Corrosion Prevention and Protection Practical Solutions

Corrosion Prevention and Protection......Page 3
Content......Page 9
Preface......Page 15
Acknowledgments......Page 17
PART I  1......Page 19
1 Introduction and Principles of Corrosion......Page 21
1.1 Impact of Corrosion......Page 30
1.2 Preliminary Aspects of Thermodynamics and Kinetics......Page 36
1.3 Nature of Corrosion Reactions......Page 38
1.3.1 Electrochemical Cells......Page 40
1.3.2 Standard Electrode Potentials......Page 41
1.3.3 Pourbaix Diagrams......Page 46
1.3.4 Dynamic Electrochemical Processes......Page 51
1.3.5 Concentration Polarization......Page 64
1.4 Oxidation and High-temperature Corrosion......Page 72
1.4.1 Oxidation of Alloys......Page 77
1.5 Corrosion Prevention......Page 81
1.6 Design Factors......Page 85
1.7 Life Prediction Analysis of Materials......Page 93
1.8.1 Corrosion Inhibitors......Page 98
1.8.2 Protective Coatings......Page 108
1.8.3 Cathodic Protection......Page 118
1.8.4 Impressed Current Protection......Page 123
References......Page 124
2.1 Corrosion Testing......Page 127
2.1.1 Testing for Environmentally Assisted Cracking (EAC)......Page 129
2.1.2 Atmospheric Corrosion Testing......Page 135
2.1.3 Galvanic Corrosion Testing......Page 137
2.1.4 Testing of Polymeric Materials......Page 138
2.1.6 Testing of Corrosion Inhibitors......Page 140
2.2 Corrosion Detection and Monitoring......Page 143
2.2.1 Visual Examination......Page 145
2.2.2 Laser Methods......Page 146
2.2.4 Radiographic Methods......Page 147
2.2.5 Liquid Penetrant Testing Method......Page 152
2.2.6 Magnetic Particle Testing......Page 153
2.2.7 Eddy Current Inspection Method......Page 154
2.2.8 Ultrasonic Inspection Method......Page 155
2.2.9 Acoustic Emission Technique......Page 160
2.2.10 Other Nondestructive Methods......Page 163
2.2.11 Thermal Methods of Inspection......Page 167
2.3 Failure Analysis......Page 168
2.3.1 Visual or Macroscopic Examination......Page 172
2.3.2 Metallography......Page 174
2.3.4 Fracture Mechanics in Failure Analysis......Page 177
2.3.5 Determinaton of Residual Stress by X-ray Diffraction......Page 179
2.3.6 Mechanical Properties......Page 180
2.3.7 Corrosion and Wear-related Failures......Page 182
2.3.8 Failure Analysis of Polymeric Materials......Page 187
2.3.9 Failure Analysis of Ceramic Materials......Page 190
References......Page 191
3.1 Regulations and Specifications......Page 195
3.2 Safety Considerations......Page 199
3.2.1 Safety in the Corrosion Laboratory......Page 210
3.2.2 General Outline for a Model Chemical Hygiene Plan......Page 211
3.2.3 Safety Guidelines for Radiation Sources......Page 212
3.2.4 Nonionizing Radiation Sources......Page 214
3.2.5 Safety at the Design Stage......Page 215
3.2.7 Safety in Storage and Transport......Page 216
References......Page 217
4.1 Cast Irons......Page 219
4.2 Carbon and Low-alloy Steels......Page 220
4.2.1 Corrosion of Carbon Steels in Fresh Waters......Page 222
4.2.2 Corrosion of Carbon Steels in Seawater......Page 225
4.2.3 Corrosion of Carbon Steels in Soils......Page 228
4.3 Stainless Steels......Page 232
4.3.1 Duplex Stainless Steels......Page 237
4.3.2 Martensitic Stainless Steels......Page 242
4.4 Aluminum and Aluminum Alloys......Page 245
4.4.1 Corrosion Behavior of Aluminum and its Alloys......Page 246
4.5 Copper and Copper Alloys......Page 254
4.5.1 Atmospheric Corrosion......Page 255
4.5.3 General Corrosion in Aqueous Media......Page 256
4.5.6 Flow-induced Corrosion......Page 259
4.5.9 Stress–Corrosion Cracking......Page 260
4.6 Nickel and its Alloys......Page 262
4.7 Titanium and its Alloys......Page 273
4.7.2 Resistance to Chemical Environments......Page 275
4.8 Cobalt Alloys......Page 277
4.9 Lead and Lead Alloys......Page 281
4.10 Magnesium and Magnesium Alloys......Page 288
4.10.2 Corrosion of Magnesium and its Alloys......Page 289
4.11.1 Atmospheric Corrosion......Page 300
4.11.2 Corrosion in Aqueous Media......Page 303
4.11.4 Corrosion of Painted Materials......Page 305
4.11.5 Corrosion in Concrete......Page 306
4.11.6 Forms of Corrosion......Page 307
4.12.1 Corrosion of Zirconium Alloys......Page 309
4.13 Tin and Tin Plate......Page 310
4.13.1 Aqueous Corrosion......Page 311
4.13.2 Corrosion of Tin Plate......Page 314
4.14 Refractories and Ceramics......Page 315
4.14.1 Corrosion of Structural Ceramics......Page 316
4.15 Polymeric Materials......Page 318
4.15.1 Application of Polymers in Corrosion Control......Page 320
References......Page 323
5.1 Corrosion Economics......Page 329
5.2 Corrosion Management......Page 335
5.3 Computer Applications......Page 337
References......Page 345
PART II......Page 347
6.1 Corrosion Reactions......Page 349
6.2.4 Process Media......Page 350
6.3 Active and Active–Passive Corrosion Behavior......Page 351
6.4 Forms of Corrosion......Page 354
6.5 Types and Modes of Corrosion......Page 355
6.6 The Morphology of Corroded Materials......Page 356
6.7 Published Corrosion Data......Page 357
6.7.1 General Corrosion......Page 358
6.7.2 Galvanic Corrosion......Page 362
6.7.3 Localized Corrosion......Page 373
6.7.4 Metallurgically Influenced Corrosion......Page 388
6.7.5 Microbiologically Influenced Corrosion......Page 402
6.7.6 Mechanically Assisted Corrosion......Page 411
6.7.7 Environmentally Induced Cracking......Page 441
References......Page 471
Bibliography......Page 477
7.1.1 Ductile Iron Main......Page 479
7.1.2 Cast-iron-lined Main......Page 480
7.2.1 Destructive Visual Inspection......Page 483
7.2.2 Corrosion-induced Cracking......Page 484
7.2.3 Corrosion Mechanism......Page 486
7.3 Some Common Failure Modes in Aircraft Structures......Page 487
7.3.1 Example 1......Page 488
7.3.2 Example 2......Page 489
7.3.3 Example 3......Page 490
7.4 Premature Failure of Tie Rods of a Suspension Bridge......Page 491
7.5.1 Hot Water System Corrosion......Page 494
7.6 Cathodic Protection of Steel in Concrete......Page 496
7.7 Corrosion of Aluminum Components in the Glass Curtain Wall of a Building......Page 498
7.7.2 Observations......Page 499
7.8 Corrosion in a Water Cooling System......Page 501
7.9.2 SEM and EDS Studies......Page 504
7.9.3 Pitting Initiation and Propagation Mechanism......Page 505
7.10 Weld Metal Overlay: a Cost-effective Solution to High-temperature Corrosion and Wear Problems......Page 507
7.11.1 Industrial Engine Crankshaft Failure......Page 510
7.11.2 Electric Motor Drive Shaft Failure......Page 513
7.12 Failure of a Conveyor Drive Shaft......Page 517
7.12.1 Conclusions......Page 518
7.13.1 Observations......Page 519
7.14 Failure of Rock Bolts......Page 522
7.14.2 Fracture and Failure......Page 523
7.15.1 Problem......Page 527
7.15.3 Results......Page 528
7.15.4 SEM Examination......Page 529
7.15.5 Conclusions......Page 530
References......Page 532
7.16 Failure of a Landing Gear Steel Pin......Page 533
7.17 Hydrogen-induced Cracking......Page 534
7.17.1 Extent of Problem: Failures due to Hydrogen-induced Cracking......Page 536
7.17.2 HIC Development and Failures Occur Predominantly in Welded Pipe......Page 537
7.17.4 Mechanism of Hydrogen-induced Cracking......Page 541
References......Page 542
7.18.1 Liquid Metal-induced Embrittlement (LMIE)......Page 543
References......Page 546
7.19.1 Materials......Page 547
References......Page 550
7.20 Performance of Stainless Steel Rebar in Concrete......Page 551
Bibliography......Page 553
7.21 Corrosion of an Oil Storage Tank......Page 554
7.21.2 Color......Page 555
7.21.4 Pitting......Page 556
7.21.5 Pitted Surface......Page 557
7.21.7 Discussion......Page 558
7.22 Corrosion of a Carbon Steel Tank in a Phosphatizing Process......Page 559
7.22.1 Galvanic Corrosion......Page 561
7.22.2 Localized Corrosion......Page 563
7.23.1 Observations......Page 565
7.24 Corrosion in Drilling and Well Stimulation......Page 567
7.24.3 Corrosion in Underbalanced Drilling Operations......Page 568
References......Page 569
Index......Page 571
Color Section......Page 576