Corrosion Science and Engineering

  1. Forms of Corrosion
    1. Classification of Corrosion Types
      1. Morphological Classification
        1. Mechanistic Classification
          1. Environmental Classification
          2. Uniform Corrosion
            1. Mechanism and Characteristics
              1. Even Material Loss
                1. Predictable Behavior
                2. Surface Morphology
                  1. Uniform Thinning
                    1. Surface Roughening
                    2. Factors Influencing Uniform Corrosion
                      1. Environmental Conditions
                        1. Material Properties
                          1. Surface Condition
                          2. Measurement and Assessment
                            1. Weight Loss Methods
                              1. Thickness Measurements
                              2. Prevention Strategies
                              3. Galvanic Corrosion
                                1. Fundamental Principles
                                  1. Potential Difference Requirements
                                    1. Galvanic Coupling Effects
                                    2. Factors Affecting Galvanic Corrosion
                                      1. Potential Difference Magnitude
                                        1. Area Ratio Effects
                                          1. Distance Between Metals
                                            1. Electrolyte Conductivity
                                            2. Area Effect Considerations
                                              1. Large Cathode-Small Anode
                                                1. Large Anode-Small Cathode
                                                2. Environmental Factors
                                                  1. Electrolyte Composition
                                                    1. Temperature Effects
                                                      1. Oxygen Availability
                                                      2. Prevention and Control
                                                        1. Material Selection
                                                          1. Electrical Isolation
                                                            1. Sacrificial Anodes
                                                              1. Coatings and Barriers
                                                            2. Localized Corrosion
                                                              1. Pitting Corrosion
                                                                1. Pitting Mechanisms
                                                                  1. Passive Film Breakdown
                                                                    1. Autocatalytic Process
                                                                      1. Pit Chemistry Development
                                                                      2. Initiation Factors
                                                                        1. Chloride Ion Role
                                                                          1. Surface Defects
                                                                            1. Inclusions and Precipitates
                                                                            2. Propagation Mechanisms
                                                                              1. Anodic Dissolution
                                                                                1. Cathodic Reactions
                                                                                  1. pH Changes
                                                                                  2. Morphology and Characteristics
                                                                                    1. Pit Shape and Size
                                                                                      1. Depth-to-Diameter Ratio
                                                                                      2. Susceptible Materials
                                                                                        1. Stainless Steels
                                                                                          1. Aluminum Alloys
                                                                                            1. Other Passive Metals
                                                                                            2. Environmental Factors
                                                                                              1. Chloride Concentration
                                                                                                1. pH Effects
                                                                                                  1. Temperature Influence
                                                                                                  2. Assessment Methods
                                                                                                    1. Pitting Potential Measurements
                                                                                                      1. Pit Depth Measurements
                                                                                                        1. Pitting Factor Calculation
                                                                                                      2. Crevice Corrosion
                                                                                                        1. Crevice Corrosion Mechanism
                                                                                                          1. Differential Aeration Cells
                                                                                                            1. Oxygen Depletion
                                                                                                              1. Chemistry Changes
                                                                                                              2. Crevice Geometry Effects
                                                                                                                1. Gap Width Requirements
                                                                                                                  1. Depth Considerations
                                                                                                                    1. Surface Contact
                                                                                                                    2. Initiation and Propagation
                                                                                                                      1. Incubation Period
                                                                                                                        1. Active Propagation
                                                                                                                          1. Stabilization
                                                                                                                          2. Susceptible Designs
                                                                                                                            1. Bolted Joints
                                                                                                                              1. Gasket Interfaces
                                                                                                                                1. Deposit-Covered Surfaces
                                                                                                                                2. Material Factors
                                                                                                                                  1. Alloy Composition
                                                                                                                                    1. Surface Finish
                                                                                                                                    2. Prevention Strategies
                                                                                                                                      1. Design Modifications
                                                                                                                                        1. Material Selection
                                                                                                                                          1. Sealants and Gaskets
                                                                                                                                        2. Filiform Corrosion
                                                                                                                                          1. Mechanism and Appearance
                                                                                                                                            1. Thread-Like Corrosion
                                                                                                                                              1. Advancing Head
                                                                                                                                                1. Inactive Tail
                                                                                                                                                2. Conditions for Occurrence
                                                                                                                                                  1. Humidity Requirements
                                                                                                                                                    1. Coating Defects
                                                                                                                                                      1. Substrate Preparation
                                                                                                                                                      2. Susceptible Systems
                                                                                                                                                        1. Coated Aluminum
                                                                                                                                                          1. Coated Steel
                                                                                                                                                          2. Prevention Methods
                                                                                                                                                        2. Metallurgically Influenced Corrosion
                                                                                                                                                          1. Intergranular Corrosion
                                                                                                                                                            1. Grain Boundary Chemistry
                                                                                                                                                              1. Segregation Effects
                                                                                                                                                                1. Precipitate Formation
                                                                                                                                                                2. Sensitization Phenomena
                                                                                                                                                                  1. Chromium Carbide Precipitation
                                                                                                                                                                    1. Chromium Depletion
                                                                                                                                                                      1. Temperature Effects
                                                                                                                                                                      2. Susceptible Alloy Systems
                                                                                                                                                                        1. Austenitic Stainless Steels
                                                                                                                                                                          1. Aluminum Alloys
                                                                                                                                                                            1. Nickel Alloys
                                                                                                                                                                            2. Weld Decay
                                                                                                                                                                              1. Heat-Affected Zone
                                                                                                                                                                                1. Thermal Cycles
                                                                                                                                                                                  1. Cooling Rate Effects
                                                                                                                                                                                  2. Testing Methods
                                                                                                                                                                                    1. Electrochemical Tests
                                                                                                                                                                                      1. Metallographic Examination
                                                                                                                                                                                      2. Prevention Strategies
                                                                                                                                                                                        1. Low Carbon Grades
                                                                                                                                                                                          1. Stabilized Alloys
                                                                                                                                                                                            1. Solution Annealing
                                                                                                                                                                                          2. Selective Leaching
                                                                                                                                                                                            1. Dealloying Mechanisms
                                                                                                                                                                                              1. Selective Dissolution
                                                                                                                                                                                                1. Residual Structure
                                                                                                                                                                                                2. Dezincification of Brass
                                                                                                                                                                                                  1. Plug-Type Dezincification
                                                                                                                                                                                                    1. Layer-Type Dezincification
                                                                                                                                                                                                      1. Factors Affecting Susceptibility
                                                                                                                                                                                                      2. Graphitic Corrosion of Cast Iron
                                                                                                                                                                                                        1. Iron Matrix Removal
                                                                                                                                                                                                          1. Graphite Retention
                                                                                                                                                                                                            1. Structural Weakening
                                                                                                                                                                                                            2. Other Dealloying Systems
                                                                                                                                                                                                              1. Dealuminification
                                                                                                                                                                                                                1. Denickelification
                                                                                                                                                                                                                2. Prevention Methods
                                                                                                                                                                                                                  1. Alloy Modification
                                                                                                                                                                                                                    1. Inhibitor Addition
                                                                                                                                                                                                                      1. Cathodic Protection
                                                                                                                                                                                                                  2. Mechanically Assisted Corrosion
                                                                                                                                                                                                                    1. Stress Corrosion Cracking
                                                                                                                                                                                                                      1. SCC Requirements
                                                                                                                                                                                                                        1. Susceptible Material
                                                                                                                                                                                                                          1. Specific Environment
                                                                                                                                                                                                                            1. Tensile Stress
                                                                                                                                                                                                                            2. Crack Initiation Mechanisms
                                                                                                                                                                                                                              1. Anodic Dissolution
                                                                                                                                                                                                                                1. Film Rupture
                                                                                                                                                                                                                                  1. Hydrogen Embrittlement
                                                                                                                                                                                                                                  2. Crack Propagation
                                                                                                                                                                                                                                    1. Continuous Crack Growth
                                                                                                                                                                                                                                      1. Discontinuous Crack Growth
                                                                                                                                                                                                                                      2. Common SCC Systems
                                                                                                                                                                                                                                        1. Austenitic Stainless Steel-Chlorides
                                                                                                                                                                                                                                          1. Carbon Steel-Caustic
                                                                                                                                                                                                                                            1. Brass-Ammonia
                                                                                                                                                                                                                                            2. Stress Sources
                                                                                                                                                                                                                                              1. Applied Stresses
                                                                                                                                                                                                                                                1. Residual Stresses
                                                                                                                                                                                                                                                  1. Thermal Stresses
                                                                                                                                                                                                                                                  2. Environmental Factors
                                                                                                                                                                                                                                                    1. Temperature Effects
                                                                                                                                                                                                                                                      1. Concentration Effects
                                                                                                                                                                                                                                                        1. pH Influence
                                                                                                                                                                                                                                                        2. Prevention Strategies
                                                                                                                                                                                                                                                          1. Stress Relief
                                                                                                                                                                                                                                                            1. Material Selection
                                                                                                                                                                                                                                                              1. Environmental Control
                                                                                                                                                                                                                                                            2. Corrosion Fatigue
                                                                                                                                                                                                                                                              1. Synergistic Effects
                                                                                                                                                                                                                                                                1. Mechanical Fatigue
                                                                                                                                                                                                                                                                  1. Corrosive Environment
                                                                                                                                                                                                                                                                  2. Crack Initiation
                                                                                                                                                                                                                                                                    1. Surface Pits
                                                                                                                                                                                                                                                                      1. Stress Concentrations
                                                                                                                                                                                                                                                                      2. Crack Growth Mechanisms
                                                                                                                                                                                                                                                                        1. Anodic Dissolution
                                                                                                                                                                                                                                                                          1. Hydrogen Effects
                                                                                                                                                                                                                                                                          2. Factors Affecting Corrosion Fatigue
                                                                                                                                                                                                                                                                            1. Stress Amplitude
                                                                                                                                                                                                                                                                              1. Frequency Effects
                                                                                                                                                                                                                                                                                1. Environmental Aggressivity
                                                                                                                                                                                                                                                                                2. Fatigue Life Reduction
                                                                                                                                                                                                                                                                                  1. Prevention Methods
                                                                                                                                                                                                                                                                                  2. Erosion-Corrosion
                                                                                                                                                                                                                                                                                    1. Mechanisms of Material Loss
                                                                                                                                                                                                                                                                                      1. Mechanical Erosion
                                                                                                                                                                                                                                                                                        1. Corrosive Attack
                                                                                                                                                                                                                                                                                          1. Synergistic Effects
                                                                                                                                                                                                                                                                                          2. Particle Erosion
                                                                                                                                                                                                                                                                                            1. Solid Particle Impact
                                                                                                                                                                                                                                                                                              1. Particle Size and Hardness
                                                                                                                                                                                                                                                                                              2. Cavitation Erosion
                                                                                                                                                                                                                                                                                                1. Bubble Collapse
                                                                                                                                                                                                                                                                                                  1. Pressure Fluctuations
                                                                                                                                                                                                                                                                                                  2. Susceptible Systems
                                                                                                                                                                                                                                                                                                    1. Piping Systems
                                                                                                                                                                                                                                                                                                      1. Pump Components
                                                                                                                                                                                                                                                                                                        1. Heat Exchangers
                                                                                                                                                                                                                                                                                                        2. Material Selection
                                                                                                                                                                                                                                                                                                          1. Design Considerations
                                                                                                                                                                                                                                                                                                          2. Fretting Corrosion
                                                                                                                                                                                                                                                                                                            1. Fretting Mechanisms
                                                                                                                                                                                                                                                                                                              1. Micro-Motion Effects
                                                                                                                                                                                                                                                                                                                1. Oxide Formation
                                                                                                                                                                                                                                                                                                                  1. Debris Generation
                                                                                                                                                                                                                                                                                                                  2. Contact Conditions
                                                                                                                                                                                                                                                                                                                    1. Normal Load
                                                                                                                                                                                                                                                                                                                      1. Slip Amplitude
                                                                                                                                                                                                                                                                                                                        1. Surface Roughness
                                                                                                                                                                                                                                                                                                                        2. Environmental Factors
                                                                                                                                                                                                                                                                                                                          1. Humidity Effects
                                                                                                                                                                                                                                                                                                                            1. Temperature Influence
                                                                                                                                                                                                                                                                                                                            2. Applications
                                                                                                                                                                                                                                                                                                                              1. Bolted Connections
                                                                                                                                                                                                                                                                                                                                1. Bearing Surfaces
                                                                                                                                                                                                                                                                                                                                  1. Wire Rope Systems
                                                                                                                                                                                                                                                                                                                                  2. Prevention Strategies
                                                                                                                                                                                                                                                                                                                                2. Environmentally Induced Cracking
                                                                                                                                                                                                                                                                                                                                  1. Hydrogen Embrittlement
                                                                                                                                                                                                                                                                                                                                    1. Hydrogen Sources
                                                                                                                                                                                                                                                                                                                                      1. Cathodic Charging
                                                                                                                                                                                                                                                                                                                                        1. Chemical Reactions
                                                                                                                                                                                                                                                                                                                                          1. Manufacturing Processes
                                                                                                                                                                                                                                                                                                                                          2. Hydrogen Uptake Mechanisms
                                                                                                                                                                                                                                                                                                                                            1. Surface Adsorption
                                                                                                                                                                                                                                                                                                                                              1. Absorption into Metal
                                                                                                                                                                                                                                                                                                                                                1. Diffusion Processes
                                                                                                                                                                                                                                                                                                                                                2. Embrittlement Mechanisms
                                                                                                                                                                                                                                                                                                                                                  1. Hydrogen-Enhanced Decohesion
                                                                                                                                                                                                                                                                                                                                                    1. Hydrogen-Enhanced Localized Plasticity
                                                                                                                                                                                                                                                                                                                                                      1. Hydride Formation
                                                                                                                                                                                                                                                                                                                                                      2. Susceptible Materials
                                                                                                                                                                                                                                                                                                                                                        1. High-Strength Steels
                                                                                                                                                                                                                                                                                                                                                          1. Titanium Alloys
                                                                                                                                                                                                                                                                                                                                                            1. Nickel Alloys
                                                                                                                                                                                                                                                                                                                                                            2. Testing Methods
                                                                                                                                                                                                                                                                                                                                                              1. Slow Strain Rate Tests
                                                                                                                                                                                                                                                                                                                                                                1. Constant Load Tests
                                                                                                                                                                                                                                                                                                                                                                2. Prevention Strategies
                                                                                                                                                                                                                                                                                                                                                                  1. Hydrogen Removal
                                                                                                                                                                                                                                                                                                                                                                    1. Material Selection
                                                                                                                                                                                                                                                                                                                                                                      1. Coating Applications
                                                                                                                                                                                                                                                                                                                                                                    2. Hydrogen-Induced Cracking
                                                                                                                                                                                                                                                                                                                                                                      1. HIC Mechanisms
                                                                                                                                                                                                                                                                                                                                                                        1. Hydrogen Accumulation
                                                                                                                                                                                                                                                                                                                                                                          1. Internal Pressure Buildup
                                                                                                                                                                                                                                                                                                                                                                            1. Crack Formation
                                                                                                                                                                                                                                                                                                                                                                            2. Blister Formation
                                                                                                                                                                                                                                                                                                                                                                              1. Surface Blisters
                                                                                                                                                                                                                                                                                                                                                                                1. Subsurface Defects
                                                                                                                                                                                                                                                                                                                                                                                2. Susceptible Materials
                                                                                                                                                                                                                                                                                                                                                                                  1. Pipeline Steels
                                                                                                                                                                                                                                                                                                                                                                                    1. Pressure Vessel Steels
                                                                                                                                                                                                                                                                                                                                                                                    2. Environmental Factors
                                                                                                                                                                                                                                                                                                                                                                                      1. Hydrogen Sulfide
                                                                                                                                                                                                                                                                                                                                                                                        1. Wet Conditions
                                                                                                                                                                                                                                                                                                                                                                                        2. Prevention Methods
                                                                                                                                                                                                                                                                                                                                                                                        3. Sulfide Stress Cracking
                                                                                                                                                                                                                                                                                                                                                                                          1. SSC Mechanisms
                                                                                                                                                                                                                                                                                                                                                                                            1. Hydrogen Sulfide Role
                                                                                                                                                                                                                                                                                                                                                                                              1. Stress Requirements
                                                                                                                                                                                                                                                                                                                                                                                              2. Material Susceptibility
                                                                                                                                                                                                                                                                                                                                                                                                1. Hardness Effects
                                                                                                                                                                                                                                                                                                                                                                                                  1. Microstructure Influence
                                                                                                                                                                                                                                                                                                                                                                                                  2. Environmental Conditions
                                                                                                                                                                                                                                                                                                                                                                                                    1. H2S Concentration
                                                                                                                                                                                                                                                                                                                                                                                                      1. pH Effects
                                                                                                                                                                                                                                                                                                                                                                                                        1. Temperature Influence
                                                                                                                                                                                                                                                                                                                                                                                                        2. Industry Standards
                                                                                                                                                                                                                                                                                                                                                                                                          1. NACE Requirements
                                                                                                                                                                                                                                                                                                                                                                                                            1. Material Specifications
                                                                                                                                                                                                                                                                                                                                                                                                            2. Prevention and Control

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                                                                                                                                                                                                                                                                                                                                                                                                        6. Corrosion in Specific Environments