Crevice Corrosion of Stainless Steels 904L, 2205, and 2507 in High-Temperature Sulfuric Acid Solution Containing Chlorides: Influence of Metal Cations

Crevice corrosion influences the integrity of materials in many industrial sectors, such as hydrometallurgy. The conditions in hydrometallurgical processes are severe, with high concentrations of sulfuric acid leachant as well as high-chloride impurity, oxygen, and metal cation contents. In this study, crevice corrosion behavior of highly-alloyed austenitic and duplex stainless steels is investigated in aerated high-temperature sulfuric acid solution with 1 g/L chlorides in the presence of three types of metal cations: Fe³⁺, Cu²⁺, and Fe²⁺. The experimental work contains the determination of the oxidizing capacity of the solutions, immersion crevice corrosion tests followed by characterization of the corrosion attack, and potentiodynamic polarization measurements. The results show that the alloy with the highest PRE_N value, grade 2507, was not susceptible to crevice corrosion under the test conditions. In the case of grades 904L and 2205 of relatively equal PRE_N values, the extent and nature of crevice corrosion attack was different and dependent on the ratio of activities of chlorides to sulfates and the type of metal cations. The results are presented and discussed in the light of IR drop mechanism.