in 15% Concentration

Fig. 12 Work Piece D4

C. Weight Observation
The weight of the samples after welding was
observed before the corrosion test was
conducted and was tabulated in Table 3. The
weight of the individual samples was to be

Fig. 5 Work Piece in 25% Concentration

ISBN 978-93-80609-17-1
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International Conference on Recent Advances in Mechanical Engineering and Interdisciplinary Developments [ICRAMID - 2014]

noted after the samples were cleaned used

emery paper. pH for test solutions were
measured by pH meter.
TABLE III
WEIGHT BEFORE CORROSION

Sl.No.

Identification

Weight Before
Corrosion

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20

A1
A2
A3
A4
B1
B2
B3
B4
C1
C2
C3
C4
D1
D2
D3
D4
E
F
G
H

1.312
1.310
1.309
1.256
1.355
1.220
1.221
1.283
1.310
1.350
1.256
1.220
1.306
1.353
1.305
1.355
1.300
1.304
1.350
1.355

Fig. 13 Dilution of welded samples

The Fig. 13 shows that sample C2 has the

maximum dilution. This implies that the
reinforcement of the sample C2 was maximum
affected. The chart shows that effect of Sodium
Chloride and Ammonium Chloride have
adverse affects on SS 316L filler metal. It is
also noted that the sample immersed in sea
water shows less effect on the weld, thereby
increasing the scope of the filler metal in weld
repair works for pipeline projects.
Sl.
No.

IV.RESULTS & DISCUSSIONS

A1
A2
A3
A4
B1
B2
B3
B4
C1
C2
C3
C4
D1
D2
D3
D4
E
F
G
H
I

The results and observations of the

experimental procedure conducted are discussed
in this section. The weight loss analysis was
carried out for studying effect of corrosion on
the test specimen. Also the corrosion rate was
calculated for each specimen.
The weld bead geometry was measured and
the corresponding dimensions are tabulated
below. Conclusions are drawn from the
observations and given below. The image of the
weld bead of each sample is also shown for
better understanding.
The weld bead geometry was observed using
Metallurgical microscope with digital camera
with a capacity of 100 X. Dilution of the weld
was also calculated using the formula,
Dilution =
B/ (A + B) ----------------- (1)
Where,
A- Reinforcement.
B- Penetration.
Using the above specified formula dilution
was calculated for each specimen dipped in the
solutions were tabulated and shown in TABLE
IV. Also the graphical representation of the
dilution values of each sample observed is
given in Fig. 13.

TABLE IV
DILUTION OF THE WELDED SAMPLES

Width
mm
9.93
9.87
9.85
9.87
9.95
9.81
9.90
9.95
10.10
9.89
9.88
9.92
9.93
9.92
9.91
9.93
9.93
10.08
9.89
9.88
10.12

Reinforcement
A
mm
1.93
1.86
1.78
1.83
1.94
1.78
1.80
1.78
1.92
1.82
1.85
1.85
1.89
1.80
1.89
1.88
1.79
1.85
1.98
1.88
1.99

Penetration
B
mm
1.85
1.94
1.85
1.87
1.91
1.85
1.86
1.89
1.93
1.94
1.73
1.74
1.91
1.85
1.83
1.84
1.89
1.89
1.89
1.89
1.94

Dilution
D
48.94
51.05
50.96
50.54
49.61
50.96
50.82
51.50
50.13
51.60
48.32
48.47
50.26
50.68
49.19
49.46
51.36
50.53
48.84
50.13
49.36

V.CONCLUSION
From all the observations made and the
graphs plotted it is noted that Ammonium
Chloride
and
Sodium
Chloride
have
comparatively higher corrosive effect than

ISBN 978-93-80609-17-1
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International Conference on Recent Advances in Mechanical Engineering and Interdisciplinary Developments [ICRAMID - 2014]

Citric acid and Acetic acid. Dilution of the

standard specimen was observed as 49.36. The
test specimen C2 showed the maximum
deviation with increase in dilution. For a better
quality weld bead dilution has to be as low as
possible. It can also be stated that if the
reinforcement area exposed to corrosive
medium was affected badly, then there will be
increase in the value of dilution. Thus it was
observed that Sodium Chloride had the
maximum corrosive effect on the weld bead. It
is also noted that difference between dilution of
the samples G and I was negligible.
Though the weld sample in Sea water showed
an increased rate in weight loss, dilution was
not affected. This clearly shows that the weld
bead was not affected by Sea water. The weight
loss analysis showed that samples tested in
Ammonium
Chloride
solution
showed
maximum weight loss. It was also noted that as
the concentration of solutions were increased
the weight loss gradually increased. When the
comparison was made between the width of the
weld bead of the welded samples in different
solutions with constant percentage of solution,
the samples tested with Ammonium Chloride
showed maximum bead width. The maximum
corrosion rate was also observed for the
specimen C2. Thus welding of SS 316L on Cast
Iron proves to increase the corrosion resistance
on the welded area.

Lietai Yang, Roberto T. Pabalan, Lauren Browning,

and Gustavo A. Cragnolino (2009). Measurement of
Corrosion in Saturated Solutions under Salt Deposits
Using Coupled Multielectrode Array Sensors.

[4].

Ukoba, O.K, Oke, P.K, Ibegbulam, M.C, Corrosion

Behaviour of Ductile Iron in Different Environment,
International Journal of Science and Technology
(2012).

F.O. Aramide, E.O. Olorunniwo, P.O. Atanda and J.O.

Borode Corrosion Characteristics of Ascast Ductile
Iron in Lime Juice. Journal of Minerals & Materials
Characterization & Engineering, Vol. 9, No.10,
pp.867-877, 2010.

[8].

C.A. Cooper, R.J. Young and R. Elliott, Cast Iron: A

Natural Metal Matrix Composite.

[9].

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Corrosion Inhibitors on Bronze and Cast Iron with
Prefilming Treatment, International Journal of
Electrochemical Science, 2013.

[12]. Sami A. Ajeel and Safaa Mohommed Hasoni, Ductile

and Gray Cast Irons Deterioration with Time in
Various NaCl Salt Concentrations, Engineering &
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[13]. A.U.Malik, S. Basu, Ismail Andijani and Shahreer
Ahmad, Corrosion Behavior of Ni-Resist Cast Irons
in Seawater.
[14]. Neculai Aelenei, Maria Lungu, Daniel Mareci, Nicanor
Cimpoeu HSLA Steel and Cast Iron Corrosion in
Natural Seawater, Environmental Engineering and
Management Journal, 2011.
[15]. W.B. Wan Nik, F. Zulkifli, M.M. Rahman & R.
Rosliza, Corrosion Behavior of Mild Steel in
Seawater from Two Different Sites of Kuala
Terengganu Coastal Area International Journal of
Basic & Applied Sciences, 2011.
[16]. H. Mller, E.T. Boshoff and H. Froneman, The
Corrosion Behaviour of A Low T Carbon Steel in
Natural and Synthetic Seawaters, The Journal of the
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2008.
[17]. Rita Mehra and Aditi Soni, Cast Iron Deterioration
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[18]. H. Mohebbi and C. Q. Li, Experimental Investigation
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[1]. T T. Charng and F. Lansing Review of Corrosion

Causes and Corrosion Control in a Technical
Facility.

[3].

[7].

[11]. S.K. Singh, A.K. Mukherjee and M.M. Singh,

Corrosion Behaviour of Mild Steel in Aqueous
Acetic Acid Solutions Containing Different Amounts
of Formic Acid, Indian Journal of Chemical
Technology, 2011.

REFERENCES

Satya Vani Yadla, V.Sridevi, M.V.V.Chandana

Lakshmi, S.P.Kiran Kumari, A Review on Corrosion
of Metals and Protection, International Journal of
Engineering Science & Advanced Technology (2012).

Laurie S. McNeill and Marc Edwards, Review of Iron

Pipe Corrosion in Drinking Water Distribution
Systems.

[10]. S.K. Singh and A.K. Mukherjee, Kinetics of Mild

Steel Corrosion in Aqueous Acetic Acid Solutions, J.
Material Science and Technology, 2010.

ACKNOWLEDGEMENT
The authors are grateful to the Department of
Mechanical Engineering, SVS College of
Engineering, Coimbatore, Tamil Nadu, India for
providing all the necessary facilities for the
completion of the work.

[2].

[6].

[19]. Erhi Zahani and Binti Buyong, The Investigation of

MIG Welding Parameter Effects on Welding of
Dissimilar Metal (Stainless Steel to Cast Iron).

[5]. Qi Beimeng, Wang Beijia, Wu Chenguang and

YuanYixing, Electrochemical Behavior of Cast Iron
in the Presence of Bacteria in Water Distribution
Systems, International Journal of Electrochemical
Science (2013).

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