Corrosion control surface films

Corrosion Control. Surfaces that become wetted by a lubricant and its additives are typically much less prone to corrosive damage from water, acids, bacteria, and other similar corrosion agents. Additives can neutralize acids as well as form a barrier film, which repels water and other chemically aggressive contaminants. 

Alkenylsuccinic anhydrides made from several linear alpha olefins are used in paper sizing, detergents, and other uses. Sulfosuccinic acid esters serve as surface active agents. Alkyd resins (qv) are used as surface coatings. Chlorendric anhydride [115-27-5] is used as a flame resistant component (see Flame retardants). Tetrahydrophthalic acid [88-98-2] and hexahydrophthalic anhydride [85-42-7] have specialty resin appHcations. Gas barrier films made by grafting maleic anhydride to polypropylene [25085-53-4] film are used in food packaging (qv). Poly(maleic anhydride) [24937-72-2] is used as a scale preventer and corrosion inhibitor (see Corrosion and corrosion control). Maleic anhydride forms copolymers with ethylene glycol methyl vinyl ethers which are partially esterified for biomedical and pharmaceutical uses (189) (see Pharmaceuticals). 

Metal Finishing and Corrosion Control. The exceptional corrosion protection provided by electroplated chromium and the protective film created by applying chromium surface conversion techniques to many active metals, has made chromium compounds valuable to the metal finishing industry. Cr(VI) compounds have dominated the formulas employed for electroplating (qv) and surface conversion, but the use of Cr(III) compounds is growing in both areas because of the health and safety problems associated with hexavalent chromium and the low toxicity of trivalent chromium (see... 

Alloys having varying degrees of corrosion resistance have been developed in response to various environmental needs. At the lower end of the alloying scale are the low alloy steels. These are kon-base alloys containing from 0.5—3.0 wt % Ni, Cr, Mo, or Cu and controlled amounts of P, N, and S. The exact composition varies with the manufacturer. The corrosion resistance of the alloy is based on the protective nature of the surface film, which in turn is based on the physical and chemical properties of the oxide film. As a rule, this alloying reduces the rate of corrosion by 50% over the fkst few years of atmosphere exposure. Low alloy steels have been used outdoors with protection. 

The contact ends of printed circuit boards are copper. Alloys of nickel and iron are used as substrates in hermetic connectors in which glass (qv) is the dielectric material. Terminals are fabricated from brass or copper from nickel, for high temperature appHcations from aluminum, when aluminum conductors are used and from steel when high strength is required. Because steel has poor corrosion resistance, it is always plated using a protective metal, such as tin (see Tin and tin alloys). Other substrates can be unplated when high contact normal forces, usually more than 5 N, are available to mechanically dismpt insulating oxide films on the surfaces and thereby assure metaUic contact (see Corrosion and corrosion control). 

Beryllium is readily attacked by most acids and, being amphoteric, is slowly attacked by caustic alkalis with the evolution of hydrogen. As might be anticipated, in view of the controlling influence of the surface film of beryllia on corrosion behaviour, concentrated nitric acid has little effect on beryllium , while the dilute acid results in slow attack. Hot acid is much more reactive. Nitric acid is in fact often used to pickle-off residual mild steel from hot-extruded clad beryllium. 

Variation in the pressure of the reacting gas can affect corrosion processes in two ways. In the cases more usually met with in practice, in which the corrosion rate is controlled by diffusion processes in the surface film of corrosion product, the influence of gas pressure on corrosion rate is slight. If, however, the dissociation pressure of the oxide or of a constituent of the scale lies within the range involved, the stability of the corrosion product will be critically dependent on the pressure. The effect of temperature is, however, far more critical and thus, in practical cases, pressure variations rarely decide the stability of corrosion products. 

The basis of OT therefore is to maintain a controlled level of oxygen in the FW (approximately 150 to 250 ppb 02) to promote and enhance the development of these various Fe and Cu passivated surface films and thus reduce expensive operational corrosion problems of one sort or another. 

Microelectronic circuits for communications. Controlled permeability films for drug delivery systems. Protein-specific sensors for the monitoring of biochemical processes. Catalysts for the production of fuels and chemicals. Optical coatings for window glass. Electrodes for batteries and fuel cells. Corrosion-resistant coatings for the protection of metals and ceramics. Surface active agents, or surfactants, for use in tertiary oil recovery and the production of polymers, paper, textiles, agricultural chemicals, and cement. 

Corrosion-inhibiting properties of fuel stabilizers can be a secondary effect of the dispersing action of a fuel stabilizer. By functioning as a dispersant, sludge and water are held in suspension and prevented from initiating metal surface corrosion. Also, some stabilizer dispersants can form a thin film on the metal surfaces of fuel system components. This film-forming property enables the stabilizer-dispersant to function in corrosion control. A typical oil-soluble dispersant compound is shown in FIGURE 6-3. 

The surface of a solid sample interacts with its environment and can be changed, for instance by oxidation or due to corrosion, but surface changes can occur due to ion implantation, deposition of thick or thin films or epitaxially grown layers.91 There has been a tremendous growth in the application of surface analytical methods in the last decades. Powerful surface analysis procedures are required for the characterization of surface changes, of contamination of sample surfaces, characterization of layers and layered systems, grain boundaries, interfaces and diffusion processes, but also for process control and optimization of several film preparation procedures. 

Corrosion control of metal surfaces depends on the formation and maintenance of a protective corrosion inhibitor film on the exposed metal surface. This protective film may be established during normal application of a corrosion inhibitor program however, there will be some lag time before the film is completely built up. Metal surfaces that are exposed to the cooling water before the film is completed may become candidates for accelerated corrosion during the initial system operation. Normally, localized corrosion or pitting is common during these early stages of operation. 

Active metals such as aluminum, titanium, and high-chromium steels become corrosion resistant under oxidizing conditions because of a very adherent and impervious surface oxide film that, although one molecule thick, develops on the surface of the metal. This film is stable in a neutral medium, but it dissolves in an acid or alkaline environment. In a few cases, such as certain acid concentrations, metals can be kept passive by applying a carefully controlled potential that favors the formation of the passive surface film. The ability to keep the desired potential over the entire structure is very critical in anodic control. If a higher or lower potential is applied, the metal will corrode at a higher rate, possibly higher than if it is not protected at all. 

During exposure, galvanized steel and weathering steel are expected to corrode by forming a protective surface film that retards corrosion. The rate of corrosion would then be diffusion controlled and depend upon the thickness of the film. Many of the corrosion products, particularly the carbonates, hydroxides, etc. within the film are soluble in acid solutions. In environments where increased acidity is present, dissolution of the protective film is a competing mechanism that accelerates the rate of corrosion of metals. 

Corrosion control by pigments relies on well-known principles of corrosion inhibition. Iron and steel exposed to air are quickly covered by an oxide film aqueous electrolytes tend to break down this film, and further oxidation of the metal surface ensues. The role of anodic corrosion inhibitors is to supplement or to aid in the repair of the surface oxide film. Basic pigments may form soaps, for example, with linseed oil autoxidation of these soaps may yield soluble inhibitors in the film. Some other pigments of limited solubility act directly as inhibitors. Active metal pigments supply electrons to the iron substrate and thus lower its potential and prevent metal dissolution. 

The toxicity of chromate treatment has led to the development of alternative anodic inhibitors. Orthophosphate forms an iron phosphate film that protects the surface fi om corrosion attack, but the layer is less adherent and therefore is not so long lasting, as chromate derived protection. At the same time orthophosphate corrosion control can be made effective provided the system is properly managed. Because of the biological nutrient properties of orthophosphates it is likely that their use will additionally involve the application of a biocide. 

Chemical Treatment. A wide variety of chemicals and water treatments are used for corrosion control. Corrosion inhibitors usually act by forming some type of impervious layer on the metallic surface of either the anode or cathode that impedes the reaction at the electrode and thereby slows or inhibits the corrosion reaction. For example, various alkali metal hydroxides, carbonates, silicates, borates, phosphates, chromates, and nitrites promote the formation of a stable surface oxide on metals. The presence of these chemicals in the electrolyte allows any faults in the metal surface or its oxide film to be repaired. If they are used in too small a quantity as anodic inhibitors, they may promote intense local attack because they can leave a small unprotected area on the anode where the current density will be very high. This is particularly true of chromates and polyphosphates. 

---