Corrosion Chemistry

Scrivener Publishing 3 Winter Street, Suite 3 Salem, MA 01970 Scrivener Publishing Collections Editors James E. R. Couper Richard Erdlac Pradip Khaladkar Norman Lieberman W. Kent Muhlbauer S. A. Sherif Ken Dragoon Rafiq Islam Vitthal Kulkarni Peter Martin Andrew Y. C. Nee James G. Speight

Publishers at Scrivener Martin Scrivener (martin@scrivenerpublishing.com) Phillip Carmical (pcarmical@scrivenerpublishing.com)

Corrosion Chemistry

Volkan Cicek and Bayan Al-Numan

Scrivener

) WILEY

Copyright 2011 by Scrivener Publishing LLC. All rights reserved. Co-published by John Wiley & Sons, Inc. Hoboken, New Jersey, and Scrivener Publishing LLC, Salem, Massachusetts. Published simultaneously in Canada. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, scanning, or otherwise, except as permitted under Section 107 or 108 of the 1976 United States Copyright Act, without either the prior written permission of the Publisher, or authorization through payment of the appropriate per-copy fee to the Copyright Clearance Center, Inc., 222 Rosewood Drive, Danvers, MA 01923, (978) 750-8400, fax (978) 750-4470, or on the web at www.copyright.com. Requests to the Publisher for permission should be addressed to the Permissions Department, John Wiley & Sons, Inc., Ill River Street, Hoboken, NJ 07030, (201) 748-6011, fax (201) 748-6008, or online at http://www.wiley.com/go/permission. Limit of Liability/Disclaimer of Warranty: While the publisher and author have used their best efforts in preparing this book, they make no representations or warranties with respect to the accuracy or completeness of the contents of this book and specifically disclaim any implied warranties of merchantability or fitness for a particular purpose. No warranty may be created or extended by sales representatives or written sales materials. The advice and strategies contained herein may not be suitable for your situation. You should consult with a professional where appropriate. Neither the publisher nor author shall be liable for any loss of profit or any other commercial damages, including but not limited to special, incidental, consequential, or other damages. For general information on our other products and services or for technical support, please contact our Customer Care Department within the United States at (800) 7622974, outside the United States at (317) 572-3993 or fax (317) 572-4002. Wiley also publishes its books in a variety of electronic formats. Some content that appears in print may not be available in electronic formats. For more information about Wiley products, visit our web site at www.wiley.com. For more information about Scrivener products please visit www.scrivenerpublishing. com.

Library of Congress Cataloging-in-Publication ISBN 978-0-470-94307-6

Data:

Printed in the United States of America 10 9 8 7 6 5 4 3 2 1

Contents
List of tables Acknowledgements Preface 1. Corrosion and Its Definition 2. The Corrosion Process and Affecting Factors 3. Corrosion Types Based on Mechanism 3.1 Uniform Corrosion 3.2 Pitting Corrosion 3.3 Crevice Corrosion 3.4 Galvanic Corrosion 3.5 Intergranular Corrosion 3.6 Selective Corrosion 3.7 Erosion or Abrasion Corrosion 3.8 Cavitation Corrosion 3.9 Fretting Corrosion 3.10 Stress Corrosion Cracking 3.11 Microbial Corrosion 4. Corrosion Types of Based on the Media 4.1 Atmospheric Corrosion 4.2 Corrosion in Water 4.3 Corrosion in Soil 5. Nature of Protective Metal Oxide Films 6. Effect of Aggressive Anions on Corrosion 7. Corrosion Prevention Methods v ix xi xiii 01 03 07 07 08 09 10 11 12 12 12 13 13 13 15 15 18 20 23 27 31

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CONTENTS

8. Commonly Used Alloys and their Properties 8.1 Aluminum 2024 Alloy 8.2 Aluminum 7075 Alloy 8.3 Aluminum 6061 Alloy 9. Cost of Corrosion and Use of Corrosion Inhibitors 10. Types of Corrosion Inhibitors 10.1 Anodic Inhibitors 10.2 Cathodic Inhibitors 11. Chromates: Best Corrosion Inhibitors to Date 11.1 Limitations on the Use of Chromates due to Toxicity 11.2 Corrosion Inhibition Mechanism of Chromates 12. Chromate Inhibitor Replacements: Current and Potential Applications 12.1 Nitrites 12.2 Trivalent Chromium Compounds 12.3 Oxyanions Analogous to Chromate 12.4 Synergistic Use of Oxyanions Analogues of Chromate 13. Sol-Gels (Ormosils) as Chromate Inhibitor Replacements: Properties and Uses 13.1 Types of Sol-Gels 13.2 Corrosion Inhibition Mechanism of Sol-Gel Coatings 13.3 Synthesis of Sol-Gels 13.4 Incorporation of Corrosion Inhibitive Pigments to Sol-Gel Coatings 14. Corrosion in Engineering Materials 14.1 Introduction 14.2 Steel Structures 14.3 Concrete Structures

33 35 36 36 39 43 44 44 47 48 53 57 58 59 00 66 69 70 72 75 77 81 81 82 85

CONTENTS

vii

14.4 14.5 14.6 14.7

Protection against Corrosion in Construction Corrosion of Unbonded Prestressing Tendons Cathodic Protection Corrosion in Industrial Projects

95 116 120 135 145 173

References Index

List of Tables
1. Designations for Alloyed Wrought and Cast Aluminum Alloys 2. Chemical Composition of Aluminum Alloys 3. Chloride Limit for New Constructions 4. Calcium Nitrite Dosage

IX

Acknowledgements
First of all, I would like to express my sincere appreciation and gratefulness to Wiley-Scrivener Publications since they were eager to fund such a project at a time, when almost all academic publications in Iraq ceased. We all hope that the negative situation in Iraq is temporary and Iraq will take its place in the academic world in the near future once more. I also would like to acknowledge Dr. Bayan Al Numan for contributing to this book with a vast chapter "Corrosion in Engineering Materials," and graphic artist Khabbab Habib for his support when needed. I also would like to acknowledge my Ph.D. advisor, Dr. Allen W. Apblett, for his guidance, motivation, and inspiration throughout my Ph.D. education. His valuable advice, criticism, and encouragement have greatly helped me. I have benefited much from his broad range of knowledge, and his scientific approach. Thanks are also due to my father, my mom, my sister, my relatives, and friends for their moral support, and encouragement throughout the years. Finally, I am deeply indebted to my wife, Mine Cicek, for her unconditional love, patience, care, and sacrifice. Your moral support during this time, together with the enthusiasm that I got from our two lovely children, Furkan and Zehra, was invaluable to me.

XI

Preface
This book was written and published as a reference for engineers and a textbook for students, due to the necessity of such a book in the area of corrosion chemistry and corrosion science in general. Corrosion is, in essence, a chemical process, and it is crucial to understand the dynamics from a chemical perspective before proceeding with analyses, designs and solutions from engineering aspect. The opposite is also true in the sense that scientists should take into consideration the contemporary aspects of the issue as it relates to the daily life before proceeding with specifically designed theoretical solutions. Thus, this book is advised to both theoreticians and practitioners of corrosion alike. Corrosion costs billions of dollars to each and every single economy in the world however is only taught in the form of a single semester elective course and that is sometimes at undergraduate level since most probably it is a joint discipline that is associated with many others, thus does not belong to any major science altogether. Corrosion is associated primarily with major engineering sciences such as chemical engineering, civil engineering, petroleum engineering, mechanical engineering, metallurgical engineering, mining engineering among others and major fundamental sciences such as subdisciplines of physical, inorganic and analytical chemistry as well as physics and biology, e.g., electrochemistry, surface chemistry and physics, solution chemistry, crystalline and amorphous structures and solid state chemistry and physics in general, microbiology, etc. Hence, a reference book that summarizes the process with its contemporary aspects with respect to both scientific and xin

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PREFACE

engineering aspects was needed. Additionally, being such a joint discipline such a book should not overwhelm the reader with too much detail but only enough to understand the process as this was aimed in this book. In addition to be used as a reference, this book could be used as a textbook most conveniently for a single semester elective course; however, the period of the course could be adjusted to fit into a long or a short summer term as well as a complete year depending on the course. In the case that this book is used as a textbook for a full year course, using supplementary resources may be beneficial especially in the case of engineering sciences.