Corrosion Failure Analysis in Heat Exchanger Systems
Summary
Heat exchangers are indispensable across energy, chemical and process industries for efficient thermal management. Despite robust design codes, corrosion remains a principal mode of degradation, compromising performance, safety and operating life. Failure analysis in this context seeks to elucidate the mechanisms by which corrosive media interact with construction materials, often under combined thermal, mechanical and chemical stressors. Key processes include uniform attack, pitting, intergranular corrosion and stress corrosion cracking. These phenomena can be exacerbated by fluid composition (such as chlorides, ammonia or hydrogen sulphide), flow dynamics and temperature gradients. Systematic analysis draws upon visual and microscopic examination, metallography, electrochemical testing and flow simulation to identify root causes and recommend mitigation strategies. Effective corrosion failure analysis informs material selection, inhibitor application, protective coatings and design modifications to safeguard long-term operation under diverse service conditions.
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Corrosion Failure Analysis in Heat Exchanger Systems publication trend
The graph below shows the total number of articles in corrosion failure analysis in heat exchanger systems across all publications each year (not limited to Nature Index journals).
Technical terms
Corrosion perforation: Localised penetration of a metal wall due to chemical or electrochemical attack, leading to leakage.
Intergranular corrosion: Attack preferentially along grain boundaries, often due to precipitate formation or depletion of alloying elements.
Stress corrosion cracking: Brittle fracture induced by the combined action of tensile stress and a corrosive environment.
Leak path: Minimum continuous through-wall opening in a joint or weld, determining containment integrity.
Pulsed thermography: Non-destructive technique using transient infrared imaging to detect subsurface defects by thermal signature variations.
References
- Degradation Study of Heat Exchangers. Procedia CIRP (2015).
- Analysis of Causes and Protective Measures against Corrosion Perforation in the Shell-Side Outlet Flange of a Sour Water Steam Heater. Coatings (2024).
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