Aluminum alloys corrosion production

Aluminum and aluminum alloys are employed in many appHcations because of the abiHty to resist corrosion. Corrosion resistance is attributable to the tightly adherent, protective oxide film present on the surface of the products. This film is 5 —10 nm thick when formed in air if dismpted it begins to form immediately in most environments. The weathering characteristics of several common aluminum alloy sheet products used for architectural appHcations are shown in Eigure 30. The loss in strength as a result of atmospheric weathering and corrosion is small, and the rate decreases with time. The amount of... 

The resistance to corrosion of some alloy sheet is improved by cladding the sheet with a thin layer of aluminum or aluminum alloy that is anodic to the base alloy. These anodic layers are typically 5—10% of the sheet thickness. Under corrosive conditions, the cladding provides electrochemical protection to the core at cut edges, abrasions, and fastener holes by corroding preferentially. Aircraft skin sheet is an example of such a clad product. 

Pitting is also promoted by low pH. Thus, acidic deposits contribute to attack on stainless steels. Amphoteric alloys such as aluminum are harmed by both acidic and alkaline deposits (Fig. 4.4). Other passive metals (those that form protective corrosion product layers spontaneously) are similarly affected. 

The resistance of a metal to erosion-corrosion is based principally on the tenacity of the coating of corrosion products it forms in the environment to which it is exposed. Zinc (brasses), aluminum (aluminum brass), and nickel (cupronickel) alloyed with copper increase the coating s tenacity. An addition of V2 to 1)4% iron to cupronickel can greatly increase its erosion-corrosion resistance for the same reason. Similarly, chromium added to iron-base alloys and molybdenum added to austenitic stainless steels will increase resistance to erosion-corrosion. 

Exfoliation corrosion is especially prevalent in aluminum alloys. The grain structure of the metal determines whether exfoliation corrosion will occur. In this form of corrosion, degradation propagates below the surface of the metal. Corrosion products in layers below the metal surface cause flaking of the metal. 

Select the engine coolant or antirust with care to ensure adequate corrosion protection. Use only those products conforming to recognized standards such as ASTM D 3306 for engine coolant. Additionally, if your vehicle engine contains major cast aluminum components, be certain the engine coolant meets the heat rejection corrosion limits in ASTM specification D 3306 as determined by ASTM Test Method for Corrosion of Cast Aluminum Alloys in Engine Coolants Under Heat-Transfer Conditions (D 4340). 

Steel sheets are aluminized by a hot-dip process similar to galvanizing. The principal applications for such a product are furnaces and ovens, automobile mufflers, and other equipment requiring heat and corrosion resistance. When a sheet which has been coated with aluminum by a hot-dip process is exposed to a temperature over l,000°F (538aC). the aluminum forms an iron-aluminum alloy which is heat- and corrosion-resistant. 

G139, Standard Test Method for Determining Stress Corrosion Resistance of Heat-Treatable Aluminum Alloy Products using Breaking Load Method, ASTM, West Conshohoken, PA, 1996. 

Metallic Pigments. These pigments are metal flakes of various sizes made up of aluminum, copper, zinc, and/or their alloys. The aluminum flakes develop the silver metallic colors, whereas the copper, zinc, and aluminum alloys produce the gold, copper, brass, and bronze colors. The metal effect is modified, not only by shape and size, but also by perticle size distribution within a given product. Since aluminum, in particular, as a fine dry powder, can form explosive mixtures with air, most of these materials are commercially available in paste or liquid concentrates. In addition, surface treatments of these materials enhance their appearance and performance. Flakes of other metals, such as stainless steel, are used for surface protection purposes such as corrosion resistance and electrical conductivity. 

Hydrochloric add Nitric add Dissolves most water scales and corrosion products Dissolves most water scales and corrosion products On boilers, heat exchangers, pipelines, etc. On stainless steel and aluminum Corrosive to steel temperature must be below 175T Cannot be used on copper and ferrous alloys... 

Paralinear corrosion (related to dissolution of corrosion product) does not occur for all aluminum alloys in water at all high temperatures. In Figure 13 are plotted data for an alloy (Al, 1% Ni, 0.1% Ti) corroded in water at 350°C (10). The corrosion rate was low and constant, as shown better in other figures in the same publication. For some specimens in the figure 1/3 or 2/3 of the corrosion product was removed mechanically after the first exposure period. There was no discernible effect on subsequent corrosion, indicating that control of corrosion probably resided close to the metal-oxide interface. Similar experiments for the alloys and temperatures where paralinear behavior occurs showed that removing some of the product caused an increase in subsequent corrosion rate. 

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