Passivity breakdown

It is also well known that a local breakdown passivity that leads to pitting can be treated as a random phenomenon occurring stochastically with respect to time and location on the surface of the metal.21-23,97 Reigata et al.% have recently formulated the stochastic formation mechanism of a pit... 

Under certain special environmental conditions, the passive films, which were described earlier in this Chapter, are susceptible to localized breakdown. Passivity breakdown may result in accelerated local dissolution (localized corrosion) of the metal or alloy. There are two (related) major forms of localized corrosion following passivity breakdown localized corrosion initiated on an open surface is called pitting corrosion, and localized corrosion initiated at an occluded site is called crevice corrosion. In the presence of mechanical stress, localized dissolution may promote the initiation of cracks. 

I. Epelboin and M. Keddam, Electrochemical techniques for studying passivity and its breakdown, Passivity of Metals (R. R Frankenthal and J. Kroger, eds.), Electrochemical Society, Pennington, NJ, 1978, p. 184. 

Highly protective layers can also fonn in gaseous environments at ambient temperatures by a redox reaction similar to that in an aqueous electrolyte, i.e. by oxygen reduction combined with metal oxidation. The thickness of spontaneously fonned oxide films is typically in the range of 1-3 nm, i.e., of similar thickness to electrochemical passive films. Substantially thicker anodic films can be fonned on so-called valve metals (Ti, Ta, Zr,. ..), which allow the application of anodizing potentials (high electric fields) without dielectric breakdown. 

The following mechanisms in corrosion behavior have been affected by implantation and have been reviewed (119) (/) expansion of the passive range of potential, (2) enhancement of resistance to localized breakdown of passive film, (J) formation of amorphous surface alloy to eliminate grain boundaries and stabilize an amorphous passive film, (4) shift open circuit (corrosion) potential into passive range of potential, (5) reduce/eliminate attack at second-phase particles, and (6) inhibit cathodic kinetics. 

Niobium is used as a substrate for platinum in impressed-current cathodic protection anodes because of its high anodic breakdown potential (100 V in seawater), good mechanical properties, good electrical conductivity, and the formation of an adherent passive oxide film when it is anodized. Other uses for niobium metal are in vacuum tubes, high pressure sodium vapor lamps, and in the manufacture of catalysts. 

An especially insidious type of corrosion is localized corrosion (1—3,5) which occurs at distinct sites on the surface of a metal while the remainder of the metal is either not attacked or attacked much more slowly. Localized corrosion is usually seen on metals that are passivated, ie, protected from corrosion by oxide films, and occurs as a result of the breakdown of the oxide film. Generally the oxide film breakdown requires the presence of an aggressive anion, the most common of which is chloride. Localized corrosion can cause considerable damage to a metal stmcture without the metal exhibiting any appreciable loss in weight. Localized corrosion occurs on a number of technologically important materials such as stainless steels, nickel-base alloys, aluminum, titanium, and copper (see Aluminumand ALUMINUM ALLOYS Nickel AND nickel alloys Steel and Titaniumand titanium alloys). 

Chlorides, which are ubiquitous in nature, play an important role in the corrosion of metals. Chlorides and other anions also play an important role in locali2ed corrosion, ie, the breakdown of the insoluble protective reaction product films, eg, passive films, that prevent corrosion of the underlying metal. A variety of mechanisms attempting to explain the role of chloride in general and in locali2ed corrosion have been proposed (23—25). 

Short-time tests also can give misleading results on alloys that form passive films, such as stainless steels. With Borderline conditions, a prolonged test may be needed to permit breakdown of the passive film and subsequently more rapid attack. Consequently, tests run for long periods are considerably more reahstic than those conducted for short durations. This statement must be quahfied by stating that corrosion should not proceed to the point at which the original specimen size or the exposed area is drastic y reduced or the metal is perforated. 

Because the film growth rate depends so strongly on the electric field across it (equation 1.115), separation of the anodic and cathodic sites for metals in open circuit is of little consequence, provided film growth is the exclusive reaction. Thus if one site is anodic, and an adjacent site cathodic, film thickening on the anodic site itself causes the two sites to swap roles so that the film on the former cathodic site also thickens correspondingly. Thus the anodic and cathodic sites of the stably passive metal dance over the surface. If however, permanent separation of sites can occur, as for example, where the anodic site has restricted access to the cathodic component in the electrolyte (as in crevice), then breakdown of passivity and associated corrosion can follow. 

In view of the fact that there are two opposing views on the mechanism of passivity it is not surprising that a similar situation prevails concerning the mechanism of breakdown of passivity. The solid film theory of passivity and breakdown of passivity is dealt with in some detail in Section 1.5, so that it is appropriate here to discuss briefly the views based on the adsorption theory. 

The corrosion rate of many important metals and alloys is controlled by the formation of a passive film, and the thermodynamics and kinetics of their formation and breakdown are dealt with in Section 1.2. 

For many metals and alloys the determination of /p is complex, and its magnitude is governed by many factors such as surface finish, rate of formation, alloying constituents, and the presence of those anions, such as halides, that promote localised breakdown. In many instances the attack on passive films by halide ions shows a temperature and concentration dependence similar to the effect of hydrogen ions, i.e. the rate of film dissolution increases with concentration in accordance with a Freundlich adsorption relationship... 

Increasing concentrations of bicarbonate tended to raise the breakdown potentials but also increased the corrosion potentials. This, in combination with a high chloride concentration, high bicarbonate concentrations may raise the corrosion potentials such that they border on passivation breakdown. The increase in hysteresis loop size on potentiodynamic cycles with increasing bicarbonate concentration shows a lowered resistance to pitting attack and crevice corrosion. 

Variations in pH promoted increases in corrosion potentials from acid pH levels to neutral pH thereafter, however, corrosion potentials were lowered in alkaline solutions to more active values. Decreasing pH caused a lowering of breakdown potentials in the presence of Cl and an increase in the current densities for passivation. 

Fig. 4.35 Influence of temperature on breakdown of passivity of nickel in H2SO4 + Na2S04 solution (pH 0-4) containing 0-05 m C1 (after Gressmann )...

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