At OLI Systems, innovation drives our mission to solve some of the most critical challenges in water chemistry and materials science. Our recent research, conducted in collaboration with Shell India and published in CORROSION Journal, represents a significant step forward in understanding and mitigating localized corrosion in stainless steels. This work was recently recognized as one of the Top 10 Most-Read Articles of 2024, underscoring its relevance to the field and its potential to impact industries worldwide.
Breaking Ground in Localized Corrosion Prediction
Localized corrosion, such as pitting or crevice corrosion, poses significant risks in industries like oil and gas, where equipment often operates in harsh, highly saline environments with the possibility of oxygen ingress. Our research focused on two widely used stainless steel grades—UNS S31603 (316L) and UNS S32205 (2205). By combining advanced testing methodologies and rigorous modeling, we have achieved four key breakthroughs:
- Improved Testing Accuracy: Testing protocols were refined to more accurately measure critical electrochemical potentials. This has enhanced our ability to predict when and where localized corrosion might occur under varying conditions.
- Understanding Oxygen’s Impact: Even trace amounts of dissolved oxygen can drastically increase the risk of localized corrosion. Our work introduces an improved mixed-potential model that accounts for these subtle yet critical variations.
- Field-Validated Modeling: The improved corrosion model has been validated against real-world field data, ensuring its reliability in practical applications.
- Smarter Material Selection: Using the OLI Corrosion Analyzer, we have demonstrated how precise modeling can guide cost-effective decisions on material selection. For instance, our study identifies the specific environmental conditions under which UNS S31603 or UNS S32205 stainless steels are not likely to undergo localized corrosion.
The Intersection of Testing and Modeling
This research highlights the synergy between experimental science and computational modeling. In particular, we utilized the Tsujikawa-Hisamatsu Electrochemical (THE) and cyclic potentiodynamic polarization (CPP) methods to accurately determine repassivation potentials under controlled conditions. These experimental results served as inputs for an improved mechanistic model, which uses an accurate speciation-based thermodynamic framework to model the solution environment—a feature often overlooked in conventional approaches.
Why This Matters for Industry
The insights from this study are more than academic – they are actionable. By providing a clearer understanding of how stainless steels behave in corrosive environments, we empower engineers and decision-makers to design systems that are safer, more efficient, and longer-lasting. Whether it is selecting the right materials for a subsea pipeline or optimizing a water injection system, the ability to predict corrosion with precision can save billions in operational costs and prevent catastrophic failures.
A Call to Collaborate
As the complexity of industrial challenges grows, so does the need for robust, science-driven solutions. At OLI, we are committed to advancing the science of corrosion modeling and look forward to continued collaborations with industry leaders, research institutions, and regulatory bodies.
If you are interested in learning more about our research or exploring how OLI’s tools can enhance your organization’s materials performance, we would love to hear from you. Together, we can turn the tide on corrosion challenges and build a more resilient industrial future.
To explore our groundbreaking study in detail, read the full abstract here: Improved Test Methods and Models for Localized Corrosion.