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Why Study Corrosion 1: Sheldon W. Dean 12/7/02
Why Study Corrosion 1: Sheldon W. Dean 12/7/02
What is Corrosion?
What does it look like?
What is Corrosion?
Metals made by smelting ( reduction of ore) Metals in air want to return to their oxidized state Corrosion is a natural process!
Is Corrosion Important?
National issue? International issue? What industries are affected? Does it affect us personally?
Importance to USA
CC Technologies study March 2002 In 2000 about 3.1% of GDP spent on corrosion repair and control Total cost $276Billion! Of industries analyzed, the cost was $137.9 Billion
Corrosion is Electrochemical
Two different reactions occur oxidation and reduction Electron transfer occurs Potential (voltage) driving force required Oxidation occurs at anode Reduction occurs at cathode
Corrosion Reactions
Oxidation - e.g. Fe Fe++ + 2e Reduction e.g. O2 + 2H2O 4OH- - 4e Secondary - e.g. 4 Fe++ + O2 Fe2O3 + 8H+
Conclusions
Corrosion rate depends upon the corrosion products that form Solubility of corrosion products determines the rate If solubility is high, the rate is high! If solubility is low, the rate is low
Metallic Coatings
Widely used to protect steel and to make other metals more attractive Zn and Zn alloys on steel Galvanizing Ni + Cr on steel, brass or zinc to give a bright finish Cu + Ni + Cr also used for bright finish
Electrochemical Protection
Cathodic protection reduce the potential and also corrosion rate widely used underground and in sea water Anodic protection increase potential to produce a less soluble corrosion product used in some chemical plants
Corrosion Inhibitors
Used in water systems: - Automotive cooling systems - Cooling towers - Boilers, especially high pressure steam Temporary preservatives for metals - Volatile corrosion inhibitors Paints and primers
Quiz Time!
What is the most corrosive substance we can think of? Corrosion damage only causes metals to become thinner True or False? How does corrosion affect me?
Answers!
Water!!! False! Corrosion also causes cracking, pitting, staining, wedging in crevices, loss of electrical conductivity, and failure of components What is your answer?
Break Time
NACE International
Short courses, some with certification Annual meeting and show Standards development Local sections Symposia Books, videos and computer products
ASTM International
Standards development, Vol.03.02 Training courses Symposia Address:100 Barr Harbor Drive, West Conshocken, PA 19428-2959 Website: www.astm.org Corrosion committee: G-1
Corrosion Testing
Used for a variety of purposes Standard test methods available Some tests are simple and easy to run ASTM corrosion tests are in Volume 03.02 of the Annual Book of ASTM Standards
Corrosion TestingPurposes
Accelerated tests to demonstrate products durability Acceptance tests to show that a material meets standard Monitoring tests to show changes in a system corrosivity Research tests to determine mechanism of corrosion
Standard Tests
Usually corrosion tests have many parameters Corrosion tests often give results that are difficult to reproduce Standardization helps reproducibility Consensus standard tests: ASTM and NACE
ASTM G 69 Continued
Solution: 1M Na Cl + 2.7%H2O2, 22oC Surface preparation: 00 steel wool rub 1 Hour immersion Measure potential every 5 minutes after 30 minutes against SCE electrode Average result: -750+/-10mV for pure Al Al foil is pure Al
Analyze Data
Arrange values in ascending order and number the values sequentially Determine plotting position,f f = r/(n +1) where r is the measurement number, and n is the total number of values Plot on probability paper
Demonstration of Corrosion
A simple test to show local cathodes and anodes with a corroding specimen Uses indicators to show where reactions occur Phenolphthalein turns red at cathode (OH ion generated there) K3Fe(CN)6 turns blue at anode
Summary
Corrosion is an important issue Corrosion technology shows where chemistry can be used to prevent problems Corrosion tests can provide good hands-on experience for students Many opportunities for careers in corrosion prevention
Thank You!
Questions please?