Corrosion research at TWI

Corrosion research

TWI has a long tradition of corrosion research & development stretching back to the 1950s into the aspects of corrosion performance of materials with particular emphasis on the influence of welding upon degradation of materials' behaviour in static and dynamic loading. Knowledge derived from our research work enhances our expertise which is brought to bear on issues requiring up-to-date consultancy knowledge and failure analysis, ensuring leading edge support on your most critical requirements.

TWI develops specialised testing equipment to undertake these studies and has unique facilities available, plus a depth of experience in the design and construction of advanced equipment to undertake testing and performance assessment to support the most demanding projects worldwide. Testing can include electrochemical measurements including those undertaken at elevated pressure and temperature.

As a prerequisite to understanding the impact of welding and joining technologies upon corrosion behaviour, TWI has extensive knowledge of the performance of the parent material. Indeed, many enquiries and consultancy issues may involve components which are not welded. However, our world reputation is centred on our understanding of in-service performance and degradation of welded materials.

The industry drivers for our research activities include cost reduction through development of new materials, improved productivity welding technology, use of 'cheaper' materials in new conditions and new engineering developments e.g. catenary riser systems, flexible risers in mild sour operation etc. This leads to the following demands:

  • New materials and the consequent need to understand their weldability and corrosion behaviour
  • New welding technologies and joining processes requiring establishment of the joint performance
  • Application of materials in new service conditions or service envelope extension
  • Corrosion fatigue in sour service and high pressure high temperature applications
  • Industry failure occurrences which have wide potential impact necessitating research to understand the underlying mechanisms
  • Single client confidential work for development of new products and designs to maintain technical excellence in the market place

With the continuous development of new knowledge and expertise through the Joint Industry Projects (JIP)/Group Sponsored Projects (GSP) and the Core Research Programme of TWI, you can be assured that our staff are at the leading edge of developments in materials and joining technology, and knowledge of their impact upon in-service performance.

Our research embraces all engineering materials and recent/current corrosion related activities include:

  • Carbon and low alloy steels:
    • corrosion fatigue in sour conditions
    • corrosion fatigue in sweet conditions
    • sour service cracking
    • effect of plastic strain on cracking resistance in sour service
    • engineering critical assessment in sour service
    • performance of flexible risers for mild sour operation
    • HIC/HPIC
    • SOHIC
    • hydrogen embrittlement
    • behaviour of weldments in mildly sour service
    • preferential weldment corrosion in sweet production environments
    • acceptability of ERW/HFI and Spiral Welded pipe for sour service
  • Duplex and super duplex stainless steels:
    • sour service limits
    • test methods
    • influence of intermetallic and third phase precipitates
    • performance under cathodic protection
  • Weldable martensitic and supermartensitic stainless steels (13%Cr)
    • weldability and limits of application in sour or sweet service
    • corrosion fatigue of CRA risers
  • Nickel-base alloys and Ti alloys in severe service conditions such as sour brines
  • Non-ferrous materials in various duties
  • Corrosion performance of welds produced by new joining methods:
    • Friction stir welds in aluminium
    • CRA welds made by friction, electron beam and laser for offshore applications.
  • TWI's expertise in thermal sprayed coatings has developed improved applications and quality of coatings for corrosion and wear/erosion prevention, further enhancing the specialist skills available in corrosion research.

See further details of the history of TWI sour service expertise (available only to TWI Industrial Members), from which the Sour Assurance Service has been derived.

Corrosion Services
Contact our Corrosion Team to discuss in confidence your requirements.