Corrosion Engineering
Principles and Solved Problems
- 2nd Edition - November 19, 2024
- Imprint: Elsevier
- Author: Branko N. Popov
- Language: English
- Hardback ISBN:9 7 8 - 0 - 4 4 3 - 2 2 0 1 1 - 1
- eBook ISBN:9 7 8 - 0 - 4 4 3 - 2 2 0 1 2 - 8
Corrosion Engineering: Principles and Solved Problems, Second Edition gives a comprehensive overview and introduction to the field through an extensive, theoretical descripti… Read more
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Request a sales quoteCorrosion Engineering: Principles and Solved Problems, Second Edition gives a comprehensive overview and introduction to the field through an extensive, theoretical description of the principles of corrosion theory, passivity and corrosion prevention strategies, and design of corrosion protection systems. The second edition has been thoroughly updated with new knowledge and includes solved corrosion case studies, corrosion analysis and solved corrosion problems to help the reader to understand the corrosion fundamental principles from thermodynamics and electrochemical kinetics, the mechanism that triggers the corrosion processes at the metal interface and how to control or inhibit the corrosion rates.
A key goal of the updated book is to help the next generation of engineers and scientists: (i) understand the theory of hydrogen embrittlement and stress corrosion cracking as well as hydrogen damage prevention strategies, (ii) design models for developing hydrogen damage-resistant alloys, and (iii) prevent damage of different industrial components due to the presence and localization of hydrogen in metals. To accomplish these objectives, the book offers case studies of hydrogen permeation, hydrogen embrittlement, mechanical properties of alloys, and hydrogen damage control.
- Addresses corrosion theory, passivity, material selections, and designs
- Includes extensive coverage of corrosion engineering protection strategies
- Contains over 500 solved problems, diagrams, case studies, and end-of-chapter exercises
- Suitable for advanced/graduate corrosion courses, and as a self-study reference for corrosion engineers
Corrosion engineers, and scientists in electrochemical, corrosion, mechanical, and civil engineering, and material science attending the University Programs Instructors who teach undergraduate/graduate level courses and short courses in corrosion engineering, mechanical engineering, hydrogen embrittlement and materials science Engineers in: NASA, nuclear energy, defense, aviation industries and in various industries including chemical, metallurgy, civil and construction. Also intended for practicing corrosion engineers, chemical engineers, mechanical engineers, civil engineers, materials scientists, and energy engineers Graduate and undergraduate students who take corrosion engineering courses in chemical engineering, mechanical engineering, civil engineering, chemistry, and materials science courses
- Corrosion Engineering
- Cover image
- Title page
- Table of Contents
- Copyright
- Dedication
- About the Author
- Popov’s Corrosion Engineering Research at the University of South Carolina (USC)
- International Collaboration
- Preface
- Chapter 1 Evaluation of Corrosion
- Abstract
- Keywords
- 1.1 Significance and Cost of Corrosion
- 1.2 Definition
- 1.3 Conditions for the Initiation of Corrosion
- 1.4 Electrochemical Polarization
- 1.5 Passivity
- 1.6 Types of Corrosion
- 1.7 Brief Description of Different Types of Corrosion
- 1.7.1 Uniform corrosion
- 1.7.2 Galvanic corrosion
- 1.7.3 Pitting corrosion
- 1.7.4 Crevice corrosion
- 1.7.5 Filiform corrosion
- 1.7.6 Stress corrosion cracking
- 1.7.7 Intergranular corrosion
- 1.7.8 Selective leaching
- 1.7.9 Erosion corrosion
- 1.7.10 Hydrogen damage
- 1.7.11 Metallurgy of SCC
- 1.7.12 Solid solution composition and grain boundary segregation
- 1.7.13 Alloy phase transformation and associated solute depleted zones
- 1.7.14 Duplex structure
- 1.7.15 Cold work
- 1.7.16 Hydrogen embrittlement
- 1.7.17 Corrosion fatigue cracking (CFC)
- 1.8 Corrosion Rate Determination
- 1.8.1 Calculation of corrosion rate form corrosion current
- References
- Chapter 2 Thermodynamics in the Electrochemical Reactions of Corrosion
- Abstract
- Keywords
- 2.1 Introduction
- 2.2 Electrochemical Corrosion
- 2.3 Thermodynamics of Corrosion Processes
- 2.4 Equilibrium Electrode Potentials
- 2.5 Electrochemical Half-Cells and Electrode Potentials
- 2.6 Electromotive Force Series
- 2.7 Determination of Electrochemical/Corrosion Reaction Direction by Gibbs Energy
- 2.8 Reference Electrodes of Importance in Corrosion Processes
- 2.8.1 Determination of reversible potential of the hydrogen electrode
- 2.8.2 Determination of reversible potential of the oxygen electrode
- 2.8.3 Determination of cell potential of the hydrogen-oxygen cell (fuel cell)
- 2.8.4 Determination of electrode potential of a standard Weston cell
- 2.8.5 Determination of electrode potentials for electrodes of the second kind
- 2.8.6 Calomel electrode
- 2.8.7 Silver-silver chloride electrode
- 2.8.8 Copper-copper sulfate electrode
- 2.9 Measurement of Reversible Cell Potential With Liquid Junction Potential
- 2.10 Measurement of Corrosion Potential
- 2.11 Construction of Pourbaix Diagrams
- 2.11.1 Regions of electrochemical stability of water
- 2.11.2 Construction of Pourbaix diagram for zinc
- 2.11.3 Construction of Pourbaix diagram for tin
- 2.11.4 Pourbaix diagram for iron
- 2.11.5 Construction of Pourbaix diagram for nickel
- 2.12 Case Studies
- 2.12.1 Activity coefficients
- 2.12.2 Evaluation of theoretical tendency of metals to corrode
- 2.12.3 Hydrogen and oxygen electrodes
- 2.13 Exercises
- References
- Chapter 3 Electrochemical Kinetics of Corrosion
- Abstract
- Keywords
- 3.1 Introduction
- 3.2 Ohmic Polarization
- 3.3 Electrochemical Polarization
- 3.3.1 Special cases of Butler-Volmer equation—High-field approximation
- 3.3.2 Low-field approximation
- 3.4 Concentration Polarization
- 3.5 Relevance of Electrochemical Kinetics to Corrosion
- 3.6 Construction of Evans Diagrams
- 3.7 Effects of Polarization Behavior on the Corrosion Rate
- 3.8 Effects of Mass Transfer on Electrode Kinetics
- 3.8.1 Diffusion-limited corrosion rate
- 3.8.2 Rotating disk electrode
- 3.9 Exercises
- References
- Chapter 4 Passivity
- Abstract
- Keywords
- 4.1 Active-Passive Corrosion Behavior
- 4.2 Applications of Potentiostatic Polarization Measurements
- 4.3 Galvanostatic Anode Polarization
- 4.4 Fundamentals of Passivity
- 4.4.1 The film and adsorption theories of passivity
- 4.4.2 Thermodynamics
- 4.4.3 Kinetics of passivation processes
- 4.5 Factors Affecting Passivation
- 4.5.1 Effect of acid concentration on passivity of an active-passive metal
- 4.5.2 Effect of solution velocity on active-passive metals and alloys—Construction of polarization curve for stainless steel alloy in aerated solution
- 4.5.3 Criterion for passivation
- 4.5.4 Effect of oxidizer concentration on passivity
- 4.6 Methods for Spontaneous Passivation of Metals
- 4.7 Alloy Evaluation
- 4.8 Anodic Protection
- 4.8.1 Anodic protection systems
- 4.8.2 Design requirements
- 4.8.3 Applications
- 4.9 Composition and Structure of Iron Passive Films
- 4.9.1 Stainless Steel
- 4.9.2 Crystalline structure
- 4.10 Exercises
- References
- Chapter 5 Basics of Corrosion Measurements
- Abstract
- Keywords
- 5.1 Introduction
- 5.2 Polarization Resistance
- 5.3 Calculation of Corrosion Rate From Polarization Data
- 5.3.1 Calculation of corrosion rate from the corrosion current
- 5.4 Electrochemical Techniques to Measure Polarization Resistance
- 5.4.1 Linear polarization technique
- 5.4.2 Galvanostatic technique
- 5.4.3 Nonlinearity of polarization curves
- 5.5 Applications of Linear Polarization Technique—Estimation of Corrosion Rates
- 5.6 Corrosion Potential Measurements as a Function of Time (OCP vs Time)
- 5.7 Tafel Extrapolation Method
- 5.7.1 Principles of Tafel extrapolation method
- 5.7.2 Tafel extrapolation procedure
- 5.8 Potentiodynamic Polarization Measurements
- 5.9 Electrochemical Impedance Spectroscopy
- 5.9.1 Principles of the method
- 5.9.2 Expression for impedance of the R-L-C series circuit
- 5.9.3 AC-impedance plots: Impedance spectra with their associated equivalent circuits
- 5.9.4 Application of electrochemical impedance to corrosion studies
- 5.10 Advantages and Limitations of EIS
- 5.11 Recent Corrosion Research
- 5.12 Exercises
- References
- Chapter 6 Galvanic Corrosion
- Abstract
- Keywords
- 6.1 Definition of Galvanic Corrosion
- 6.2 Galvanic Series
- 6.3 Experimental Measurements
- 6.3.1 Polarization in galvanic couples
- 6.3.2 Zero resistance ammeter
- 6.3.3 Scanning vibrating electrode technique
- 6.4 Prevention of Galvanic Corrosion
- 6.5 Theoretical Aspects
- 6.5.1 Effect of exchange current density on galvanic current in Fe-Zn galvanic couple
- 6.5.2 Differential aeration: Oxygen concentration cell
- 6.6 Testing Methods in Galvanic Corrosion
- 6.6.1 Scanning vibrating electrode technique (SVET)
- 6.6.2 Shadowgraphy and Mach-Zehnder interferometry
- 6.6.3 Other methods
- 6.7 Automotive Application
- 6.8 Galvanic Corrosion in Concrete Structures
- 6.9 Refrigeration
- 6.10 Dental Applications
- 6.11 Corrosion of Microstructures
- 6.12 Galvanic Coatings
- 6.13 Numerical Modeling of Galvanic Corrosion Couples
- 6.14 Exercises
- References
- Chapter 7 Pitting and Crevice Corrosion
- Abstract
- Keywords
- 7.1 Introduction
- 7.2 Critical Pitting Potential and Evaluation of Pitting Corrosion
- 7.3 Mechanism of Pitting Corrosion
- 7.3.1 Passive film breakdown
- 7.3.2 Autocatalytic mechanism of pit growth
- 7.4 Effect of Temperature
- 7.5 Effects of Alloy Composition on Pitting Corrosion
- 7.6 Inhibition of Pitting Corrosion
- 7.7 Crevice Corrosion
- 7.7.1 Mechanism of crevice corrosion
- 7.7.2 Inhibition of crevice corrosion
- 7.8 Filiform Corrosion
- 7.9 Prevention
- 7.10 Exercises
- References
- Chapter 8 Hydrogen Permeation and Hydrogen-Induced Cracking
- Abstract
- Keywords
- 8.1 Introduction
- 8.2 Hydrogen Evolution Reaction
- 8.2.1 Kinetics of hydrogen evolution reaction (HER)
- 8.2.2 Theoretical diffusion solution
- 8.2.3 Evaluation of diffusivity
- 8.2.4 Basic model for hydrogen permeation: The Iyer-Pickering-Zamanzadeh (IPZ) model
- 8.2.5 Case study: Experimental determination of hydrogen permeation parameters
- 8.2.6 Evaluation of rate constants for hydrogen absorption and diffusivity into metals
- 8.3 Hydrogen-Induced Damage
- 8.3.1 Hydrogen-induced cracking (HIC)
- 8.3.2 Hydrogen embrittlement
- 8.3.3 Hydrogen blistering
- 8.3.4 Hydrogen stress cracking (HSC)
- 8.3.5 Recent studies on hydrogen-induced damage
- 8.4 Preventing Hydrogen Damage in Metals
- 8.5 Evaluation of Hydrogen Permeation Through Alloys Under Corroding Conditions
- 8.5.1 Mathematical model development for hydrogen evolution by a coupled discharge-chemical recombination mechanism on corroding metals and alloys
- 8.5.2 Case study: Determination of hydrogen permeation parameters through zinc-nickel alloys under corroding conditions by using the corrosion model
- 8.6 Exercises
- References
- Chapter 9 Stress Corrosion Cracking
- Abstract
- Keywords
- 9.1 Definition and Characteristic of Stress Corrosion Cracking
- 9.2 Testing Methods
- 9.2.1 Constant deformation tests
- 9.2.2 Sustained load tests
- 9.2.3 Slow strain rate testing
- 9.3 Fracture Mechanics Testing
- 9.3.1 Test methods
- 9.3.2 Precracked cantilever beam specimens
- 9.3.3 Linearly increasing stress test (LIST)
- 9.4 Examples of Stress Corrosion Cracking
- 9.5 Stress Corrosion Cracking Models
- 9.5.1 Film rupture model
- 9.5.2 Film-induced cleavage model
- 9.5.3 Localized surface plasticity (LSP)
- 9.5.4 Atomic surface mobility model
- 9.6 Metallurgy of Stress Corrosion Cracking
- 9.6.1 Solid solution composition
- 9.6.2 Grain boundary segregation
- 9.6.3 Alloy phase transformation and associated solute-depleted zones
- 9.6.4 Duplex structures
- 9.6.5 Cold work
- 9.7 Electrochemical Effects
- 9.8 Hydrogen Embrittlement
- 9.9 Corrosion Fatigue Cracking
- 9.10 Prevention of Stress Corrosion Cracking
- 9.11 Exercises
- References
- Chapter 10 Hydrogen Entry Into Metal and Alloys
- Abstract
- Keywords
- 10.1 Thermodynamic Properties and Solubility of Hydrogen
- 10.1.1 Hydrogen evolution reaction
- 10.1.2 Solubility of hydrogen and evaluation of hydrogen concentration
- 10.1.3 Thermodynamic properties
- 10.2 Solubility and Diffusion of Hydrogen in Pure Metals and Alloys
- 10.2.1 Hydrogen solubility and its segregation to vacancies and dislocations
- 10.2.2 Hydrogen segregation to dislocations
- 10.3 Solubility Enhancement in Cold-Worked Substitutional f.c.c. Palladium Alloys
- 10.4 Vacancy Trapping of Hydrogen
- 10.5 Partial Molar Volume and Interactions with Stress and Strain Fields
- 10.6 Lattice Location of Hydrogen
- References
- Chapter 11 High-Temperature Corrosion
- Abstract
- Keywords
- 11.1 Introduction
- 11.2 High-Temperature Corrosion Thermodynamics
- 11.2.1 Melting points and volatility of oxides
- 11.3 Pilling-Bedworth Ratio
- 11.4 Formation of Oxides Layers at High Temperature
- 11.4.1 Oxide microstructure
- 11.4.2 Benefits of alloying
- 11.5 Electrochemical Nature of Oxidation Processes
- 11.6 Oxidation Kinetics
- 11.6.1 Parabolic rate equation
- 11.6.2 Logarithmic rate equation
- 11.6.3 Linear rate equation
- 11.6.4 Combination of rate equations
- 11.7 Hot Corrosion
- 11.7.1 Molten halides
- 11.7.2 Molten nitrates
- 11.7.3 Molten sulfates
- 11.7.4 Molten carbonates
- 11.8 Methods of Protecting Against Hot Corrosion and High-Temperature Corrosion
- 11.8.1 High velocity oxy-fuel (HVOF) basics
- 11.8.2 Future work in HVOF
- 11.8.3 Platinum and aluminide coating
- 11.8.4 Silicon diffusion layers
- 11.8.5 Chemical additions
- 11.8.6 Ion implantation
- 11.8.7 Preformation of oxide layers
- 11.9 Exercises
- References
- Chapter 12 Corrosion of Structural Concrete
- Abstract
- Keywords
- 12.1 Introduction
- 12.2 Corrosion Mechanism of Reinforcement in Concrete
- 12.2.1 Chloride-induced corrosion mechanism
- 12.2.2 Surface depassivation with carbon dioxide
- 12.3 Electrochemical Techniques for Corrosion Evaluation of Reinforcement in Concrete
- 12.3.1 Corrosion potential measurements
- 12.3.2 Linear polarization measurements
- 12.3.3 Tafel polarization
- 12.3.4 Electrochemical impedance spectroscopy (EIS)
- 12.4 Chloride-Induced Damage
- 12.5 Corrosion Control of Reinforcing Steel
- 12.6 Inhibitors
- 12.6.1 Classification of corrosion inhibitors
- 12.6.2 Determination of inhibitor efficiency
- 12.7 Sacrificial Zinc Coatings
- 12.8 Concrete Permeability
- 12.9 Case Study: Prediction of Corrosion Initiation Time and Life of Rebars Under Real-Time (Practical) Conditions
- References
- Chapter 13 Organic Coatings
- Abstract
- Keywords
- 13.1 Introduction
- 13.2 Classification of Organic Coatings
- 13.3 Pigments
- 13.4 Solvents, Additives, and Fillers
- 13.5 Surface Preparation
- 13.6 Application
- 13.7 Exposure Testing
- 13.8 Electrochemical Techniques
- 13.9 Evaluation Methods
- 13.10 Chemical and Physical Aging of Organic Coatings
- References
- Chapter 14 Corrosion Inhibitors
- Abstract
- Keywords
- 14.1 Introduction
- 14.2 Types of Inhibitors
- 14.2.1 Anodic passivating inhibitors
- 14.2.2 Cathodic precipitation inhibitors
- 14.2.3 Organic inhibitors
- 14.2.4 Organic inhibitors used for inhibition of steel in an aqueous environment
- 14.2.5 Ohmic inhibitors
- 14.2.6 Vapor phase inhibitors/volatile corrosion inhibitors (VCI)
- 14.2.7 Anodic inorganic inhibitors
- References
- Chapter 15 Cathodic Protection
- Abstract
- Keywords
- 15.1 Introduction
- 15.2 Fundamentals
- 15.2.1 Principle
- 15.2.2 Types of cathodic protection
- 15.2.3 Selection of cathodic protection system
- 15.3 Cathodic Protection Criteria
- 15.3.1 Potential criteria
- 15.3.2 IR drop considerations
- 15.3.3 Electrochemical basis for CP criteria
- 15.4 Field Data and Design Aspects
- 15.4.1 Soil resistance
- 15.4.2 Hydrogen ion activity (pH)
- 15.4.3 Microbiological activity and redox potential
- 15.4.4 Coating resistance
- 15.4.5 Required current density
- 15.5 Monitoring Methods
- 15.5.1 Potential surveys
- 15.5.2 Corrosion rate measurements
- 15.6 Design of Cathodic Protection Systems
- 15.6.1 Choice of the CP system
- 15.6.2 Design of sacrificial protection system
- 15.6.3 Design of impressed current system
- 15.7 Computer-Aided Design of Cathodic Protection
- 15.8 Exercises
- References
- Chapter 16 Mechanisms of Hydrogen Degradation of Metals
- Abstract
- Keywords
- 16.1 Internal Pressure Mechanism
- 16.2 Surface Energy (Adsorption Mechanism)
- 16.3 Hydrogen-Enhanced Decohesion Mechanism (HEDE)
- 16.4 Adsorption-Induced Localized Slip Model
- 16.5 Corrosion-Enhanced Plasticity (CEP) Model
- 16.6 Hydrogen-Induced Phase Transformation (HIPT)
- 16.6.1 Description of hydride-induced cracking
- 16.6.2 Hydrogen-induced martensitic transformation
- 16.7 Adsorption-Induced Dislocation Emission Mechanism (AIDE)
- 16.8 Hydrogen-Enhanced Localized Plasticity (HELP) Mechanism
- 16.9 Hydrogen-Enhanced Strain-Induced Vacancy Formation (HESIV)
- 16.10 Conclusion
- References
- Chapter 17 Atmospheric Corrosion
- Abstract
- Keywords
- 17.1 Introduction
- 17.2 Atmospheric Classification
- 17.3 Electrochemical Mechanism
- 17.3.1 Corrosion of iron and low alloy steels
- 17.3.2 Moisture
- 17.3.3 Temperature
- 17.3.4 Atmospheric pollutants
- 17.4 Atmospheric Corrosion of Selected Metals
- 17.4.1 Atmospheric corrosion of iron
- 17.4.2 Atmospheric corrosion of magnesium alloy
- 17.4.3 Atmospheric corrosion of nickel
- 17.5 Classification of Atmospheric Corrosion
- 17.5.1 The International Standard Organization (ISO) classification of atmospheric corrosion
- 17.5.2 PACER LIME algorithm for atmospheric corrosion classification
- 17.6 Role of Pollutants
- References
- Solutions Guide Chapter 2: Thermodynamics in the Electrochemical Reactions of Corrosion
- Solutions Guide Chapter 3: Electrochemical Kinetics of Corrosion
- Solutions Guide Chapter 4: Passivity
- Solutions Guide Chapter 5: Basics of Corrosion Measurements
- Solutions Guide Chapter 6: Galvanic Corrosion
- Solutions Guide Chapter 7: Pitting and Crevice Corrosion
- Solutions Guide Chapter 8: Hydrogen Permeation and Hydrogen-Induced Cracking
- Solutions Guide Chapter 9: Stress Corrosion Cracking
- Solutions Guide Chapter 11: High-Temperature Corrosion
- Solutions Guide Chapter 15: Cathodic Protection
- Index
- Edition: 2
- Published: November 19, 2024
- Imprint: Elsevier
- No. of pages: 992
- Language: English
- Hardback ISBN: 9780443220111
- eBook ISBN: 9780443220128
BP
Branko N. Popov
Branko N. Popov is Carolina Distinguished Professor at the Department of Chemical Engineering, University of South Carolina, USA is. He has established at USC an internationally recognized research program in corrosion and electrochemical engineering and is among the world’s most highly cited and respected researchers in the field.
In the last four years, his work at University of South Carolina led to research grants of $10M from the government and industry. During his seventeen years of service at USC and as the Director of the Centre for Electrochemical engineering. his research group has published 220 peer-reviewed articles, 52 proceeding volume articles, and 13 book chapters. His research group presented more than 220 conference papers on the National and International Conferences organized globally. His research group presented more than 235 conference papers on the National and International Conferences organized globally. He has received funding from DOE, NSF, ONR, ARMY, Reconnaissance Office, NRO, NASA, AESF, DOT and private companies. Dr. Popov has been included in the lists in 2014 and 2015 of ISI Highly Cited Researchers, which represents a world’s leading scientist, according to Tomson Reuters. According to Scholar Commons, his papers were accessed more than 53,500 times.
Affiliations and expertise
Carolina Distinguished Professor and Director of the Centre for Electrochemical Engineering, Department of Chemical Engineering, University of South Carolina, Columbia, SC, USARead Corrosion Engineering on ScienceDirect