Corrosion and corrosion control : an introduction to corrosion science and engineering

Title:

Personal Author:

Revie, R. Winston (Robert Winston), 1944-

Edition:

4th ed.

Publication Information:

Hoboken, NJ : J. Wiley, 2008

ISBN:

9780471732792

Subject Term:

Corrosion and anti-corrosives

Added Author:

Uhlig, Herbert Henry, 1907-

Available:*

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Summary

The classic book on corrosion science and engineering--now in a valuable new edition

The ability to prevent failures by managing corrosion is one of the main global challengesof the twenty-first century. However, most practicing engineers and technologists have only a basic understanding of how they can actively participate in this urgent economic and environmental issue. Now, students and professionals can turn to this newly revised edition of the trusted Corrosion and Corrosion Control for coverage of the latest developments in the field, including advances in knowledge, new alloys for corrosion control, and industry developments in response to public demand.

This Fourth Edition presents an updated overview of the essential aspects of corrosion science and engineering that underpin the tools and technologies used for managing corrosion, enhancing reliability, and preventing failures. Although the basic organization of the book remains unchanged from the previous edition, this new update includes:

An introduction to new topics, including the element of risk management in corrosion engineering and new advanced alloys for controlling corrosion

Expanded discussions on electrochemical polarization, predicting corrosion using thermodynamics, steel reinforcements in concrete, and applications of corrosion control technologies in automotive, nuclear, and other industries

A stronger emphasis on environmental concerns and regulations in the context of their impact on corrosion engineering

A discussion of the challenge of reliability in nuclear reactors; stainless steels; the concept of critical pitting temperature; and information on critical pitting potential (CPP)

Complemented with numerous examples to help illustrate important points, Corrosion and Corrosion Control , Fourth Edition enables readers to fully understand corrosion and its control and, in turn, help reduce massive economic and environmental loss. It is a must-read for advanced undergraduates and graduate students in engineering and materials science courses, as well as for engineers, technologists, researchers, and other professionals who need information on this timely topic.

Author Notes

R. Winston Revie, PhD, is a past chair of the ASM Canada Council and of The Electrochemical Society (Canadian Section), and a past president of the Metallurgical Society of CIM. He is on the Board of Directors of NACE International

Preface	p. xvii
1 Definition and Importance of Corrosion	p. 1
1.1 Definition of Corrosion	p. 1
1.1.1 Corrosion Science and Corrosion Engineering	p. 1
1.2 Importance of Corrosion	p. 2
1.3 Risk Management	p. 5
1.4 Causes of Corrosion	p. 6
1.4.1 Change in Gibbs Free Energy	p. 6
1.4.2 Pilling-Bedworth Ratio	p. 6
References	p. 6
General References	p. 7
Problems	p. 7
2 Electrochemical Mechanisms	p. 9
2.1 The Dry-Cell Analogy and Faraday's Law	p. 9
2.2 Definition of Anode and Cathode	p. 11
2.3 Types of Cells	p. 13
2.4 Types of Corrosion Damage	p. 15
References	p. 18
General References	p. 19
Problems	p. 19
3 Thermodynamics: Corrosion Tendency and Electrode Potentials	p. 21
3.1 Change of Gibbs Free Energy	p. 21
3.2 Measuring the Emf of a Cell	p. 22
3.3 Calculating the Half-Cell Potential-The Nernst Equation	p. 22
3.4 The Hydrogen Electrode and the Standard Hydrogen Scale	p. 24
3.5 Convention of Signs and Calculation of Emf	p. 25
3.6 Measurement of pH	p. 28
3.7 The Oxygen Electrode and Differential Aeration Cell	p. 28
3.8 The Emf and Galvanic Series	p. 30
3.9 Liquid Junction Potentials	p. 33
3.10 Reference Electrodes	p. 34
3.10.1 Calomel Reference Electrode	p. 35
3.10.2 Silver-Silver Chloride Reference Electrode	p. 36
3.10.3 Saturated Copper-Copper Sulfate Reference Electrode	p. 36
References	p. 37
General References	p. 38
Problems	p. 38
Answers to Problems	p. 40
4 Thermodynamics: Pourbaix Diagrams	p. 43
4.1 Basis of Pourbaix Diagrams	p. 43
4.2 Pourbaix Diagram for Water	p. 44
4.3 Pourbaix Diagram for Iron	p. 45
4.4 Pourbaix Diagram for Aluminum	p. 47
4.5 Pourbaix Diagram for Magnesium	p. 48
4.6 Limitations of Pourbaix Diagrams	p. 49
References	p. 50
General References	p. 50
Problems	p. 50
Answers to Problem	p. 51
5 Kinetics: Polarization and Corrosion Rates	p. 53
5.1 Polarization	p. 53
5.2 The Polarized Cell	p. 54
5.3 How Polarization Is Measured	p. 56
5.3.1 Calculation of IR Drop in an Electrolyte	p. 58
5.4 Causes of Polarization	p. 58
5.5 Hydrogen Overpotential	p. 63
5.6 Polarization Diagrams of Corroding Metals	p. 66
5.7 Influence of Polarization on Corrosion Rate	p. 68
5.8 Calculation of Corrosion Rates from Polarization Data	p. 71
5.9 Anode-Cathode Area Ratio	p. 73
5.10 Electrochemical Impedance Spectroscopy	p. 75
5.11 Theory of Cathodic Protection	p. 77
References	p. 79
General References	p. 80
Problems	p. 80
Answers to Problems	p. 82
6 Passivity	p. 83
6.1 Definition	p. 83
6.2 Characteristics of Passivation and the Flade Potential	p. 84
6.3 Behavior of Passivators	p. 88
6.3.1 Passivation of Iron by HNO[subscript 3]	p. 89
6.4 Anodic Protection and Transpassivity	p. 90
6.5 Theories of Passivity	p. 92
6.5.1 More Stable Passive Films with Time	p. 95
6.5.2 Action of Chloride Ions and Passive-Active Cells	p. 96
6.6 Critical Pitting Potential	p. 97
6.7 Critical Pitting Temperature	p. 99
6.8 Passivity of Alloys	p. 100
6.8.1 Nickel-Copper Alloys	p. 103
6.8.2 Other Alloys	p. 108
6.9 Effect of Cathodic Polarization and Catalysis	p. 108
References	p. 109
General References	p. 111
Problems	p. 112
Answers to Problems	p. 113
7 Iron and Steel	p. 115
7.1 Introduction	p. 115
7.2 Aqueous Environments	p. 116
7.2.1 Effect of Dissolved Oxygen	p. 116
7.2.2 Effect of Temperature	p. 120
7.2.3 Effect of pH	p. 120
7.2.4 Effect of Galvanic Coupling	p. 127
7.2.5 Effect of Velocity on Corrosion in Natural Waters	p. 129
7.2.6 Effect of Dissolved Salts	p. 131
7.3 Metallurgical Factors	p. 138
7.3.1 Varieties of Iron and Steel	p. 138
7.3.2 Effects of Composition	p. 138
7.3.3 Effect of Heat Treatment	p. 142
7.4 Steel Reinforcements in Concrete	p. 143
References	p. 145
General References	p. 147
Problems	p. 147
Answers to Problems	p. 148
8 Effect of Stress	p. 149
8.1 Cold Working	p. 149
8.2 Stress-Corrosion Cracking	p. 150
8.2.1 Iron and Steel	p. 151
8.3 Mechanism of Stress-Corrosion Cracking of Steel and Other Metals	p. 156
8.3.1 Electrochemical Dissolution	p. 157
8.3.2 Film-Induced Cleavage	p. 158
8.3.3 Adsorption-Induced Localized Slip	p. 158
8.3.4 Stress Sorption	p. 158
8.3.5 Initiation of Stress-Corrosion Cracking and Critical Potentials	p. 161
8.3.6 Rate of Crack Growth (Fracture Mechanics)	p. 162
8.4 Hydrogen Damage	p. 166
8.4.1 Mechanism of Hydrogen Damage	p. 167
8.4.2 Effect of Metal Flaws	p. 170
8.5 Radiation Damage	p. 172
8.6 Corrosion Fatigue	p. 173
8.6.1 Critical Minimum Corrosion Rates	p. 177
8.6.2 Remedial Measures	p. 178
8.6.3 Mechanism of Corrosion Fatigue	p. 179
8.7 Fretting Corrosion	p. 180
8.7.1 Mechanism of Fretting Corrosion	p. 182
8.7.2 Remedial Measures	p. 184
References	p. 185
General References	p. 188
Problems	p. 190
Answers to Problems	p. 190
9 Atmospheric Corrosion	p. 191
9.1 Introduction	p. 191
9.2 Types of Atmospheres	p. 192
9.3 Corrosion-Product Films	p. 192
9.4 Factors Influencing Corrosivity of the Atmosphere	p. 195
9.4.1 Particulate Matter	p. 196
9.4.2 Gases in the Atmosphere	p. 197
9.4.3 Moisture (Critical Humidity)	p. 199
9.5 Remedial Measures	p. 201
References	p. 202
General References	p. 203
Problems	p. 204
10 Corrosion in Soils	p. 205
10.1 Introduction	p. 205
10.2 Factors Affecting the Corrosivity of Soils	p. 206
10.3 Bureau of Standards Tests	p. 207
10.3.1 Pitting Characteristics	p. 208
10.4 Stress-Corrosion Cracking	p. 210
10.5 Remedial Measures	p. 211
References	p. 212
General References	p. 212
11 Oxidation	p. 215
11.1 Introduction	p. 215
11.2 Initial Stages	p. 216
11.3 Thermodynamics of Oxidation: Free Energy-Temperature Diagram	p. 218
11.4 Protective and Nonprotective Scales	p. 218
11.4.1 Three Equations of Oxidation	p. 220
11.5 Wagner Theory of Oxidation	p. 223
11.6 Oxide Properties and Oxidation	p. 224
11.7 Galvanic Effects and Electrolysis of Oxides	p. 227
11.8 Hot Ash Corrosion	p. 229
11.9 Hot Corrosion	p. 229
11.10 Oxidation of Copper	p. 230
11.10.1 Internal Oxidation	p. 231
11.10.2 Reaction with Hydrogen ("Hydrogen Disease")	p. 231
11.11 Oxidation of Iron and Iron Alloys	p. 232
11.12 Life Test for Oxidation-Resistant Wires	p. 233
11.13 Oxidation-Resistant Alloys	p. 234
11.13.1 Reactive Element Effect (REE)	p. 234
11.13.2 Chromium-Iron Alloys	p. 235
11.13.3 Chromium-Aluminum-Iron Alloys	p. 236
11.13.4 Nickel and Nickel Alloys	p. 236
11.13.5 Furnace Windings	p. 237
References	p. 237
General References	p. 239
Problems	p. 239
Answers to Problems	p. 240
12 Stray-Current Corrosion	p. 241
12.1 Introduction	p. 241
12.2 Sources of Stray Currents	p. 242
12.3 Quantitative Damage by Stray Currents	p. 244
12.4 Detection of Stray Currents	p. 245
12.5 Soil-Resistivity Measurement	p. 246
12.6 Means for Reducing Stray-Current Corrosion	p. 246
References	p. 247
General References	p. 247
Problems	p. 247
Answers to Problems	p. 249
13 Cathodic Protection	p. 251
13.1 Introduction	p. 251
13.2 Brief History	p. 252
13.3 How Applied	p. 253
13.3.1 Sacrificial Anodes	p. 254
13.4 Combined Use with Coatings	p. 255
13.5 Magnitude of Current Required	p. 257
13.6 Anode Materials and Backfill	p. 258
13.6.1 Overprotection	p. 259
13.7 Criteria of Protection	p. 260
13.7.1 Potential Measurements	p. 260
13.7.2 Doubtful Criteria	p. 262
13.7.3 Position of Reference Electrode	p. 262
13.8 Economics of Cathodic Protection	p. 263
13.9 Anodic Protection	p. 263
References	p. 265
General References	p. 265
Problems	p. 266
Answers to Problems	p. 267
14 Metallic Coatings	p. 269
14.1 Methods of Application	p. 269
14.2 Classification of Coatings	p. 271
14.3 Specific Metal Coatings	p. 272
14.3.1 Nickel Coatings	p. 272
14.3.2 Lead Coatings	p. 274
14.3.3 Zinc Coatings	p. 274
14.3.4 Cadmium Coatings	p. 276
14.3.5 Tin Coatings	p. 277
14.3.6 Chromium-Plated Steel for Containers	p. 279
14.3.7 Aluminum Coatings	p. 280
References	p. 281
General References	p. 282
15 Inorganic Coatings	p. 285
15.1 Vitreous Enamels	p. 285
15.2 Portland Cement Coatings	p. 286
15.3 Chemical Conversion Coatings	p. 286
References	p. 288
General References	p. 288
16 Organic Coatings	p. 289
16.1 Introduction	p. 289
16.2 Paints	p. 289
16.3 Requirements for Corrosion Protection	p. 291
16.4 Metal Surface Preparation	p. 293
16.4.1 Cleaning All Dirt, Oils, and Greases from the Surface	p. 293
16.4.2 Complete Removal of Rust and Mill Scale	p. 294
16.5 Applying Paint Coatings	p. 295
16.5.1 Wash Primer	p. 296
16.5.2 Painting of Aluminum and Zinc	p. 296
16.6 Filiform Corrosion	p. 296
16.6.1 Theory of Filiform Corrosion	p. 298
16.7 Plastic Linings	p. 299
References	p. 300
General References	p. 301
17 Inhibitors and Passivators	p. 303
17.1 Introduction	p. 303
17.2 Passivators	p. 304
17.2.1 Mechanism of Passivation	p. 304
17.2.2 Applications of Passivators	p. 308
17.3 Pickling Inhibitors	p. 310
17.3.1 Applications of Pickling Inhibitors	p. 312
17.4 Slushing Compounds	p. 313
17.5 Vapor-Phase Inhibitors	p. 313
17.5.1 Inhibitor to Reduce Tarnishing of Copper	p. 314
References	p. 315
General References	p. 316
18 Treatment of Water and Steam Systems	p. 317
18.1 Deaeration and Deactivation	p. 317
18.2 Hot- and Cold-Water Treatment	p. 321
18.2.1 Cooling Waters	p. 322
18.3 Boiler-Water Treatment	p. 323
18.3.1 Boiler Corrosion	p. 323
18.3.2 Boiler-Water Treatment for Corrosion Control	p. 326
18.3.3 Mechanisms	p. 328
References	p. 330
General References	p. 331
19 Alloying for Corrosion Resistance; Stainless Steels	p. 333
19.1 Introduction	p. 333
19.2 Stainless Steels	p. 335
19.2.1 Brief History	p. 336
19.2.2 Classes and Types	p. 337
19.2.3 Intergranular Corrosion	p. 343
19.2.4 Pitting and Crevice Corrosion	p. 350
19.2.5 Stress-Corrosion Cracking and Hydrogen Cracking	p. 354
19.2.6 Cracking of Sensitized Austenitic Alloys in Polythionic Acids	p. 359
19.2.7 Galvanic Coupling and General Corrosion Resistance	p. 361
References	p. 362
General References	p. 365
20 Copper and Copper Alloys	p. 367
20.1 Copper	p. 367
20.1.1 Corrosion in Natural Waters	p. 369
20.2 Copper Alloys	p. 371
20.2.1 Copper-Zinc Alloys (Brasses)	p. 371
20.2.2 Dealloying/Dezincification	p. 372
20.2.3 Stress-Corrosion Cracking (Season Cracking)	p. 374
20.2.4 Condenser Tube Alloys Including Copper-Nickel Alloys	p. 378
References	p. 379
General References	p. 381
Problems	p. 381
Answers to Problems	p. 381
21 Aluminum and Aluminum Alloys	p. 383
21.1 Aluminum	p. 383
21.1.1 Clad Alloys	p. 384
21.1.2 Corrosion in Water and Steam	p. 384
21.1.3 Effect of pH	p. 387
21.1.4 Corrosion Characteristics	p. 388
21.1.5 Galvanic Coupling	p. 392
21.2 Aluminum Alloys	p. 393
21.2.1 Stress-Corrosion Cracking	p. 394
References	p. 396
General References	p. 397
22 Magnesium and Magnesium Alloys	p. 399
22.1 Introduction	p. 399
22.2 Magnesium	p. 399
22.3 Magnesium Alloys	p. 400
22.3.1 Stress-Corrosion Cracking	p. 402
22.3.2 Coatings	p. 403
22.4 Summary	p. 404
References	p. 405
General References	p. 405
23 Nickel and Nickel Alloys	p. 407
23.1 Introduction	p. 407
23.2 Nickel	p. 408
23.3 Nickel Alloys	p. 411
23.3.1 General Behavior	p. 411
23.3.2 Ni-Cu System: Alloy 400-70% Ni, 30% Cu	p. 414
23.3.3 Ni-Cr-Fe System: Alloy 600-76% Ni, 16% Cr, 7% Fe	p. 414
23.3.4 Ni-Mo System: Alloy B-60% Ni, 30% Mo, 5% Fe	p. 415
23.3.5 Ni-Cr-Fe-Mo-Cu System: Alloy G-Ni, 22% Cr, 20% Fe, 6.5% Mo, 2% Cu	p. 416
23.3.6 Ni-Cr-Mo System: Alloy C-54% Ni, 15% Cr, 16% Mo, 4% W, 5% Fe	p. 416
23.3.7 Ni-Fe-Cr System: Alloy 825-Ni, 31% Fe, 22% Cr	p. 417
References	p. 417
General References	p. 418
24 Cobalt and Cobalt Alloys	p. 419
24.1 Introduction	p. 419
24.2 Cobalt Alloys	p. 420
References	p. 423
General References	p. 423
25 Titanium	p. 425
25.1 Titanium	p. 425
25.2 Titanium Alloys	p. 427
25.3 Pitting and Crevice Corrosion	p. 429
25.4 Intergranular Corrosion and Stress-Corrosion Cracking	p. 430
References	p. 432
General References	p. 434
Problem	p. 434
26 Zirconium	p. 435
26.1 Introduction	p. 435
26.2 Zirconium Alloys	p. 436
26.3 Behavior in Hot Water and Steam	p. 437
References	p. 439
General References	p. 440
27 Tantalum	p. 441
27.1 Introduction	p. 441
27.2 Corrosion Behavior	p. 441
References	p. 443
General Reference	p. 443
28 Lead	p. 445
28.1 Introduction	p. 445
28.2 Corrosion Behavior of Lead and Lead Alloys	p. 446
28.2.1 Lead-Acid Battery	p. 447
28.3 Summary	p. 448
References	p. 449
General References	p. 449
29 Appendix	p. 451
29.1 Activity and Activity Coefficients of Strong Electrolytes	p. 451
29.2 Derivation of Stern-Geary Equation for Calculating Corrosion Rates from Polarization Data Obtained at Low Current Densities	p. 456
29.2.1 The General Equation	p. 458
29.3 Derivation of Equation Expressing the Saturation Index of a Natural Water	p. 461
29.4 Derivation of Potential Change along a Cathodically Protected Pipeline	p. 467
29.5 Derivation of the Equation for Potential Drop along the Soil Surface Created by Current Entering or Leaving a Buried Pipe	p. 469
29.6 Derivation of the Equation for Determining Resistivity of Soil by Four-Electrode Method	p. 470
29.7 Derivation of the Equation Expressing Weight Loss by Fretting Corrosion	p. 471
29.8 Conversion Factors	p. 474
29.8.1 Additional Conversion Factors	p. 475
29.8.2 Current Density Equivalent to a Corrosion Rate of 1 gmd	p. 475
29.9 Standard Potentials	p. 476
29.10 Notation and Abbreviations	p. 476
References	p. 478
Index	p. 479

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