Metallurgy

9.

Corrosion and Degradation of Metals

9.1.

Electrochemical Principles of Corrosion

9.1.1.

Electrochemical Cells

9.1.1.1.

9.1.1.2.

Electrolytic Cells

9.1.1.3.

Mixed Potential Theory

9.1.2.

Electrode Potentials

9.1.2.1.

Standard Electrode Potentials

9.1.2.2.

Nernst Equation

9.1.2.3.

Reference Electrodes

9.1.3.

9.1.3.1.

Activation Polarization

9.1.3.2.

Concentration Polarization

9.1.3.3.

Resistance Polarization

9.1.4.

Pourbaix Diagrams

9.1.4.1.

Construction and Interpretation

9.1.4.2.

Immunity, Corrosion, and Passivation Regions

9.1.4.3.

Applications in Corrosion Prediction

9.1.5.

9.1.5.1.

Passive Film Formation

9.1.5.2.

Breakdown of Passivity

9.1.5.3.

9.2.

Forms of Corrosion

9.2.1.

Uniform Corrosion

9.2.1.1.

9.2.1.2.

Corrosion Rate Measurement

9.2.1.3.

Weight Loss Methods

9.2.2.

Galvanic Corrosion

9.2.2.1.

Galvanic Series in Seawater

9.2.2.2.

9.2.2.3.

Distance Effects

9.2.2.4.

Prevention Methods

9.2.3.

Crevice Corrosion

9.2.3.1.

Mechanism of Crevice Attack

9.2.3.2.

Factors Affecting Crevice Corrosion

9.2.3.3.

Design Considerations

9.2.4.

Pitting Corrosion

9.2.4.1.

9.2.4.2.

Pit Propagation

9.2.4.3.

Pitting Potential

9.2.4.4.

Chloride Effects

9.2.5.

Intergranular Corrosion

9.2.5.1.

9.2.5.2.

Carbide Precipitation

9.2.5.3.

Knife-Line Attack

9.2.6.

Stress Corrosion Cracking

9.2.6.1.

Required Conditions

9.2.6.2.

Crack Propagation Mechanisms

9.2.6.3.

Susceptible Alloy-Environment Combinations

9.2.7.

Corrosion Fatigue

9.2.7.1.

Interaction of Fatigue and Corrosion

9.2.7.2.

Environmental Effects on Fatigue Life

9.2.8.

Erosion-Corrosion

9.2.8.1.

Flow-Induced Corrosion

9.2.8.2.

Cavitation Damage

9.2.8.3.

Impingement Attack

9.2.9.

Fretting Corrosion

9.2.9.1.

Mechanism and Conditions

9.2.9.2.

Prevention Methods

9.2.10.

Microbiologically Influenced Corrosion

9.2.10.1.

Types of Microorganisms

9.2.10.2.

Mechanisms of Microbial Corrosion

9.2.10.3.

Detection and Prevention

9.3.

Corrosion Prevention and Control

9.3.1.

Material Selection

9.3.1.1.

Corrosion Resistance Properties

9.3.1.2.

Cost-Benefit Analysis

9.3.1.3.

Environmental Compatibility

9.3.2.

Design Considerations

9.3.2.1.

Avoiding Crevices

9.3.2.2.

Drainage Design

9.3.2.3.

Stress Concentration Avoidance

9.3.2.4.

Galvanic Compatibility

9.3.3.

Protective Coatings

9.3.3.1.

Barrier Coatings

9.3.3.1.1.

Organic Coatings

9.3.3.1.1.1.

9.3.3.1.1.2.

Polymer Coatings

9.3.3.1.2.

Inorganic Coatings

9.3.3.1.2.1.

Ceramic Coatings

9.3.3.1.2.2.

9.3.3.2.

Metallic Coatings

9.3.3.2.1.

9.3.3.2.1.1.

Hot-Dip Galvanizing

9.3.3.2.1.2.

Electrogalvanizing

9.3.3.2.2.

Aluminum Coatings

9.3.3.2.3.

Zinc-Rich Coatings

9.3.3.2.4.

Noble Metal Coatings

9.3.3.3.

Conversion Coatings

9.3.3.3.1.

9.3.3.3.2.

9.3.3.3.3.

9.3.4.

Cathodic Protection

9.3.4.1.

Sacrificial Anode Systems

9.3.4.1.1.

Anode Materials

9.3.4.1.2.

Design Calculations

9.3.4.1.3.

Installation Methods

9.3.4.2.

Impressed Current Systems

9.3.4.2.1.

Rectifier Systems

9.3.4.2.2.

Anode Materials

9.3.4.2.3.

Current Distribution

9.3.5.

Anodic Protection

9.3.5.1.

Principles and Applications

9.3.5.2.

Passivation Maintenance

9.3.6.

Corrosion Inhibitors

9.3.6.1.

Anodic Inhibitors

9.3.6.2.

Cathodic Inhibitors

9.3.6.3.

Mixed Inhibitors

9.3.6.4.

Vapor Phase Inhibitors

9.3.7.

Environmental Control

9.3.7.1.

9.3.7.2.

9.3.7.3.

Temperature Control

9.3.7.4.

Humidity Control

9.4.

High-Temperature Oxidation

9.4.1.

Oxidation Mechanisms

9.4.1.1.

Parabolic Rate Law

9.4.1.2.

Linear Rate Law

9.4.1.3.

Logarithmic Rate Law

9.4.2.

Oxide Scale Formation

9.4.2.1.

Scale Structure

9.4.2.2.

9.4.2.3.

9.4.3.

Protective Oxide Formation

9.4.3.1.

9.4.3.2.

9.4.3.3.

9.4.4.

Factors Affecting Oxidation

9.4.4.1.

Temperature Effects

9.4.4.2.

Oxygen Partial Pressure

9.4.4.3.

Alloying Element Effects

9.4.5.

High-Temperature Corrosion

9.4.5.1.

9.4.5.2.

9.4.5.3.

9.4.5.4.

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10. Metallurgical Characterization and Testing