Galvanizing alloys

N. Boshkov, K. Petrov, S. Vitkova, G. Raichevsky, Galvanic alloys Zn-Mn composition of the corrosion products and their protective abihty in sulfate-containing medium. Surf. Coat. Techol. 194 (2005) 276-282. 

Because the corrosion resistance of lead and lead alloys is associated with the formation of the protective corrosion film, removal of the film in any way causes rapid attack. Thus the velocity of a solution passing over a surface can lead to significantly increased attack, particularly if the solution contains suspended particulate material. Lead is also attacked rapidly in the presence of high velocity deionised water. The lack of dissolved minerals in such water prevents the formation of an insoluble protective film. In most solutions, lead and lead alloys are resistant to galvanic corrosion because of the formation of a nonconductive corrosion film. In contact with more noble metals, however, lead can undergo galvanic attack which is accelerated by stray electrical currents. 

Table 8 indicates the compatibiUty of magnesium with a variety of chemicals and common substances. Because the presence of even small amounts of impurities in a chemical substance may result in significantly altered performance, a positive response in the table only means that tests under the actual service conditions are warranted (132). Other factors which may significantly alter magnesium compatibiUty include the presence of galvanic couples, variations in operating temperatures, alloy composition, or humidity levels. 

Some tests indicate that magnesium alloys are resistant to loam sod. However, in the presence of chlorides, corrosive attack may be serious particularly if galvanic couples are present as a result of coupling to iron stmctures. 

D. L. Hawke, J. E. HiUis, and W. Unsworth, Preventive Practice for Controlling the Galvanic Corrosion of Magnesium Alloys, International Magnesium Association, McLean, Va., 1988. 

Tungsten has Htde effect on recrystallization temperature or the high temperature properties of molybdenum. However, the Mo—30% W alloy is recognized as a standard commercial alloy for stirrers, pipes, and other equipment that is required to be in contact with molten zinc during processing of the metal and in galvanizing and die casting operations. 

Table 4 shows a galvanic series for some commercial metals and alloys. When two metals from the series are in contact in solution, the corrosion rate of the more active (anodic) metal increases and the corrosion rate of the more noble (cathodic) metal decreases. 

The most serious form of galvanic corrosion occurs in cooling systems that contain both copper and steel alloys. It results when dissolved copper plates onto a steel surface and induces rapid galvanic attack of the steel. The amount of dissolved copper required to produce this effect is small and the increased corrosion is difficult to inhibit once it occurs. A copper corrosion inhibitor is needed to prevent copper dissolution. 

Zinc consumption is categorized in five semifabricating markets (see Table 15). Galvanizing was the main market for zinc in the 1970s followed by zinc-base casting alloys and brass and bronze. Depressed constmction and automotive industries caused a decline from 1979 to 1980 of ca 18%, and the die-casting business declined 34% and galvanizing 24%. 

Hard plating is noted for its excellent hardness, wear resistance, and low coefficient of friction. Decorative plating retains its brilliance because air exposure immediately forms a thin, invisible protective oxide film. The chromium is not appHed directiy to the surface of the base metal but rather over a nickel (see Nickel and nickel alloys) plate, which in turn is laid over a copper (qv) plate. Because the chromium plate is not free of cracks, pores, and similar imperfections, the intermediate nickel layer must provide the basic protection. Indeed, optimum performance is obtained when a controlled but high density (40—80 microcrack intersections per linear millimeter) of microcracks is achieved in the chromium lea ding to reduced local galvanic current density at the imperfections and increased cathode polarization. A duplex nickel layer containing small amounts of sulfur is generally used. In addition to... 

Fig. 4. Galvanic series in flowing seawater. Certain alloys may become more active in low velocity or poorly aerated seawater and the potentials exhibited...

Liquid-Metal Corrosion Liquid metals can also cause corrosion failures. The most damaging are liqmd metals which penetrate the metal along grain boundaries to cause catastrophic failure. Examples include mercury attack on aluminum alloys and attack of stainless steels by molten zinc or aluminum. A fairly common problem occurs when galvanized-structural-steel attachments are welded to stainless piping or eqmpment. In such cases it is mandatoty to remove the galvanizing completely from the area which will be heated above 260°C (500°F). 

When the layer of graphite and corrosion products is impervious to the solution, corrosion wdl cease or slow down. If the layer is porous, corrosion will progress by galvanic behavior between graphite and iron. The rate of this attack will be approximately that for the maximum penetration of steel by pitting. The layer of graphite formed may also be effective in reducing the g vanic action between cast iron and more noble alloys such as bronze used for valve trim and impellers in pumps. 

Test Specimens In carrying out plant tests it is necessary to install the test specimens so that they wih not come into contact with other metals and alloys this avoids having their normal behavior disturbed by galvanic effects. It is also desirable to protect the specimens from possible mechanical damage. 

Copper alloys often show only weak crevice corrosion. This is especially the case if the copper alloy is coupled to a less noble alloy such as steel. The corrosion of the steel is stimulated by the galvanic effect caused by the coupling of dissimilar metals. Hence, the sacrificial corrosion of the steel protects the copper alloy (Fig. 2.9). See Chap. 16, Galvanic Corrosion. ... 

Oxygen corrosion only occurs on metal surfaces exposed to oxygenated waters. Many commonly used industrial alloys react with dissolved oxygen in water, forming a variety of oxides and hydroxides. However, alloys most seriously affected are cast irons, galvanized steel, and non-stainless steels. Attack occurs in locations where tuberculation also occurs (see Chap. 3). Often, oxygen corrosion is a precursor to tubercle development. 

When possible, avoid coupling materials having widely dissimilar galvanic potentials. If this cannot he avoided, make use of favorable area ratios by giving the active metal a large exposed area relative to the noble metal. For example, copper or copper-based alloy tubes may be joined to a steel tube sheet. Because of the favorable area ratio in this case, a relatively inexpensive steel tube sheet may be intentionally substituted for a bronze or a brass tube sheet if thickness specifications allow for a small amount of galvanic corrosion of the steel. 

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