Corrosion and Protection

Contents......Page 8
Preface......Page 6
1.2 Importance of Corrosion and Prevention Efforts......Page 14
1.3 Corrosion Science and Corrosion Technology......Page 16
References......Page 17
2.1 Description of a Wet Corrosion Process......Page 18
2.2 Crucial Mechanisms Determining Corrosion......Page 19
2.3 Corrosion Prevention Measures......Page 20
2.4 Expressions and Measures of Corrosion Rates......Page 21
Exercises......Page 23
3.2 Free Enthalpy and Cell Voltage......Page 26
3.3 The Influence of the State of Matter on Free Enthalpy and the Change of Free Enthalpy......Page 29
3.4 Change of Free Enthalpy in Chemical Reactions. Reversible Cell Voltage......Page 31
3.5 Electrode Reactions and Electrode Potentials......Page 32
3.7 Equilibrium Potentials of Reactions with Iron at 25°C......Page 36
3.8 Pourbaix Diagram......Page 39
3.9 A Simplified Presentation of Equilibrium Potential and Deviation from It......Page 42
3.10 Possible Range for Real Potentials Under Corrosion Conditions......Page 44
Exercises......Page 45
4.1 Introduction: Anodic and Cathodic Reactions......Page 48
4.2 Polarization and Overvoltage......Page 49
4.4 Activation Polarization......Page 50
4.5 Concentration Polarization......Page 51
4.6 Overvoltage Due to Concentration Polarization......Page 55
4.7 Combined Activation and Concentration Polarization......Page 56
4.9 Determination of Corrosion Potential and Corrosion Rate......Page 57
4.10 Recording Polarization Curves with a Potentiostat......Page 60
References......Page 63
Exercises......Page 64
5.1 Passivation and Passivity Described by Anodic Polarization and Overvoltage Curves......Page 66
5.2 Passivity – Reasons and Characteristic Features......Page 67
5.3 Breakdown of Passive Films......Page 70
5.4 Stable and Unstable Passive State......Page 71
5.5 Practical Utilization of Passivation and Passivity......Page 74
Exercises......Page 75
6.1 General......Page 78
6.2.1 General Circumstances and Data......Page 79
6.2.2 Effect of Temperature......Page 81
6.2.4 Effect of Flow Velocity......Page 83
6.2.5 Corrosion under Thin Films of Water......Page 87
6.3 Corrosion under Hydrogen Evolution......Page 88
6.4 Corrosion under Effects of Bacteria......Page 90
6.5.2 Mechanisms......Page 91
6.5.3 Corrosion Rate......Page 93
6.6 H[sub(2)]S Corrosion......Page 95
6.7 Other Cathodic Reactions......Page 96
References......Page 97
Exercises......Page 99
7.1 Introduction......Page 102
7.2 Uniform (General) Corrosion......Page 104
7.3.1 Conditions That Determine Corrosion Rates......Page 107
7.3.2 Prevention of Galvanic Corrosion......Page 118
7.4 Thermogalvanic Corrosion......Page 120
7.5.1 Occurrence, Conditions......Page 121
7.5.2 Mechanism......Page 122
7.5.3 Mathematical Models of Crevice Corrosion......Page 126
7.5.4 Crevice Corrosion Testing......Page 128
7.5.5 Practical Cases of Crevice and Deposit Corrosion......Page 132
7.5.6 Galvanic Effects on Crevice Corrosion......Page 133
7.5.7 Prevention of Crevice Corrosion......Page 134
7.6.1 Conditions, Characteristic Features and Occurrence......Page 135
7.6.2 Mechanisms......Page 137
7.6.3 Influencing Factors......Page 139
7.6.4 The Time Dependence of Pitting......Page 140
7.6.5 Pitting Corrosion Testing......Page 143
7.7.1 General Characteristics, Causes and Occurrence......Page 144
7.7.2 Austenitic Stainless Steels......Page 145
7.7.3 Ferritic Stainless Steels......Page 147
7.8 Selective Corrosion (Selective Leaching)......Page 148
7.9.1 Characteristic Features and Occurrence......Page 151
7.9.2 Types and Mechanisms......Page 152
7.9.3 Erosion and Erosion Corrosion in Liquid Flow with Solid Particles......Page 153
7.9.4 Influencing Factors and Conditions in Liquids and Liquid–Gas Mixtures......Page 157
7.9.5 Critical Velocities......Page 159
7.9.6 Abrasion and Other Wear Processes Combined with Corrosion......Page 162
7.9.7 Preventive Measures......Page 163
7.10 Cavitation Corrosion......Page 165
7.11 Fretting Corrosion (Fretting Oxidation)......Page 167
7.12.1 Characteristic Features and Occurrence......Page 169
7.12.2 Mechanisms......Page 170
7.12.3 Fracture Mechanics Quantities......Page 176
7.12.4 Cracking Course and Data for Some SCC Conditions......Page 177
7.13.1 Definition, Characteristic Features and Occurrence......Page 183
7.13.2 Influencing Factors and Mechanisms......Page 184
7.13.3 Factors Most Important for Crack Initiation and Early Growth......Page 188
7.13.4 Crack Growth Rate and Factors Affecting It......Page 189
7.13.5 Calculation of Number of Cycles to Failure of Welded Steel Structures......Page 192
7.13.6 Prevention of Corrosion Fatigue......Page 193
References......Page 194
Exercises......Page 197
8.1.1 Environmental Factors and Their Effects......Page 206
8.1.2 Atmospheric Corrosion on Different Materials......Page 209
8.2 Corrosion in Fresh Water and Other Waters......Page 211
8.3 Corrosion in Seawater......Page 216
8.4 Corrosion in Soils......Page 219
8.5 Corrosion in Concrete......Page 223
8.6 Corrosion in the Petroleum Industry......Page 225
References......Page 228
Exercises......Page 230
9.1.1 Objectives......Page 232
9.1.2 Test Methods......Page 233
9.1.3 Testing Procedure......Page 234
9.2 Electrochemical Testing......Page 236
9.3 Corrosion Monitoring and Inspection......Page 239
9.3.1 Monitoring of Cathodic Protection......Page 240
9.3.2 Inspection and Monitoring of Process Plants......Page 242
9.3.3 Monitoring and Testing in Other Environments......Page 245
References......Page 246
Exercise......Page 247
10.1.1 General Considerations......Page 250
10.1.2 Some Special Aspects of Materials Selection for the Offshore Industry......Page 253
10.1.3 Unalloyed and Low-alloy Steels and Cast Irons......Page 254
10.1.4 High-alloy Cast Irons......Page 255
10.1.5 Stainless Steels......Page 256
10.1.7 Copper and Its Alloys......Page 263
10.1.8 Aluminium and Its Alloys......Page 267
10.1.9 Titanium and Its Alloys......Page 269
10.1.10 Other Metallic Materials......Page 270
10.1.11 Non-metallic Materials......Page 271
10.2 Change of Environment......Page 272
10.3 Proper Design......Page 275
10.4.1 Principle......Page 279
10.4.2 Protection Criteria and Specifications......Page 282
10.4.3 Cathodic Protection with Sacrificial Anodes......Page 286
10.4.4 Cathodic Protection with Impressed Current......Page 289
10.4.5 Electrolyte Resistance, Potential Variation and Current Distribution in CP Systems and Galvanic Elements......Page 291
10.5 Anodic Protection......Page 294
10.6 Corrosion Protection by Coatings......Page 295
10.6.1 Metallic Coatings......Page 296
10.6.2 Other Inorganic Coatings......Page 305
10.6.3 Paint Coatings......Page 306
10.6.4 Other Forms of Organic Coatings......Page 312
10.6.5 Pre-treatment Before Coating......Page 313
References......Page 315
Exercises......Page 317
C......Page 322
G......Page 324
O......Page 325
S......Page 326
U......Page 327
Z......Page 328