Erosion corrosion forms

Impingement and erosion-corrosion forms of attack will usually be intensified by the presence of solid particles in the fluid. Variations of the jet test have been proposed to take this effect into account. ... 

Localized corrosion, which occurs when the anodic sites remain stationary, is a more serious industrial problem. Forms of localized corrosion include pitting, selective leaching (eg, dezincification), galvanic corrosion, crevice or underdeposit corrosion, intergranular corrosion, stress corrosion cracking, and microbiologicaHy influenced corrosion. Another form of corrosion, which caimot be accurately categorized as either uniform or localized, is erosion corrosion. 

It is often localized at areas where water changes direction. Cavitation (damage due to the formation and coUapse of bubbles in high velocity turbines, propellers, etc) is a form of erosion corrosion. Its appearance is similar to closely spaced pits, although the surface is usually rough. 

High Water Velocities. The abiUty of high water velocities to minimize fouling depends on the nature of the foulant. Clay and silt deposits are more effectively removed by high water velocities than aluminum and iron deposits, which are more tacky and form interlocking networks with other precipitates. Operation at high water velocities is not always a viable solution to clay and silt deposition because of design limitations, economic considerations, and the potential for erosion corrosion. 

After only 4 months of service, the main condenser at a large fossil utility began to perforate. Initial perforations were due to erosion-corrosion (see Case History 11.5). Small clumps of seed hairs entering the condenser after being blown into the cooling tower were caught on surfaces. The entrapped seed hairs acted as sieves, filtering out small silt and sand particles to form lumps of deposit (Fig. 6.24A and B). Immediately downstream from each deposit mound, an erosion-corrosion pit was found. 

Metal surfaces in a well-designed, well-operated cooling water system will establish an equilibrium with the environment by forming a coating of protective corrosion product. This covering effectively isolates the metal from the environment, thereby stifling additional corrosion. Any mechanical, chemical, or chemical and mechanical condition that affects the ability of the metal to form and maintain this protective coating can lead to metal deterioration. Erosion-corrosion is a classic example of a chemical and mechanical condition of this type. A typical sequence of events is ... 

Metals that depend on a relatively thick protective coating of corrosion product for corrosion resistance are frequently subject to erosion-corrosion. This is due to the poor adherence of these coatings relative to the thin films formed by the classical passive metals, such as stainless steel and titanium. Both stainless steel and titanium are relatively immune to erosion-corrosion in most cooling water environments. 

The resistance of a metal to erosion-corrosion is based principally on the tenacity of the coating of corrosion products it forms in the environment to which it is exposed. Zinc (brasses), aluminum (aluminum brass), and nickel (cupronickel) alloyed with copper increase the coating s tenacity. An addition of V2 to 1)4% iron to cupronickel can greatly increase its erosion-corrosion resistance for the same reason. Similarly, chromium added to iron-base alloys and molybdenum added to austenitic stainless steels will increase resistance to erosion-corrosion. 

Note the incomplete attack of the surface in Fig. 11.17. This illustrates erosion-corrosion in its early stages. Compare this to the general metal loss illustrated in Fig. 11.18. Note the horseshoe-shaped depressions aligned with water flow. This tube illustrates erosion-corrosion in its mature form. 

Figure 11.18 Erosion-corrosion in its mature form. Note the horseshoe-shaped depressions aligned with flow direction.

Impingement is corrosion caused by aerated water streams constricting metal surfaces. It is similar to erosion corrosion in which air bubbles take the place of particles. The pits formed by impingement attack have a characteristic tear drop shape. 

The various types of localised corrosion have been enumerated in Table 1.2 in Section 1.1, and many of them are dealt with in some detail in other sections of this volume. For this reason this section will be confined to a consideration of the factors that give rise to crevice corrosion, filiform corrosion, pitting, selective leaching and erosion-corrosion and of the mechanisms of these forms of localised attack. 

However, movement at appreciable rates can result in another form of attack that is brought about by the conjoint action of erosion and corrosion hence the term erosion-corrosion that includes all forms of accelerated attack in which protective films, and even the metal surface itself, are removed by the abrasive action of movement of a fluid (gas or liquid) at high velocity. In general, the higher the velocity the more abrasive the solution. 

Fig. 1.61 Erosion-corrosion. Impeller fabricated from Cu-10Sn-2Zn alloy used for pumping a slurry containing 5-10% H2SO4 after six months service. The blades of the impeller were extensively corroded. Note the directional form of the attack...

Impingement attack, as is implicit in the name, is a form of erosion-corrosion in which the solution strikes the metal surface at a high velocity—a situation that can occur at bends, tees and sudden changes in section in a... 

In considering these tests it should be remembered that the phenomenon of cavitation-erosion is often accompained by corrosion effects and that a synergistic effect may operate between the mechanically and chemically induced forms of attack. In fact the term cavitation-erosion-corrosion may often be more applicable in describing the requirements of a test procedure. The subject has recently been discussed by Wood etal. °. 

Condenser design usually calls for thin-walled tubing with high thermal conductivity characteristics plus a high degree of resistance to biofouling and the many forms of corrosion that may occur. (These forms include crevice and pitting corrosion, biocorrosion, and erosion-corrosion). 

The corrosion rate of carbon steel increases with increase in velocity until a critical velocity is reached. This behavior is different from that of the carbon steel in fresh water where the corrosion rate decreases beyond a critical velocity due to the formation of a passive him. In seawater passive films are not formed because of the presence of high concentrations of chloride. The erosion corrosion occurs after critical velocity 20 m/s is reached. The maximum corrosion rate of 1,0/mm/yr is reached at velocities up to 4 m/s. 

Macroscopic forms of corrosion affect greater areas of corroded metal and are generally observable with the naked eye or can be viewed with the aid of a low-power magnifying device. Macroscopic examination can identify the following forms galvanic, erosion-corrosion, crevice or pitting, exfoliation, and dealloying. Microscopic... 

Elevated speeds have a marked effect on wear, and this is more pronounced if the solution contains some solid particles in suspension. Aluminum forms films of aluminum nitrate or oxide in fuming nitric acid. At low flow rates there is no attack whereas for speeds greater than 1.22 m s the protective layer is removed and erosion-corrosion occurs more readily.16... 

During use, avoid stress concentrators by increasing susceptibility to different forms of degradation in service, especially localized corrosion, galvanic corrosion, and erosion-corrosion. Accidental or nondesigned cyclic loading should be avoided. 

CMP is analogous to the phenomena of erosion corrosion. Normally, during corrosion of a metal, a scale forms which slows further corrosion of the metal by acting as a barrier between the metal and the corrosive medium (Section 4.3). In erosion corrosion, low corrosion rates are accelerated by the removal of this scale via an erosion or wear process. The scale, wear process, and corrosive medium in erosion corrosion are analogous to the surface layer, mechanical abrasion, and slurry chemicals of the CMP process. Thus, in principle, the same electrochemical theories that are used to understand corrosion may be applied to CMP. In this section, we discuss the electrochemical theories that are important in metal CMP. In many instances we shall refer to the electrochemical behavior of copper for illustration. However, these electrochemical principles are applicable to the CMP of all metals. 

Fretting corrosion is a specialized form of erosion corrosion where two metal surfaces are in contact and experience very slight relative motion that causes damage to one or both surfaces. Again, in the presence of a corrodent, the movement causes mechanical damage of the protective film, leading to localized corrosion. 

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