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Failure Analysis of the Handle of Stainless Steel Cathode Blank in Copper Electroforming Process: Cu Core Connection to 316L Stainless Steel Sheath

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Abstract

Copper electroforming units around the world use 316L stainless steel (SS) cathode blanks. Cathodes play an essential role in the operating costs of high-purity copper production. Khatoonabad copper refinery asked the authors to investigate the cause of the failure of the handle of this cathode blank and to provide an operational solution. Corrosion of the copper joint to the steel handle was observed as a result of electrolyte penetration from the sides of the handle and the groove between the copper core and the steel sheath. To solve the problem at the source, using GTAW and NiCrMo3 filler, the empty space between the Cu core and the outer 316L SS sheath was filled. Afterward, metallographic analysis, scanning electron microscope equipped with energy scattered X-ray spectroscopy, X-ray diffraction analysis, microhardness and potentiostat analysis in industrial electrolytes were used to characterize the weld metal. According to laboratory results, the weld metal is composed of two phases combinations of high entropy alloys (FCC and BCC) with a higher protective efficiency of about 68.79% respect to Cu and 97.83% respect to 316L SS. In laboratory scale, the metallic properties of the weld metal and acceptable coherency with the base metals as well as the microhardness between Cu and 316L SS could effectively prevent electrolyte penetration into the groove and ensure stability against thermal shock resulting from short circuiting.

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Authors and Affiliations

  1. Department of Materials Science and Engineering, ShahidBahonar University of Kerman, Kerman, Iran

    F. Rostamzadeh & G. R. Khayati

  2. Process Control Unit, Khatoonabad Copper Refinery, Shahrebabak Copper Complex, National Iranian Copper Industries Company, Kerman, Iran

    S. M. J. Khorasani

  3. Research and Development Center, Shahrbabak Copper Complex, National Iranian Copper Industries Company, Kerman, Iran

    N. Assadat Yaghubi

Authors
  1. F. Rostamzadeh
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  2. G. R. Khayati
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  3. S. M. J. Khorasani
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  4. N. Assadat Yaghubi
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Rostamzadeh, F., Khayati, G.R., Khorasani, S.M.J. et al. Failure Analysis of the Handle of Stainless Steel Cathode Blank in Copper Electroforming Process: Cu Core Connection to 316L Stainless Steel Sheath. J Fail. Anal. and Preven. 23, 1026–1037 (2023). https://doi.org/10.1007/s11668-023-01641-8

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  • DOI: https://doi.org/10.1007/s11668-023-01641-8

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