Across oil and gas, chemicals, petrochemicals, and energy infrastructure, corrosion-related failures continue to challenge asset reliability, safety, and lifecycle performance. In many cases, these failures are not caused by design or operation alone, but by a mismatch between material selection and increasingly aggressive service environments.
One of the key themes at CORCON 2025 was a clear shift from reactive corrosion control towards predictive, data-driven asset integrity management. Asset owners are increasingly prioritising lifecycle performance, reliability, and sustainability over short-term CAPEX considerations. Advanced materials, working alongside digital monitoring and inspection technologies, are being recognised as central enablers of this transition.
At the event, we had two presentations focused on real‑world failure investigations and metallurgy upgrades that deliver cost‑effective, longer service life:
- In LNG terminal hydraulic & instrumentation (H&I) tubing, we showed why painted 316L failed at cold‑worked bends: low‑end Mo/Ni chemistry, paint‑induced crevices that seeded chloride stress corrosion cracking (SCC), and vibration‑assisted fatigue that accelerated crack growth. The message was clear: don’t paint your way out. Upgrade metallurgy. We recommended UNS N08935 (Sanicro® 35) for its high PREN (~52), high CPT/CCT, and proven SCC resistance, while retaining cold workability close to TP316L(UNS S31603).
- In chemicals, we presented two case studies: Ti‑Gr 2 tubes embrittled after high‑temperature exposure in a soda‑ash plant preheater, and SA2205 duplex tubes that suffered severe pitting attack in a Mechanical Vapor Recompression (MVR) unit. The common takeaway was material–environment mismatch; the solution again was UNS N08935 (Sanicro® 35), already running leak‑free in soda‑ash plant and delivering pitting/crevice performance on par with far costlier Ni‑base alloys
Alongside Sanicro® 35, we also highlighted SAF™ 3006 as a strategically important solution for corrosive environments dominated by strong mineral and organic acids with chlorides. As a high-alloy duplex stainless steel, SAF™ 3006 offers a strong balance of corrosion resistance and mechanical strength, making it well suited for acid production plants, fertiliser units, and chemical facilities where conventional duplex or superaustenitic grades are approaching their limits.
A recurring theme across all presentations was that correct alloy selection alone is not enough. Several documented failures have occurred despite the “right” metallurgy being specified, due to excessive intermetallic phase formation, surface integrity issues, or inconsistent material quality. Production route, microstructure control, cleanliness, and finishing all play a critical role in long-term performance.
This is where an integrated value chain becomes essential. Alleima’s fully integrated value chain, from R&D and alloy development through melting, processing, finishing, and delivery, allows tight control over microstructure, phase balance, and cleanliness, significantly reducing in-service risk. Sustainability is also embedded into this approach, with approximately 83% recycled scrap currently used in production and a target of 90% by 2030, Alleima continues to integrate circularity and emissions reduction into materials development and manufacturing.
Ultimately, these technical discussions reinforce a simple message: corrosion management is most effective when materials decisions are made early, informed by real failure experience, and supported by deep metallurgical expertise.