1 Corrosion and society 1
1.1 The lessons of history 1
1.2 The expense of corrosion 5
1.3 Social implications of corrosion 8
1.4 Corrosion and the environment 17
1.5 Concluding remarks 19
1.6 References 19
1.7 Bibliography 21
2 Enabling theory for aqueous corrosion 23
2.1 Energy: the rule of law 23
2.2 Matters of substance 26
2.3 Processes in solution 31
2.4 Metals: might and blight 34
2.5 Metals in the melting pot 35
2.6 Defects in metal structures 37
2.7 Electrical science 39
2.8 Glossary 44
2.9 Worked examples 45
2.10 Problems 47
2.11 Bibliography 48
3 Practical aqueous corrosion 49
3.1 Common apparatus 49
3.2 The experiments 51
3.3 Discussion 65
4 The theory of aqueous corrosion 69
4.1 Thermodynamics of corrosion reactions 71
4.2 The basic wet corrosion cell 75
4.3 Standard electrode potentials 81
4.4 Reference electrodes 85
4.5 Cell potential 87
4.6 Kinetics of corrosion reactions 91
4.7 Polarisation 95
4.8 Diffusion processes and the double layer 100
4.9 Mixed potential theory 102
4.10 Pourbaix diagrams 106
4.11 Three-electrode cells and E/lg i plots 111
4.12 Polarisation curves 120
4.13 Electrochemical impedance 124
4.14 References 128
4.15 Bibliography 129
5 Dissimilar metal corrosion 130
5.1 The galvanic series 135
5.2 Corrosion quantification 139
5.3 References 143
5.4 Bibliography 143
6 Selective attack 144
6.1 Grain boundary corrosion 145
6.2 Intergranular corrosion 147
6.3 Selective leaching 151
6.4 Microbiologically induced corrosion 156
6.5 References 160
6.6 Bibliography 160
7 Crevice and pitting corrosion: concentration cells 162
7.1 The mechanism of crevice corrosion 165
7.2 Pitting corrosion 168
7.3 Differential-aeration corrosion 169
7.4 Electrochemical techniques 173
7.5 Material susceptibility 186
7.6 References 187
7.7 Bibliography 190
8 Flow-induced corrosion 191
8.1 Fluid flow 191
8.2 Cavitation 196
8.3 Bibliography 197
9 Enabling theory for environment-sensitive cracking 199
9.1 Elasticity: stress and strain 199
9.2 The tensile test 201
9.3 Stress concentration 203
9.4 Linear elastic fracture mechanics 205
9.5 Fatigue 209
9.6 Bibliography 213
10 Environment-sensitive cracking 214
10.1 Stress-corrosion cracking 218
10.2 Environment-sensitive cracking: initiation 221
10.3 Environment-sensitive cracking: propagation 223
10.4 Environment-sensitive cracking: practical aspects 228
10.5 Corrosion fatigue 231
10.6 References 237
10.7 Bibliography 239
11 Corrosion management 240
11.1 Corrosion control 242
11.2 Primary and secondary corrosion mechanisms 243
11.3 The people factor 248
11.4 Knowledge-based systems 251
11.5 Concluding remarks 254
11.6 References 254
11.7 Bibliography 255
12 Corrosion control by design 256
12.1 How long do I expect it to last? 257
12.2 The ever-changing environment 259
12.3 Minimise bimetallic corrosion cells 261
12.4 Avoid differential-aeration cells 264
12.5 Tanks and pipe systems 270
12.6 Stray current corrosion 273
12.7 References 277
12.8 Bibliography 278
13 Corrosion control by environmental change 279
13.1 Atmospheric corrosion 280
13.2 Control of atmospheric corrosion 282
13.3 Modification of the electrolyte 286
13.4 Control of aqueous environments 294
13.5 Soil as an environment 299
13.6 References 300
13.7 Bibliography 301
14 Corrosion control by coatings 302
14.1 Paint systems 304
14.2 Paint characteristics 306
14.3 Paint types 308
14.4 Paint failure 319
14.5 Painting costs 322
14.6 Plastic coatings 323
14.7 Concrete coatings 325
14.8 Metallic coatings 327
14.9 Methods of metallic coating 328
14.10 Behaviour of metallic coatings 329
14.11 References 335
14.12 Bibliography 335
15 Corrosion properties of some metallic materials 336
15.1 Plain carbon and low alloy steels 338
15.2 Stainless steels 341
15.3 Cast irons 347
15.4 Aluminium and its alloys 348
15.5 Copper and its alloys 351
15.6 Titanium 356
15.7 Nickel and its alloys 361
15.8 Applications in water systems 364
15.9 Selection of materials 371
15.10 References 373
15.11 Bibliography 373
16 Cathodic and anodic protection 375
16.1 Theoretical basis 375
16.2 Sacrificial anode design 380
16.3 Sacrificial anode applications 387
16.4 Impressed current protection 393
16.5 Impressed current applications 395
16.6 Anodic protection 403
16.7 References 404
16.8 Bibliography 405
17 Corrosion at elevated temperatures 406
17.1 Metal oxides 408
17.2 Breakaway corrosion 413
17.3 Growth of oxide films 416
17.4 Oxidation of alloys 419
17.5 Hot corrosion 423
17.6 References 426
17.7 Bibliography 426
18 Worked examples and problems 427
18.1 Worked examples 427
18.2 Problems 433
index 457