Corrosion environment

Atmospheric corrosion results from a metal s ambient-temperature reaction, with the earth s atmosphere as the corrosive environment. Atmospheric corrosion is electrochemical in nature, but differs from corrosion in aqueous solutions in that the electrochemical reactions occur under very thin layers of electrolyte on the metal surface. This influences the amount of oxygen present on the metal surface, since diffusion of oxygen from the atmosphere/electrolyte solution interface to the solution/metal interface is rapid. Atmospheric corrosion rates of metals are strongly influenced by moisture, temperature and presence of contaminants (e.g., NaCl, SO2,. ..). Hence, significantly different resistances to atmospheric corrosion are observed depending on the geographical location, whether mral, urban or marine. 

Despite the benefits of lead and lead ahoys, the use of these materials is declining rapidly, owing primarily to environmental health and safety factors. Eor many years, lead ahoys were the materials of choice for many corrosive environments, but are now being replaced by stainless steel, plastics, and exotic metals. The toxic nature of lead requires special precautions and handling not necessary with other materials. These requirements have reduced the usage of lead ahoys. 

Molybdenum improves the corrosion resistance of stainless steels that are alloyed with 17—29% chromium. The addition of 1—4% molybdenum results in high resistance to pitting in corrosive environments, such as those found in pulp (qv) and paper (qv) processing (33), as weU as in food preparation, petrochemical, and poUution control systems. 

Other alloys have been developed for use in particular corrosive environments at high temperatures. Several of these are age-hardenable alloys which contain additions of aluminum and titanium. Eor example, INCONEL alloys 718 and X-750 [11145-80-5] (UNS N07750) have higher strength and better creep and stress mpture properties than alloy 600 and maintain the same good corrosion and oxidation resistance. AHoy 718 exhibits excellent stress mpture properties up to 705°C as well as good oxidation resistance up to 980°C and is widely used in gas turbines and other aerospace appHcations, and for pumps, nuclear reactor parts, and tooling. 

In the spht- or dual-pressure process, low to medium pressure gases (ca 0.3—0.6 MPa) containing nitrogen oxides are compressed to ca 1.1—1.5 MPa for efficient absorption in water to make nitric acid. Stainless steel is used for constmction in this corrosive environment and, because of the potential for... 

The first commercial use of tantalum was as filaments ia iacandescent lamps but it was soon displaced by tungsten. Tantalum is used ia chemical iadustry equipment for reaction vessels and heat exchangers ia corrosive environments. It is usually the metal of choice for heating elements and shields ia high temperature vacuum sintering furnaces. In 1994, over 72% of the tantalum produced ia the world went iato the manufacturiag of over 10 x 10 soHd tantalum capacitors for use ia the most demanding electronic appHcations. 

If the production of vinyl chloride could be reduced to a single step, such as dkect chlorine substitution for hydrogen in ethylene or oxychlorination/cracking of ethylene to vinyl chloride, a major improvement over the traditional balanced process would be realized. The Hterature is filled with a variety of catalysts and processes for single-step manufacture of vinyl chloride (136—138). None has been commercialized because of the high temperatures, corrosive environments, and insufficient reaction selectivities so far encountered. Substitution of lower cost ethane or methane for ethylene in the manufacture of vinyl chloride has also been investigated. The Lummus-Transcat process (139), for instance, proposes a molten oxychlorination catalyst at 450—500°C to react ethane with chlorine to make vinyl chloride dkecfly. However, ethane conversion and selectivity to vinyl chloride are too low (30% and less than 40%, respectively) to make this process competitive. Numerous other catalysts and processes have been patented as weU, but none has been commercialized owing to problems with temperature, corrosion, and/or product selectivity (140—144). Because of the potential payback, however, this is a very active area of research. 

A uniform coating of calcium carbonate deposited on the metal surfaces physically segregates the metal from the corrosive environment. To develop the positive LSI required to deposit calcium carbonate, it is usually necessary to adjust the pH or calcium content of the water. Soda ash, caustic soda, or lime (calcium hydroxide) may be used for this adjustment. Lime is usually the most economical alkaH because it raises the calcium content as weU as the alkalinity. 

Container. The battery container is made up of a cover, vent caps, lead bushings, and case. Cost and appHcation are the two primary factors used to select the materials of constmction for container components. The container must be fabricated from materials that can withstand the abusive environment the battery is subjected to in its appHcation. It must also be inert to the corrosive environment of the electrolyte and soHd active materials, and weather, vibration, shock, and thermal gradients while maintaining its Hquid seal. 

Powder coatings as a class are superior to Hquid coatings in abiHty to coat sharp edges and isolate the substrate from contact with corrosive environments. PVC coatings are softer and more flexible than any of the other powder coating materials. Primers used for PVC plastisols have been found generally suitable for powder coatings as weH (5). 

The gating and riseting system for cast aluminum bron2e is extremely important and must be arranged to iatroduce the metal quietly at the lowest portion of the mold. The alloys shrink well hence the gating and riseting must be well adapted to the particular casting. See Table 12 for properties of these alloys. Alloys C 95300, C 95400, and C 95500 are heat-treatable for iacreased mechanical properties and the last two should be temper-aimealed if used ia a corrosive environment. 

Corrosion also occurs as a result of the conjoint action of physical processes and chemical or electrochemical reactions (1 3). The specific manifestation of corrosion is deterrnined by the physical processes involved. Environmentally induced cracking (EIC) is the failure of a metal in a corrosive environment and under a mechanical stress. The observed cracking and subsequent failure would not occur from either the mechanical stress or the corrosive environment alone. Specific chemical agents cause particular metals to undergo EIC, and mechanical failure occurs below the normal strength (5aeld stress) of the metal. Examples are the failure of brasses in ammonia environments and stainless steels in chloride or caustic environments. 

Packed vs Plate Columns. Relative to plate towers, packed towers are more useful for multipurpose distillations, usually in small (under 0.5 m) towers or for the following specific appHcations severe corrosion environment where some corrosion-resistant materials, such as plastics, ceramics, and certain metaUics, can easily be fabricated into packing but may be difficult to fabricate into plates vacuum operation where a low pressure drop per theoretical plate is a critical requirement high (eg, above 49,000 kg/(hm ) (- 10, 000 lb/(hft )) Hquid rates foaming systems or debottlenecking plate towers having plate spacings that are relatively close, under 0.3 m. 

The advantage of this process over other xerographic processes using conventional photoconductors is that the most sensitive part of the photoconductor is protected from the corrosive environment. This helps to increase the useful life of the device. The process itself, however, is rather comphcated. 

Half-inch copper tubing is commonly used for steam tracing. Three-eighths-inch tubing is also used, but the effective circuit length is then decreased from 150 feet to about 60 feet. In some corrosive environments, stainless steel tubing is used, and occasionally standard carbon steel pipe (one half inch to one inch) is used as the tracer. 

Biological Corrosion The metabohc activity of microorganisms can either directly or indirectly cause deterioration of a metal by corrosion processes. Such activity can (1) produce a corrosive environment, (2) create electrolytic-concentration cells on the metal surface, (3) alter the resistance of surface films, (4) have an influence on the rate of anodic or cathodic reaction, and (5) alter the environment composition. 

Inhibitors The use of various substances or inhibitors as additives to corrosive environments to decrease corrosion of metals in the environment is an important means of combating corrosion. This is generally most attractive in closed or recirculating systems in which the annual cost of inhibitor is low. However, it has also proved to be economicaUv attrac tive for many once-through systems, such as those encountered in petroleum-processing operations. Inhibitors are effective as the result of their controlling influence on the cathode- or anode-area reactions. 

Electrochemical techniques have been used for years to study fundamental phenomenological corrosion reactions of metals in corrosive environments. Unfortunately, the learning curve in the reduction of these elec trochemical theories to practice has been painfully slow. However, a recent survey has shown that many organizations in the... 

FIG. 28-10 Six possible types of behavior for an active/passive alloy in a corrosive environment. 

FIG. 28-19 Equipment for measuring internal friction (modulus) changes during in situ tensile exposure of a metal in a corrosive environment. 

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