Corrosion Failures

Provides corrosion basics in a lucid manner to students and working professionals and over 80 corrosion-failure analysis case studies

• Correlates Failure Analysis with Corrosion Science

• Exclusively provides corrosion-related failure analysis case histories in one place in a convenient format

• One-stop shop for both science and real time occurrence of the phenomenon of corrosion

• Full coverage of all MOC, Materials of Construction, used for process equipments

• Simple but Lucid presentation of Failure Analysis procedure

Auteur

K. Elayaperumal has close to 50 years of experience in Corrosion and Metallurgical Analysis. Since 1979 he has been a Corrosion & Metallurgical Consultant extending advisory Consultancy Services in the areas of Corrosion Prevention, Materials Selection, Failure Analysis, Water treatment etc. as related to Process Industry. He is the recipient of the National Metallurgist Award instituted by Ministry of Iron and Steel, Government of India, for contribution in Corrosion Prevention and Failure Analysis and also the Life Time Achievement Award from NACE International India Chapter.

V. S. Raja is currently a professor in the Department of Metallurgical Engineering and Materials Science at the Indian Institute of Technology Bombay, Mumbai, India. He has guided about 20 doctoral and 100 master's students in Corrosion and has been a Consultant to over 50 industries; has over 120 publications in various peer reviewed journals & books and also delivered over 100 plenary, keynote and invited talks in conferences. He is a recipient of Meritorious award by NACE international India Section and Excellence in Teaching award by IIT Bombay and a Fellow of NACE International and Indian Institute of Metals.

Contenu

About the Authors xiii

Foreword xv

Preface xvii

1 Introduction 1

1.1 The Phenomenon of Corrosion 1

1.2 Importance of Corrosion 2

1.2.1 Cost of Corrosion: Direct and Indirect 2

1.3 The Purpose and Format of the Book 6

References 7

2 Thermodynamics and Kinetics of Electrochemical Corrosion 9

2.1 Introduction 9

2.2 Thermodynamics 10

2.2.1 Corrosion Reactions and Gibbs Free Energy Change 10

2.2.2 Electrochemical Nature of Corrosion 11

2.2.3 Summary 16

2.3 Kinetics of Corrosion 17

2.3.1 Description of a Corrosion System 18

2.3.2 Predicting Corrosion 19

2.3.3 Passivity 21

2.3.4 Summary 22

2.4 Corrosion Evaluation and Monitoring 23

2.4.1 Electrochemical Techniques 24

2.4.2 Non-electrochemical Techniques 26

References 27

3 Forms of Corrosion 29

3.1 Introduction 29

3.2 Uniform Corrosion 30

3.3 Galvanic Corrosion 31

3.3.1 Factors Affecting Galvanic Corrosion 31

3.3.2 Controlling Galvanic Corrosion 34

3.4 Pitting Corrosion 35

3.4.1 Pitting Process and Pitting Morphology 35

3.4.2 Factors Affecting Pitting Corrosion 35

3.4.3 Controlling Pitting Corrosion 38

3.5 Differential Aeration-Assisted Corrosion (Crevice Under Deposit and Water-Line Corrosion) 39

3.5.1 Characteristics of Differential Aeration Corrosion 39

3.5.2 Factors Affecting Differential Aeration Corrosion 40

3.5.3 Differential Aeration Corrosion Control 41

3.6 Intergranular Corrosion 41

3.6.1 IGC of Stainless Steels 41

3.6.2 Weld Decay of Stainless Steels 45

3.7 Selective Dissolution/Selective Attack 47

3.7.1 Characteristics of Selective Dissolution 47

3.7.2 Dezincification 47

3.7.3 Graphitic Corrosion 49

3.8 Flow-Assisted/Erosion/Cavitation Corrosion 50

3.8.1 Flow-Assisted Corrosion (FAC) 50

3.8.2 Erosion Corrosion 51

3.8.3 Cavitation Damage 55

3.9 Stress Corrosion Cracking 55

3.9.1 Characteristics of SCC 56

3.9.2 Effect of SCC on Mechanical Properties 57

3.9.3 Factors Affecting SCC 59

3.9.4 Controlling SCC 63

3.10 Hydrogen Damage 63

3.10.1 Low Temperature Hydrogen-Induced Cracking 63

3.10.2 High Temperature Hydrogen Damage/Decarburization 67

3.11 Stray Current Corrosion 68

3.12 High Temperature Corrosion 70

3.12.1 Oxidation 70

3.12.2 Sulfidation 71

3.12.3 Hot Corrosion 71

3.12.4 Chloridation 71

3.12.5 Carburization/Metal Dusting 72

References 72

4 Materials of Construction for Chemical Process Industries 75

4.1 Introduction 75

4.2 Cast Irons 76

4.3 Carbon Steels 78

4.3.1 Corrosion 79

4.3.2 Stress Corrosion Cracking Including Hydrogen Cracking and Sulfide Stress Cracking 80

4.3.3 Caustic Stress Corrosion Cracking 81

4.3.4 Favorable and Unfavorable Points in Using Carbon Steel as MOC 82

4.4 Low Alloy Steels 82

4.5 Stainless Steels 86

4.5.1 Ferritic/Martensitic Stainless Steels 87

4.5.2 Austenitic Stainless Steels 88

4.5.3 Super Austenitic Stainless Steels 92

4.5.4 Duplex Stainless Steels 94

4.6 Nickel Base Alloys 96

4.7 Copper Base Alloys 96

4.8 Titanium 99

4.9 Aluminum Alloys 100

4.10 Nonmetallic Materials 102

4.11 Ceramics/Inorganic Oxide Glasses 103

4.12 Organic Polymers/Plastics 103

4.13 Materials Selection for Corrosion Prevention in Hydrocarbon Service 104

4.13.1 Materials Selection as per NACE MR0175 107

References 109 5 Failure Analysis Procedure with Reference to Corrosion Failures 111&l...