Metals humidity resistance

Provision of corrosion and humidity resistance on metal products... 

Generally, metals arc resistant to attack in diy air. even in pure humid air. corrosion is slight when, however, air pollutanLs are present the rate uf corrosion will increase measurably, the increase being dependent upon the humidity and the character of the pollutant. Such action may he grouped as follows ... 

Epoxies cure to become thermoset adhesives and so show excellent humidity resistance, especially if one of the substrates is metal. For long-term, durable adhesively bonded metal-to-metal joints, toughened epoxies are hard to beat [6] but where plastics are involved, some of the other technology adhesives invariably offer benefits in terms of ease of application and cure speed whilst still retaining satisfactory environmental resistance. Indeed epoxies do not often show good adhesion to elastomers and for the thermoplastic elastomers cyanoacrylates will generally show the best environmental resistance. 

Some nonhygroscopic materials such as metals, glass, and plastics, have the abiUty to capture water molecules within microscopic surface crevices, thus forming an invisible, noncontinuous surface film. The density of the film increases as the relative humidity increases. Thus, relative humidity must be held below the critical point at which metals may etch or at which the electrical resistance of insulating materials is significantly decreased. 

In neutral and alkaline environments, the magnesium hydroxide product can form a surface film which offers considerable protection to the pure metal or its common alloys. Electron diffraction studies of the film formed ia humid air iadicate that it is amorphous, with the oxidation rate reported to be less than 0.01 /rni/yr. If the humidity level is sufficiently high, so that condensation occurs on the surface of the sample, the amorphous film is found to contain at least some crystalline magnesium hydroxide (bmcite). The crystalline magnesium hydroxide is also protective ia deionized water at room temperature. The aeration of the water has Httie or no measurable effect on the corrosion resistance. However, as the water temperature is iacreased to 100°C, the protective capacity of the film begias to erode, particularly ia the presence of certain cathodic contaminants ia either the metal or the water (121,122). 

Water, whether as a liquid, moisture in the soil, or water vapor in the atmosphere, is essential for corrosion processes to take place. Under dry environmental conditions most metals and alloys are resistant to corrosion. The more humidity there is at a site, the more active are the corrosion processes. Some metals and alloys that are resistant to corrosion under dry conditions rapidly corrode under humid or wet conditions, particularly, in the presence of pollutants. Depending on their susceptibility to corrosion processes, the metals and alloys can be divided into three groups ... 

Recent reports [30-31] on the use of atmospheric corrosion sensors based on changes in electrical resistance showed that when there were no contaminants [29], in tests of 100-110 h., corrosion rate was zero or insignificant. These sensors can determine changes in metal thickness lower than one nanometer. However, in the presence of 0.08 ppm of S02 or 20 pg/cm2 of NaCl in the system, changes in thickness where always detected over 75% of relative humidity. Corrosion rate was determined at temperatures of 20, 30 and 40°C and the Arrhenius equation was used to calculate the activation energy of the reactions. This method is very similar to the natural conditions. 

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