Materials Letters 61 (2007) 821 – 823

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Selective dissolution of austenite in AISI 304

stainless steel by bacterial activity
J.J. de Damborenea ⁎, A.B. Cristóbal, M.A. Arenas, V. López, A. Conde
Department of Corrosion and Protection, Centro Nacional de Investigaciones Metalúrgicas CENIM-CSIC., Av. Gregorio del Amo 8, E-28040 Madrid, Spain
Received 26 December 2005; accepted 31 May 2006
Available online 19 June 2006

Abstract

Selective attack in an AISI 304 stainless steel weld metal has been developed after three months in service in well water. Welding zones
showed a severe corrosive attack that in some cases led to the steel perforation. Optical and scanning electron microscopy (SEM/EDX) revealed a
selective attack. An in-depth analysis showed indications of microbiological activity which could be responsible of the severe attack.
© 2006 Elsevier B.V. All rights reserved.

Keywords: Austenitic stainless steel; Microbiologically influenced corrosion; Welding; Selective dissolution

1. Introduction 2. Materials and methods

The austenitic stainless steels are used for a very broad range of
applications when an excellent combination of strength and
corrosion resistance in aqueous solutions at ambient temperature is
required. The outstanding corrosion resistance of stainless steels
results from the presence of a thin oxide (passive) film on the metal
surface, typically 1–3 nm thick. [1]. However, they do not possess
antibacterial properties and then, in some occasions, corrosive
attacks can be directly related to bacterial activity which is known
as Microbiologically Influenced Corrosion (MIC) [2,3]. MIC is a
corrosion process associated with the activity of microorganisms
present in the system. They can alter the structure of inorganic
passive layers and increase their dissolution and removal from the
metal surface [4]. Generally, the welded areas are preferential areas
for the attack of microorganisms. Why bacterial activity focuses in
these areas is not totally understood although it could be either due
to residual stresses generated in weld metals as well as the rougher
surfaces exhibited by these areas [5]. But, in any case, the micro-
structure of the material seems to play a crucial role on micro-
biologically induced corrosion [6].
The current work concerns the characterisation of the pre-
ferential attack of an AISI 304 stainless steel weld metal
affected by microbiological activity.
⁎ Corresponding author. Tel.: +34 915538900; fax: +34 915347425.
E-mail address: jdambo@cenim.csic.es (J.J. de Damborenea).
0167-577X/$ - see front matter © 2006 Elsevier B.V. All rights reserved.
doi:10.1016/j.matlet.2006.05.066
The material tested corresponded to an AISI 304 L austenitic
stainless steel welded round tube (DIN 11850) with a wall thick-
ness of 2 mm. The compositions of the steel in weight percent are
0.02% C, 18.7% Cr, 9.2% Ni, 1.51% Mn and 0.45% Si.
The tubes were welded by Gas Tungsten Arc Welding (fre-
quently referred to as TIG welding) using argon as shielding gas.
The electrode used in welding was an ER308 wire 1.2 mm
diameter (10% Ni; 20,8% Cr and 1.72 Mn).
After the welding process, the tube was hydrotested in order
to check for leakage and weld strength in the system under
normal operations. Hydrotesting was conducted with low
chloride (50 mg/l) potable untreated water (well water). After
pressure testing, the water was left stagnant. Tubes revealed a
severe localized attack initiated from the inside surface of the
tube and in the welded areas after three months of stagnation.
Microstructural characterisation of the specimens and corrosion
products evaluation were performed by means of optical micro-
scopy, scanning electron microscopy (SEM) and energy dispersive
spectroscopy (EDS), respectively.
3. Results and discussion
A typical TIG welding is shown in Fig. 1a for a round tube. Although
the penetration of the weld is complete and well done, the different
thickness between the both sides of the tube creates very rough area in
822 J.J. de Damborenea et al. / Materials Letters 61 (2007) 821–823
Fig. 1. a) Optical macrograph. Detail of a welding joint; b) microstructure of
weldment: austenitic matrix with tiny patches of residual delta ferrite.
which the fluid can be retained. Fig. 1b pictures the microstructure
corresponding to the welded area which is comprised of an austenitic
matrix containing tiny patches of residual δ ferrite. The average of
ferrite in this case was estimated around 5% in the microstructure, which
is extremely beneficial in suppressing the risk of cracking. The presence
of these patches is due to the filler metal that often contains further
additions of delta ferrite to ensure crack free welds although other
authors pointed out this segregation as a possible corrosion problem [7].
It must be noted that all the corrosion problems have been located at
these areas and no attack has been found neither the heat affected zone or
Fig. 2. Optical macrograph of an attacked weld.
Fig. 3. Morphology of the attack on the stainless steel.
other areas far from the welding track. Then, pitting is only observed in
the welded metal. A representative detail of the damage exhibited in the
pipe is shown in Fig. 2. Pitting attack is extremely severe with a hemi-
spherical morphology filled with corrosion products. Moreover, at the
base material surrounding the weld joining a discolored thin film with
predominant red-orange iridescences was observed. According to
Sreekumari [8] the combination of physical and compositional changes
brought by welding process helps the accumulation of organics onto the
surface and the subsequent attachment of microorganism. In this sense,
the rough surfaces originated by welds would act as low-flow areas which
facilitate their colonisation by bacteria.
The morphology of the corrosion attack is hidden by the presence of
an organic substance (biofilm) which according to the EDS analysis is
mainly composed of C, Ca, O, Si and P. This results is in agreement with
those reported in literature [9,10]. Under the surface, the cross section of
the specimens shows a more severe attack, leaving the stainless steel
with a skeleton appearance as pictured in Fig. 3. As it was mentioned
previously, it seems clear that together with the effects produced by
welding – allowing the anchorage of the microorganisms – the deposits
of fats and oils originally present in the tube wall would supply the
carbon source required for bacterial development [11].
Fig. 4. EDS analysis of the grain remaining after bacteria attack and reference
stainless steel.
 J.J. de Damborenea et al. / Materials Letters 61 (2007) 821–823
Fig. 5. SEM image of the microorganisms on the corroded steel.
It is also suggested that the other reason for a high sensitization
exhibited by weldments to corrosive attack could be an unbalanced
situation between ferritic and austenitic phases. There is a controversy
about which phase is selectively dissolved by the bacteria. Some authors
suggest that attack could be produced only in a single phase, ferrite [12];
others conclude that either ferrite or austenite can be preferentially
attacked or they may corrode together [13]. According to SEM and EDS
analysis, Fig. 4, the austenite is removed from the duplex microstructure
in MIC stainless steel, leaving behind the skeleton of delta ferrite. This
would be in agreement with the reported in literature [14]. Once bacteria
begin to colonise surfaces and produce biofilms, the attack progresses
underneath the surface in low-oxygen conditions that could be related to
bacteria such as Gallionella or Sulphate reducing bacteria(SRB). In this
sense, Videla [15] has found that a preferential attack on the austenitic
phase on the duplex weld structure occurs because of these bacteria.
Finally, the SEM image of various single elongated stalks that resemble
bacterial colonies is presented in Fig. 5.
4. Conclusions
Microbiologically Influenced Corrosion (MIC) exhibited by
a stainless steel AISI 304 tube is located on the welding areas
823
with a ferrite and austenite biphasic structure. The rougher of
those areas facilitates the anchorage of the microorganisms and
the presence in the walls of the tube of oils and fats serves as the
carbon source needed for microbial growth.
Bacteria act preferentially by attacking the austenite phase.
Cavities are generated allowing the development of anaerobic
microorganism and hence, several stages of degradation are
observed due to the progression of the attack. The corrosion
damage is revealed as selective grain boundaries dissolution,
leaving only the ferritic phase. As a consequence of corrosion,
biofouling is formed not only on the surface but also inside the
cavities. Significant corrosion behaviour differences between
reference stainless steel and MIC stainless steel can be observed in
well water.
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