Handbook of Corrosion Engineering.pdf

Handbook of

Corrosion

Engineering

Pierre R. Roberge

McGraw-Hill

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Library of Congress Cataloging-in-Publication Data

Roberge, Pierre R.

Handbook of Corrosion Engineering / Pierre R. Roberge.

p. cm.

Includes bibliographical references.

ISBN 0-07-076516-2 (alk. paper)

1. Corrosion and anti-corrosives.

I. Title.

TA418.74.R63

1999

620.1'1223 — dc21

99-35898

CIP

McGraw-Hill

reserved. Printed in the United States of America. Except as permit-

ted under the United States Copyright Act of 1976, no part of this

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means, or stored in a data base or retrieval system, without the prior

written permission of the publisher.

1 2 3 4 5 6 7 8 9

AGM/AGM

9 0 4 3 2 1 0 9

ISBN 0-07-076516-2

The sponsoring editor of this book was Robert Esposito. The editing

supervisor was David E. Fogarty, and the production supervisor was

Sherri Souffrance. This book was set in New Century Schoolbook by

Joanne Morbit and Paul Scozzari of McGraw-Hill’s Professional Book

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Contents

Preface ix

Acknowledgments

Introduction

1.1 The Cost of Corrosion

1.2 Examples of Catastrophic Corrosion Damage

1.3 The Influence of People

References

Chapter 1. Aqueous Corrosion

1.1 Introduction

1.2 Applications of Potential-pH Diagrams

1.3 Kinetic Principles

References

Chapter 2. Environments

2.1 Atmospheric Corrosion

2.2 Natural Waters

2.3 Seawater

129

2.4 Corrosion in Soils

142

2.5 Reinforced Concrete

154

2.6 Microbes and Biofouling

187

References

216

Chapter 3. High-Temperature Corrosion

221

3.1 Thermodynamic Principles

222

3.2 Kinetic Principles

229

3.3 Practical High-Temperature Corrosion Problems

237

References

265

Contents

Chapter 4. Modeling, Life Prediction and Computer Applications

267

4.1 Introduction

267

4.2 Modeling and Life Prediction

268

4.3 Applications of Artificial Intelligence

303

4.4 Computer-Based Training or Learning

322

4.5 Internet and the Web

324

References

326

Chapter 5. Corrosion Failures

331

5.1 Introduction

332

5.2 Mechanisms, Forms, and Modes of Corrosion Failures

332

5.3 Guidelines for Investigating Corrosion Failures

359

5.4 Prevention of Corrosion Damage

360

5.5 Case Histories in Corrosion Failure Analysis

368

References

369

Chapter 6. Corrosion Maintenance Through Inspection And Monitoring

371

6.1 Introduction

372

6.2 Inspection

374

6.3 The Maintenance Revolution

6.4 Monitoring and Managing Corrosion Damage

383

406

6.5 Smart Sensing of Corrosion with Fiber Optics

448

6.6 Non-destructive Evaluation (NDE)

461

References

481

Chapter 7. Acceleration and Amplification of Corrosion Damage

485

7.1 Introduction

486

7.2 Corrosion Testing

488

7.3 Surface Characterization

562

References

574

Chapter 8. Materials Selection

577

8.1 Introduction

578

8.2 Aluminum Alloys

584

8.3 Cast Irons

612

8.4 Copper Alloys

622

8.5 High-Performance Alloys

664

8.6 Refractory Metals

692

8.7 Stainless Steels

710

8.8 Steels

736

8.9 Titanium

748

8.10 Zirconium

769

References

777

Chapter 9. Protective Coatings

781

9.1 Introduction

781

9.2 Coatings and Coating Processes

782

9.3 Supplementary Protection Systems

829

9.4 Surface Preparation

831

References

831

Chapter 10. Corrosion Inhibitors

833

10.1 Introduction

833

10.2 Classification of Inhibitors

834

10.3 Corrosion Inhibition Mechanism

838

10.4 Selection of an Inhibitor System

860

References

861

Chapter 11. Cathodic Protection

863

11.1 Introduction

863

11.2 Sacrificial Anode CP Systems

871

11.3 Impressed Current Systems

878

11.4 Current Distribution and Interference Issues

886

11.5 Monitoring the Performance of CP Systems for Buried Pipelines

904

References

919

Chapter 12. Anodic Protection

921

12.1 Introduction

921

12.2 Passivity of Metals

923

12.3 Equipment Required for Anodic Protection

927

12.4 Design Concerns

930

12.5 Applications

932

12.6 Practical Example: Anodic Protection in the Pulp and Paper Industry

933

References

938

Appendix A. SI Units

939

Appendix B. Glossary

947

Appendix C. Corrosion Economics

1001

C.1 Introduction

1001

C.2 Cash Flows and Capital Budgeting Techniques

1002

C.3 Generalized Equation for Straight Line Depreciation

1004

C.4 Examples

1006

C.5 Summary

1009

References

1009

Appendix D. Electrochemistry Basics

1011

D.1 Principles of Electrochemistry

1011

D.2 Chemical Thermodynamics

1029

D.3 Kinetic Principles

1047

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