Suction rolls are used to extract water from paper during papermaking by applying a vacuum to the paper web as it passes over the roll surface. Suction rolls have frequently suffered from corrosion-assisted cracking during service, apparently as a result of corrosion fatigue processes. The search continues for improved suction roll alloys with greater resistance to corrosion fatigue.

Conventional laboratory tests to measure corrosion and cracking resistance of candidate alloys have not always shown good correlations with the performance of these alloys in service. The need for more relevant laboratory tests to predict the service performance of suction rolls is discussed in light of the demands of suction roll applications.

Near-threshold fatigue crack growth testing has been conducted on superior and inferior suction roll alloys to determine if these tests offer better agreement with service performance. A correlation was found between service performance and near-threshold fatigue crack behavior in dilute chloride solutions under conditions of high tensile mean stress.

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