Copper alloys pitting corrosion

Dezincification Dezincification is corrosion of a brass alloy containing zinc in which the principal product of corrosion is metallic copper. This may occur as plugs rilling pits (plug type) or as continuous layers surrounding an unattacked core of brass (general type). The mechanism may involve overall corrosion of the alloy followed by redeposition of the copper from the corrosion products or selective corrosion of zinc or a high-zinc phase to leave copper residue. This form of corrosion is commonly encountered in brasses that contain more than 15 percent zinc and can be either eliminated or reduced by the addition ox small amounts of arsenic, antimony, or ph osphorus to the alloy. 

Nickel is usually alloyed with elements including copper, chromium, molybdenum and then for strengthening and to improve corrosion resistance for specific applications. Nickel-copper alloys (and copper-nickel alloys see Section 53.5.4) are widely used for handling water. Pumps and valve bodies for fresh water, seawater and mildly acidic alkaline conditions are made from cast Ni-30% Cu type alloys. The wrought material is used for shafts and stems. In seawater contaminated with sulfide, these alloys are subject to pitting and corrosion fatigue. Ammonia contamination creates corrosion problems as for commercially pure nickel. 

Metals which owe their good corrosion resistance to the presence of thin, passive or protective surface films may be susceptible to pitting attack when the surface film breaks down locally and does not reform. Thus stainless steels, mild steels, aluminium alloys, and nickel and copper-base alloys (as well as many other less common alloys) may all be susceptible to pitting attack under certain environmental conditions, and pitting corrosion provides an excellent example of the way in which crystal defects of various kinds can affect the integrity of surface films and hence corrosion behaviour. 

Gear lubricants In addition to the usual oxidation and corrosion inhibitors, lubricants for heavily loaded gears almost always contain EP additives containing sulphur, chlorine or phosphorus. In order to function, these additives must react locally with the metal surfaces, and yet the extent of the reaction should not be such that it could be described as corrosive, or promote fatigue pitting . These EP additives may be quite safe with ferrous metal surfaces, but may cause severe corrosion on copper alloys, e.g. on bronze worm wheels if for any reason excessive temperatures arise. 

Most simple inorganic salt solutions cause virtually no attack on aluminium-base alloys, unless they possess the qualities required for pitting corrosion, which have been considered previously, or hydrolyse in solution to give acid or alkaline reactions, as do, for example, aluminium, ferric and zinc chlorides. With salts of heavy metals —notably copper, silver, and gold —the heavy metal deposits on to the aluminium, where it subsequently causes serious bimetallic corrosion. 

In tests carried out by the National Bureau of Standards in the USA specimens of copper alloys, lead, zinc and zinc alloys were buried at a number of different sites for periods varying from 11 to 14 years. The soils tested covered a pH range from 2-6 to 9-4 and resistivities ranged from 62 to 17 800 fi cm. The weight losses and maximum depths of pitting were recorded, and the results indicated that the most severe corrosion occurred in soils of poor aeration having high acid and soluble-salt contents. 

Copper reduces the corrosion resistance of aluminum more than any other alloying element. It leads to a higher rate of general corrosion, a greater incidence of pitting, and, when added in small amounts (for example, 0.15% ), a lower rate of pitting penetration. 

Aluminum alloys can also be attacked by microorganisms. For example, there have been MIC problems with aluminum fuel tanks and transfer lines. In this case, microorganisms grow in the water layer under the fuel to produce volcano-shaped tubercles, frequently evolving gas. Pitting occurs under the tubercles. MIC attack on copper alloys is usually insignificant. However, corrosion of copper condenser tubes by microbially produced ammonia has been reported. In addition, sulfuric acid has been produced by microbial activity by corrosion of underground copper pipes. 

H.S. Campbell, A Review Pitting Corrosion of Copper and Its Alloys, Localized Corrosion NACE 3, R.W. Staehle, B.F. Brown, J. Kruger, and A. Agrawal, Ed., National Association of Corrosion Engineers, 1974, p 625-638... 

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