Cathodic protection materials

A comparison of typical properties of cathodic protection materials is given in Table 10.23, but is by no means comprehensive. It is obvious that the modification of an alloy, environment or other important factors will be reflected in the life and output characteristics. In some cases the maximum voltages and current densities recommended can be vastly exceeded. In others, particularly where abnormal levels of environmental dissolved solids are met, factors of safety should be applied to modify the proposed figures. Acceptance of a much reduced or uncertain life, weighed against a possible economy, may also influence the chosen working limits. For example, the life of ferrous alloy anodes may, in practice, be only two-thirds of that expected because of preferential attack eventually leading to disconnection of all or part of the anode from the source of e.m.f. 

T. Pastore, Repassivation of steel in carbonated concrete induced by cathodic protection . Materials and Corrosion, 2003, 54, 163-175. 

Haney EG. The zinc-steel potential reversal in cathodic protection. Materials Performance, 1982 21 44—51. 

Eliassen, S., and Holstad-Pettersen, N., Fabrication and Installation of Anodes for Deep Water Pipehnes Cathodic Protection, Materials Performance, 36(6) 20-23... 

Coral sands and mud lend themselves to standard cathodic protection materials, resulting in the use of low-cost components for either galvanic or impressed current systems. In such marine environments in semiarid areas, consideration must be given to atmospheric corrosion of components as well as proper monitoring procedures. 

Cathodic protection using sacrificial anodes or applied current can retard or eliminate tuberculation. However, costs can be high and technical installation can be very difficult. Costs are markedly reduced if surfaces are coated (see Material substitution below). 

Coat both materials or the noble material. Do not coat just the active material (see Area effects above). Coatings should be maintained, especially the one covering the active member of the couple. Use of cathodic protection systems in association with coatings is often recommended. 

It is not certain whether Sir Humphrey Davy (Fig. 1-7) knew of these considerations. He accepted a commission from the Admiralty for the protection of copper-clad wooden ships, which had been introduced in 1761. During his numerous laboratory experiments, he discovered the cathodic protection of copper by zinc or iron [3]. Davy had already put forward the hypothesis in 1812 that chemical and electrical changes are identical or at least arise from the same material property. He believed that chemical reaction forces could be reduced or increased by altering the electric state of the material. Materials can combine only if they have different electric charges. If an originally positive material can be artificially negatively... 

It is little known that Thomas Alva Edison tried to achieve cathodic protection of ships with impressed current in 1890 however, the sources of current and anodic materials available to him were inadequate. In 1902, K. Cohen achieved practical cathodic protection using impressed direct current. The manager of urban works at... 

Stainless steels in soil can only be attacked by pitting corrosion if the pitting potential is exceeded (see Fig. 2-16). Contact with nonalloyed steel affords considerable cathodic protection at f/jj < 0.2 V. Copper materials are also very resistant and only suffer corrosion in very acid or polluted soils. Details of the behavior of these materials can be found in Refs. 3 and 14. 

The cathodic protection of plain carbon and low-alloy steels can be achieved with galvanic anodes of zinc, aluminum or magnesium. For materials with relatively more positive protection potentials (e.g., stainless steels, copper, nickel or tin alloys), galvanic anodes of iron or of activated lead can be used. 

As in the case of corrosion at the insulating connection due to different potentials caused by cathodic protection of the pipeline, there is a danger if the insulating connection is fitted between two sections of a pipeline with different materials, e.g., mild and stainless steel. The difference between the external pipe/soil potential is changed by cell currents so that the difference between the internal pipe/ medium potential has the same value, i.e., both potential differences become equal. If the latter is lower than the former for the case of free corrosion, the part of the pipe with the material that has the more positive rest potential in the soil is polarized anodically on the inner surface. The danger increases with external cathodic protection in the part of the pipeline made of mild steel. 

Cathodic protection of different materials in installations of dissimilar metals is only possible if the protection potential ranges of the individual materials overlap. Section 2.4 gives information on the protection potential ranges of various systems. If there is no overlapping, then insulating couplings must be installed. This is also appropriate and even necessary if the protection current densities are very different. 

Fig. 11-6 Diode circuit for the cathodic protection of various materials.

Pumping or compressor stations are necessary for the transport of material in pipelines. These stations are usually electrically separated from the cathodically protected long-distance pipeline. The concrete foundations are much smaller than in power stations and refineries. Since the station piping is endangered by cell formation with the steel-reinforced concrete foundations, local cathodic protection is recommended. 

Aluminum-sheathed cables should not be connected to other cables because aluminum has the most negative rest potential of all applicable cable sheathing materials. Every defect in the protective sheath is therefore anodically endangered (see Fig. 2-5). The very high surface ratio SJS leads to rapid destruction of the aluminum sheathing according to Eq. (2-44). Aluminum can also suffer cathodic corrosion (see Fig. 2-11). The cathodic protection of aluminum is therefore a problem. Care must be taken that the protection criterion of Eq. (2-48) with the data in Section 2.4 is fulfilled (see also Table 13-1). Aluminum-sheathed cables are used only in exceptional cases. They should not be laid in stray current areas or in soils with a high concentration of salt. 

In the tidal zone and the spray zone (known as the splash zone), cathodic protection is generally not very effective. Here thick coatings or sheathing with corrosion-resistance materials (e.g., based on NiCu) are necessary to prevent corrosion attack [4]. The coatings are severely mechanically stressed and must be so formed that repair is possible even under spray conditions. Their stability against cathodic polarization (see Section 17.2), marine growths, UV rays and seawater must be ensured [4,5]. 

Production platforms are coated only in exceptional cases or for the purposes of investigation because the life of the structure is greater than the life of the coating. Therefore in the design of the cathodic protection, only the protection potential Us of the steel need be considered. Steels with an ultimate tensile strength of up to 350 N mm are used for these structures, which are weldable even in thick sections, and the hardness of the welded material can be kept to 350 HV (see Section 2.3.4 [2,10]). Aluminum anodes with the same protection effect and life as zinc anodes have much less weight. This is a very important advantage for... 

Different microstructural regions in a material which has an almost uniform composition can also lead to the formation of corrosion cells (e.g., in the vicinity of welds). Basically, corrosion cells can be successfully overcome by cathodic protection. However, in practice, care has to be taken to avoid electrical shielding by large current-consuming cathode surfaces by keeping the area as small as possible. In general, with mixed installations of different metals, it must be remembered that the protection potentials and the protection range depend on the materials (Section 2.4). This can restrict the use of cathodic protection or make special potential control necessary. 

The protection of aluminum ships demands particular attention since electrical contact with steel and copper materials can seldom be avoided and a whole range of aluminum alloys are unsuitable for cathodic protection (see Section 2.4 and Fig. 2-11). Later protective measures must therefore be observed during the construction stage since even good coatings in combination with cathodic protection are frequently not adequate to protect gaps or openings. 

Cathodic protection of reinforcing steel with impressed current is a relatively new protection method. It was used experimentally at the end of the 1950s [21,22] for renovating steel-reinforced concrete structures damaged by corrosion, but not pursued further because of a lack of suitable anode materials so that driving voltages of 15 to 200 V had to be applied. Also, from previous experience [23-26], loss of adhesion between the steel and concrete due to cathodic alkalinity [see Eqs. (2-17) and (2-19)] was feared, which discouraged further technical development. 

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