CONTENTS Preface xvii Chapter 1 Introduction 1 141 Cost of Corrosion 1 12. Comoson Engincering 3 1.3 Definition of Corrosion 4 1-4 Environments 5 1S. Corrosion Damage 5 156 Castifeation of Corrosion 3 17 Future Outlook 9 Chapter 2. Corrosion Principles 12 241 Introduction 2 22 Corrosion Rate Expressions B letrochemical Aspects “ 23 Bletrochemical Reactions “ 24 Polarization 9 25° Pasiviy 2 Enviroumental fects a 246 Bifect of Oxygen and Oxidzers 2B 27 effects of Velocity a» 28 Effect of Temperature 6 29. Efe of Corotve Concentration 2% © 210 Met of Galvanic Coupling nvill contents Metallurgical and Orher Aspects 2-11 Metalic Properties 2.12 Beonamic Considerations 2.13 Importance of Inspection 24 New Instrumentation 215 Study Sequence Chapter 3. Eight Forms of Corrosion Uniform Attack Galvanic or Two-Metal Corrosion 341 EMPand Galvani Series 3:2. Eavironmental Effects 33° Distance Elect 34 Area Effect, 35 Prevention 346 Beneficial Applications (Crevice Corrosion 347 Environmental Factors 38° Mechanism 3.9 Combating Crevice Corrosion 3410 Fliform Corrosion Pring 311 Pit Shape and Growth 312 Avtocatalytc Nature of Piting 313. Solution Composition 3418 Velocity 34S Metallurgical Variables 3-16 Evaluation of Piting Damage 317 Prevention Intergranular Corrosion 3418 Austenitic Stainless Steels 319 Weld Decay 3.20 Conteol for Austenitic Stainless Stee!s 321 KnifeLine Atack 3-22 Intergranular Corrosion of Other Alloys Selective Leaching 3:23 Dezincication: Characteristics 3-24 Dezincification: Mechanism32s 326 37 328 Dezincifcation: Prevention Graphitization Other Alloy Systems High Temperatures Erosion Corrosion 329 330 331 ES cert 334 33 36 337 Surface Fils Velocity Turbulence Impingement Galvanic Effect Nature of Metal or Alloy Combating Erosion Cor Cavitation Damage Fretting Corrosion ‘Stress Corrosion Crack Morphology Suress Effects Time to Cracking Environmental Factors Metallurgical Factors ‘Mechanism “Maltienvironment Charts (Classification of Mechanisms Methods of Prevention Corrosion Fatigue Hydrogen Damage 8 9 350 31 32 355 Characteristics Environmental Factors Hydrogen Blistering Hydrogen Embrittlement Prevention Fracture Mechanics Chapter 4 Corrosion Testing 4 42 3 4 45 46 pe 48 o Iniroduetion ‘Cassifcation Purpose Materials and Specimens Surface Preparation Measuring and Weighing Exposure Techniques Duration Pranned-Interval Tests a8 » ® 0x conrents 437 Aeration ‘Cleaning Specimens After Exposure ‘Temperature Standard Expressions for Corrosion R Galvanic Corrosion High Temperatures and Pressures Erosion Corrosion Crevice Corrosion Intergranular Corrosion Huey Test for Stainless Stels ‘Streicher Test for Stainles Stels Warren Test iting Stress Corrosion NACE Test Methods Slow -Strain-Rate Tests Linear Polarization ‘AC Impedance ‘Small-Amplitude Cyclic Voltammetry Electronic Instrumentation In Vivo Corrosion Paint Tests ‘Seawater Tests Miscellaneous Tests of Metals, Corrosion of Plastics and Elastomers Presenting and Summarizing Data [Nomograph for Corrosion Rates Interpretation of Results Chapter 5 Materials sa Mechanical Properties 5:2 Other Properties Metals and Alloys $3 Cast Irons 5-4 High-Silicon Cast Irons 55 Other Alloy Cast Irons 546 Carbon Steels and Irons 5-7 Low-Alloy Stels 58 Stainless Stels 5.9 Aluminum and Is Alloys 5:10 Magnesium and Its Alloys S11 Lead and Its Alloys 5:12 Copper and Its Alloys 5-13 Nickel and Its Alloys 5-14 Zinc and Its AlloysS15 Tin and Tin Pate 5:16 Cadmium 5.17 Titanium and Its Alloys 5:18 Refractory Metals. 5.19 Noble Metals 5:20 Metalic Glasses 5:21 Metallic Composites [Nonmetallics| 5.22 Natural and Synthetic Rubbers 5:23. Other Elastomers 5:24 Plastics ‘Thermoplasties 5.25 Fluorocarbons 5.26 Acrylics 5:27 Nylon’ 5-28 Chlorinated Polyether 529 Polyethylenes 530 Polypropylene S31 Polystyrene 532 Rigid Polyvinyl Chloride (PVC) 533. Vinyls 5534 Other Thermoplasics Thermosetters 5.35 Eponies 536 Phenolics 537 Polyesters 5.38. Silicones 539 Ureas ‘5-40 Laminates and Reinforced Plastics (Other Nonmetalics SAL Ceramics 542 Carbon and Graphite 543 Wood Chapter 6 Corrosion Prevention Materials Seleeton 61 Metals and Alloys 62. Metal Purification 63. Nonmetalics contents xi 24 21 283 256 29 29 263 263 am mn am am m m 2m 24 m4 278 a 2m 280il conrents Alteration of Eaviroament 64 Changing Mediums 65 Inhibitors Design 66 Wall Thickness 67 Design Rules Cathodic and Anodic Protection 68 Cathodic Protection 69 Anodic Protection 610 Comparison of Anodic and Cathodic Protection Coatings 6-11 Metalic and Other Inorganic Coatings 612 Organic Coatings 613 Corrosion Control Standards 614 Failure Analysis. Chapter 7 Mineral Acids Saifurie Ald TL Stee 72 Castiron 73 Chemical Lead 7-4 HighSlicon Cast Iron 75 Durimet 20 7-6 Nickel-Molybdenum and Nickel-Molybdenum-Chromium Alloys 21 Combined Iscorrosion Chart 7-8 Conventional Stainless Sees 79 Monel, Nickel, Inconel, and Ni-Resst 7-10 Copper and Its Alloys TAAL Other Metals and Alloys 7.12, Summary Coart 7-13 Equipment at Ambient Temperatures 7-14 Sulfuric Acid Plant Equipment TAS. Nonmetallics Niele Ald 7-16 Stainless Stels 717 Class | Materials 7-18 Class 2 Materials 719 Class 3 Materials 7.20 Mined Acids ge 8 Bee S888 See 8 35Hydrochloric Acid a1 7 13 74 1s 126 ‘Class 1 Metals and Alloys lass 2 Metals and Alloys Glass 3 Metals and Alloys ‘Aeration and Onidizing Agents ‘Nonmetallic Materials ‘Hydrogen Chloride and Chlorine Hydrofoorie Acid 22 78 139 ‘Aqueous Hydrofluoric Acid ‘Anhydrous Hydrofluoric Acid Fluorine Phosphoric Acid 130 731 Materials of Construction Miscellaneous Chapter 8 Other Environments 84 82 2 64 BS 86 87 ry 9. 10 an B12 a3 ss Bas 8:16 87 a8 319 820 21 82 a2 424 825 826, a7 Organic Acids Alkalies “Atmorpherie Corrosion Seawater Fresh Water High-Purty Water Soils ‘Aerospace Petroleum Industry Biological Corrosion Human Body Corrosion of Metals by Halogens Corrosion of Automobiles "Nuclear Wate Isolation Liquid Metals.and Fused Salts Solar Energy Geothermal Energy Sewage and Plant-Waste Treatment Pollution Controt Coal Conversion Pulp and Paper Industry Dew Point Corrosion ‘Corrosion Under Insulation Blectronic Equipment Liquid-Metal Embrittlement or Cracking Hydrogen Peroxide Rebar Corrosion CONTENTS. xl as a7 351 382 382 353 337 337 387 4B ate 416 arabv conresTs 8.28 Botting 8.29 Statue of Liberty Chapter 9 Modern Theory—Principles 941 Introduction ‘and the EMF Series 94 Applications of Thermodynamics to Corrosion Bhectrode Kinet 9+ Exchange Current Density 96 Activation Polarization 9.7 Concenttation Polarization 9.8 Combined Polarization 9.9 Mixed-Potential Theory 9-10 Mined Electrodes 8.11 Passivity 9-12 Mechanisms ofthe Growth and Breakdown of Passive Films Chapter 10 Modern Theory— Applications 1041 Introdvetion Predicting Corrosion Behavoe 102 Effect of Oxidizers 103 Velocity Eflecs 10-4 Galvanic Coupling 10-5 Alloy Evaluation Corrosion Prevention 106 Anodic Protection 10-7 Noble-Metal Alloying Corrosion Rate Measurements 10-8 Tafel Extrapolation 109 Linear Polarization Chapter 11 High-Temperature Corrosion 11-1 Introduction Mechaniams and Kinetics Plling-Bedworth Ratio 11-3. Electrochemical and Morphological Aspects of Oxidation “3 445 4s, 4s “7 42 454 456 49 461 a 482 42114 Oxide Defect Structure su 11-5 Oxidation Kinetics 313 11-6 Effect of Alloying 516 14-7 Catastrophic Oxidation 318 M8 Internal Oxidation 319 ‘High-Temperature Materials 50 119. Mechanical Properties 50 11-10 Oxidation Resistance 504 Other Metal-Gas Reactions 3B 1-11 Decarburzation and Hydrogen Attack 3 11-12 Corrosion of Metals by Sulfur Compounds at High Temperatures 534 11-13 Hot Corrosion of Alloys sat Index 545