Corrosion Engineering

Principles and Solved Problems

2nd Edition - November 19, 2024
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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Corrosion 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.

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
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