Corrosion Engineering : Principles and Practice

**The Latest Methods for Preventing and Controlling Corrosion in All Types of Materials and Applications** Now you can turn to __Corrosion Engineering__ for expert coverage of the theory and current practices you need to understand water, atmospheric, and high-temperature corrosion processes. This comprehensive resource explains step-by-step how to prevent and control corrosion in all types of metallic materials and applications-from steel and aluminum structures to pipelines. Filled with 300 illustrations, this skills-building guide shows you how to utilize advanced inspection and monitoring methods for corrosion problems in infrastructure, process and food industries, manufacturing, and military industries. Authoritative and complete, __Corrosion Engineering__ features: * Expert guidance on corrosion prevention and control techniques * Hands-on methods for inspection and monitoring of corrosion problems * New methods for dealing with corrosion * A review of current practice, with numerous examples and calculations **Inside This Cutting-Edge Guide to Corrosion Prevention and Control** • Introduction: Scope and Language of Corrosion • Electrochemistry of Corrosion • Environments: Atmospheric Corrosion • Corrosion by Water and Steam • Corrosion in Soils • Reinforced Concrete • High-Temperature Corrosion • Materials and How They Corrode: Engineering Materials • Forms of Corrosion • Methods of Control: Protective Coatings • Cathodic Protection • Corrosion Inhibitors • Failure Analysis and Design Considerations • Testing and Monitoring: Corrosion Testing and Monitoring Contents......Page 5 Preface......Page 15 1.1 Why Study Corrosion?......Page 17 1.2 The Study of Corrosion......Page 18 1.3 Needs for Corrosion Education......Page 21 1.4 The Functions and Roles of a Corrosion Engineer......Page 24 1.5 The Corrosion Engineer’s Education......Page 27 1.6 Strategic Impact and Cost of Corrosion Damage......Page 29 References......Page 33 2.1 Why Metals Corrode......Page 35 2.2 Matter Building Blocks......Page 38 2.3 Acidity and Alkalinity (pH)......Page 44 2.4.1 Corrosion in Acids......Page 47 2.4.2 Corrosion in Neutral and Alkaline Solutions......Page 48 Reference......Page 49 3.1 Electrochemical Reactions......Page 51 3.2 Anodic Processes......Page 54 3.3 Faraday’s Law......Page 55 3.4 Cathodic Processes......Page 56 3.5 Surface Area Effect......Page 61 Reference......Page 63 4.1 Free Energy......Page 65 4.2 Standard Electrode Potentials......Page 67 4.3 Nernst Equation......Page 70 4.4.1 The Aluminum-Air Power Source......Page 71 4.4.2 Detailed Calculations......Page 75 4.5 Reference Half-Cells (Electrodes)......Page 78 4.5.2 Silver/Silver Chloride Reference Electrode......Page 82 4.5.3 Copper/Copper Sulfate Reference Electrode......Page 84 4.6 Measuring the Corrosion Potential......Page 87 4.7 Measuring pH......Page 88 4.7.1 Glass Electrodes......Page 89 4.8 Potential-pH Diagram......Page 90 4.8.1 E-pH Diagram of Water......Page 91 4.8.2 E-pH Diagrams of Metals......Page 92 References......Page 100 5.1 What Is Overpotential?......Page 101 5.2 Activation Polarization......Page 102 5.3 Concentration Polarization......Page 106 5.4.1 Water Resistivity Measurements......Page 110 5.4.2 Soil Resistivity Measurements......Page 113 5.5.1 Activation Controlled Processes......Page 119 5.5.2 Concentration Controlled Processes......Page 120 5.6.1 Electrochemical Polarization Corrosion Testing......Page 123 5.6.2 Corrosion Monitoring......Page 137 5.6.3 Cathodic Protection......Page 150 5.6.4 Anodic Protection......Page 151 5.6.5 Aluminum Anodizing......Page 153 5.6.6 Chloride Extraction......Page 158 References......Page 160 6.1 Recognizing Corrosion......Page 163 6.2 General or Uniform Attack......Page 167 6.3.1 Pitting Corrosion......Page 171 6.3.2 Crevice Corrosion......Page 180 6.3.3 Galvanic Corrosion......Page 191 6.3.4 Intergranular Corrosion......Page 196 6.3.5 Dealloying......Page 197 6.3.6 Hydrogen-Induced Cracking......Page 199 6.3.7 Hydrogen Blistering......Page 200 6.4 Velocity Induced Corrosion......Page 201 6.4.1 Erosion–Corrosion......Page 204 6.4.2 Cavitation......Page 208 6.5 Mechanically Assisted Corrosion......Page 210 6.5.1 Stress Corrosion Cracking......Page 213 6.5.2 Corrosion Fatigue......Page 217 6.5.3 Fretting Corrosion......Page 219 References......Page 221 7.1 Introduction......Page 223 7.2.1 Temperature Effects......Page 225 7.2.2 Fluid Velocity Effects......Page 226 7.2.3 Impurities in the Environment......Page 227 7.2.5 Presence of Stray Currents......Page 229 7.3 Identifying the Corrosion Factors......Page 232 7.4 Examples of Corrosion Cells......Page 240 7.4.1 Galvanic Cells......Page 243 7.4.2 Concentration Cells......Page 247 7.4.3 Differential Aeration: Oxygen Concentration Cells......Page 249 7.4.4 Temperature Cells......Page 251 7.4.5 Stray Current Cells......Page 253 7.4.6 Stress Cells......Page 255 7.4.7 Surface Film Cells......Page 259 7.4.8 Microbial Corrosion Cells......Page 261 7.5 Corrosion Avoidance......Page 262 7.5.2 Crevice Corrosion Mitigation......Page 263 7.5.5 Mitigation of Stress Corrosion Cracking......Page 264 7.6 Visualizing Corrosion Cells......Page 266 References......Page 270 8.2 Corrosion and Water Quality and Availability......Page 273 8.2.1 Corrosion Impact......Page 274 8.2.2 Corrosion Management......Page 276 8.2.3 Condition Assessment Techniques......Page 281 8.3.1 Natural Waters......Page 284 8.3.2 Treated Waters......Page 300 8.4.1 Once-Through Systems......Page 303 8.4.2 Recirculated Systems......Page 304 8.4.3 Heat Exchangers......Page 307 8.5.1 Treatment of Boiler Feedwater Makeup......Page 310 8.5.2 Fossil Fuel Steam Plants......Page 312 8.5.3 Supercritical Steam Plants......Page 313 8.5.4 Waste Heat Boilers......Page 314 8.5.5 Nuclear Boiling Water Reactors......Page 315 8.5.6 Nuclear Pressurized Water Reactors......Page 316 8.5.7 Corrosion Costs to the Power Industry......Page 318 8.6 Water Treatment......Page 323 8.6.1 Corrosion Inhibitors......Page 325 8.6.3 Microorganisms......Page 327 8.7 Scaling Indices......Page 329 8.7.1 Langelier Saturation Index......Page 330 8.7.2 Other Indices......Page 332 8.8 Ion-Association Model......Page 334 8.8.1 Limiting Halite Deposition in a Wet High-Temperature Gas Well......Page 336 8.8.2 Identifying Acceptable Operating Range for Ozonated Cooling Systems......Page 337 8.8.3 Optimizing Calcium Phosphate Scale Inhibitor Dosage in a High-TDS Cooling System......Page 342 References......Page 343 9.1 Introduction......Page 345 9.2.1 Industrial......Page 346 9.2.3 Rural......Page 347 9.2.4 Indoor......Page 349 9.3 Factors Affecting Atmospheric Corrosion......Page 350 9.3.1 Relative Humidity and Dew Point......Page 354 9.3.2 Pollutants......Page 355 9.3.3 Deposition of Aerosol Particles......Page 356 9.3.4 Deicing Salts......Page 357 9.4.1 Time of Wetness......Page 365 9.4.3 Airborne Chlorides......Page 366 9.4.4 Atmospheric Corrosivity......Page 369 9.5.1 Environmental Severity Index......Page 374 9.5.3 Maps of Atmospheric Corrosivity......Page 378 9.6 Atmospheric Corrosion Tests......Page 382 9.7.1 Iron, Steel, and Stainless Steel......Page 386 9.7.2 Copper and Copper Alloys......Page 391 9.7.3 Nickel and Nickel Alloys......Page 392 9.7.4 Aluminum and Aluminum Alloys......Page 393 9.7.5 Zinc and Zinc Alloys......Page 395 9.7.6 Polymeric Materials......Page 397 References......Page 399 10.2 Corrosion in Soils......Page 401 10.2.1 Soil Classification......Page 403 10.2.2 Soil Parameters Affecting Corrosivity......Page 405 10.2.3 Soil Corrosivity Classifications......Page 407 10.2.4 Auxiliary Effects of Corrosion Cells......Page 410 10.2.5 Examples of Buried Systems......Page 414 10.2.6 Corrosion of Materials Other Than Steel......Page 419 10.3 Microbiologically Influenced Corrosion......Page 423 10.3.1 Planktonic or Sessile......Page 425 10.3.2 Microbes Classification......Page 427 10.3.3 Monitoring Microbiologically Influenced Corrosion......Page 432 References......Page 444 11.1 Materials Selection......Page 447 11.2.1 Multiple Forms of Corrosion......Page 449 11.2.2 Multiple Material/Environment Combinations......Page 450 11.2.3 Precision of Corrosion Data......Page 453 11.2.4 Complexity of Materials/Performance Interactions......Page 454 11.3 Selection Compromises......Page 456 11.3.1 Life-Cycle Costing......Page 457 11.3.2 Condition Assessment......Page 459 11.4 Materials Selection Road Map......Page 461 11.4.1 Identify Initial Slate of Candidate Materials......Page 462 11.4.3 Conduct Environmental Assessment......Page 463 11.4.4 Evaluate Materials Based on Potential Corrosion Failure Modes......Page 466 11.5 Design Considerations......Page 467 11.5.1 Designing Adequate Drainage......Page 470 11.5.2 Adequate Joining and Attachments......Page 475 11.6.1 Test Objectives......Page 479 11.6.2 Test Standards......Page 480 11.6.3 Cabinet Testing......Page 487 References......Page 490 12.1 Risk Assessment......Page 493 12.2 Risk Analysis......Page 494 12.3 Risk and Corrosion Control......Page 497 12.4 Key Performance Indicators......Page 500 12.4.1 Cost of Corrosion Key Performance Indicator......Page 501 12.4.2 Corrosion Inhibition Level Key Performance Indicator......Page 502 12.4.4 Selecting Key Performance Indicators......Page 504 12.5.1 Hazard and Operability......Page 507 12.5.2 Failure Modes, Effects, and Criticality Analysis......Page 509 12.5.3 Risk Matrix Methods......Page 511 12.5.4 Fault Tree Analysis......Page 512 12.5.5 Event Tree Analysis......Page 516 12.6 Risk-Based Inspection......Page 519 12.6.2 Consequence of Failure Assessment......Page 520 12.6.3 Application of Risk-Based Inspection......Page 521 12.7 Industrial Example: Transmission Pipelines......Page 523 12.7.1 External Corrosion Damage Assessment......Page 528 12.7.2 Internal Corrosion Damage Assessment......Page 531 12.7.4 In-Line Inspection......Page 534 References......Page 538 13.1 Cathodic Protection Historical Notes......Page 541 13.2 How Cathodic Protection Works in Water......Page 542 13.2.1 Sacrificial Cathodic Protection......Page 543 13.2.2 Impressed Current Cathodic Protection......Page 545 13.3 How Cathodic Protection Works in Soils......Page 548 13.3.2 Impressed Current Cathodic Protection......Page 552 13.3.3 Anode Beds......Page 554 13.3.4 Anode Backfill......Page 556 13.4 How Cathodic Protection Works in Concrete......Page 560 13.4.1 Impressed Current Cathodic Protection......Page 561 13.4.2 Sacrificial Cathodic Protection......Page 564 13.5.1 Reference Electrodes......Page 566 13.5.2 Anodes......Page 569 13.5.3 Rectified Current Sources......Page 577 13.5.4 Other Current Sources......Page 579 13.5.5 Wires and Cables......Page 580 13.6 Potential to Environment......Page 581 13.7 Current Requirement Tests......Page 582 13.7.1 Tests for a Coated System......Page 583 13.8 Stray Current Effects......Page 585 13.9.1 Close Interval Potential Surveys......Page 587 13.9.2 Pearson Survey......Page 589 13.9.3 Direct and Alternating Current Voltage Gradient Surveys......Page 592 13.9.4 Corrosion Coupons......Page 593 13.10 Simulation and Optimization of Cathodic Protection Designs......Page 594 13.10.1 Modeling Ship Impressed Current Cathodic Protection......Page 595 13.10.2 Modeling Cathodic Protection in the Presence of Interference......Page 598 References......Page 601 14.1 Types of Coatings......Page 603 14.2 Why Coatings Fail......Page 604 14.3 Soluble Salts and Coating Failures......Page 608 14.4 Economic Aspects of Coatings Selection and Maintenance......Page 614 14.5.1 Coating Functionality......Page 619 14.5.2 Basic Components......Page 626 14.6.2 Corrosion Prevention Compounds......Page 631 14.6.3 Volatile Corrosion Inhibitors......Page 636 14.7.1 Hydraulic Cement......Page 639 14.7.2 Ceramics and Glass......Page 640 14.7.4 Phosphatizing......Page 641 14.7.7 Passive Films......Page 642 14.8.1 Electroplating......Page 643 14.8.2 Electroless Plating......Page 645 14.8.4 Cladding......Page 646 14.8.5 Metallizing (Thermal Spray)......Page 647 14.9 Coating Inspection and Testing......Page 654 14.9.1 Condition of the Substrate......Page 655 14.9.3 Coating Inspection......Page 657 14.9.4 Laboratory Testing......Page 663 14.9.5 Holiday Detection......Page 668 14.10.1 Principles of Coating Adhesion......Page 670 14.10.2 Abrasive Cleaning......Page 671 14.10.3 Water Jetting......Page 674 14.10.5 Other Surface Preparation Methods......Page 675 References......Page 677 15.1 Introduction......Page 679 15.2.1 Standard Free Energy of Formation......Page 682 15.2.2 Vapor Species Diagrams......Page 685 15.2.3 2D Isothermal Stability Diagrams......Page 689 15.3 Kinetic Principles......Page 691 15.3.1 Scale as a Diffusion Barrier......Page 692 15.3.2 Basic Kinetic Models......Page 694 15.3.3 Pilling-Bedworth Ratio......Page 696 15.4 Practical High-Temperature Corrosion Problems......Page 699 15.4.1 Oxidation......Page 700 15.4.2 Sulfidation......Page 706 15.4.3 Carburization......Page 716 15.4.4 Metal Dusting......Page 720 15.4.5 Nitridation......Page 721 15.4.7 Fuel Ash and Salt Deposits......Page 722 15.4.8 Corrosion by Molten Salts......Page 724 15.4.9 Corrosion in Liquid Metals......Page 725 References......Page 726 A: Historical Perspective......Page 727 References......Page 730 B: Periodic Table......Page 731 A.1 How to Read This Table......Page 733 A.2 Using the Table......Page 739 A......Page 741 B......Page 743 C......Page 744 E......Page 750 F......Page 752 G......Page 753 H......Page 754 I......Page 755 L......Page 756 M......Page 757 N......Page 759 P......Page 760 R......Page 762 S......Page 763 T......Page 766 W......Page 768 Y......Page 769 Z......Page 770 Publisher's Products purchased from Third Party sellers are not guaranteed by the publisher for quality, authenticity, or access to any online entitlements included with the product. The Latest Methods for Preventing and Controlling Corrosion in All Types of Materials and Applications Now you can turn to Corrosion Engineering for expert coverage of the theory and current practices you need to understand water, atmospheric, and high-temperature corrosion processes. This comprehensive resource explains step-by-step how to prevent and control corrosion in all types of metallic materials and applications-from steel and aluminum structures to pipelines. Filled with 300 illustrations, this skills-building guide shows you how to utilize advanced inspection and monitoring methods for corrosion problems in infrastructure, process and food industries, manufacturing, and military industries. Authoritative and complete, Corrosion Engineering Inside This Cutting-Edge Guide to Corrosion Prevention and Control Scope and Language of Corrosion Electrochemistry of Corrosion Atmospheric Corrosion Corrosion by Water and Steam Corrosion in Soils Reinforced Concrete High-Temperature Corrosion Materials and How They Engineering Materials Forms of Corrosion Methods of Protective Coatings Cathodic Protection Corrosion Inhibitors Failure Analysis and Design Considerations Testing and Corrosion Testing and Monitoring "Turn to Corrosion Engineering for expert coverage of the theory and current practices you need to understand water, atmospheric and high-temperature corrosion processes. This comprehensive resource explains step-by-step how to prevent and control corrosion in all types of metallic materials and applications - from steel and aluminum structures to pipelines. Filled with 300 illustrations, this guide shows you how to utilize advanced inspection and monitoring methods for corrosion problems in infrastructure, process and food industries, manufacturing, and military industries."--Jacket