On carbon steels

C. W. Ho esch, A Methodfor Predicting Service Efie of Zinc Rich Primers on Carbon Steel, NASA technical memorandum 93101, Keimedy Space Center, Fla., 1986. 

Cladding metal on carbon steel backers a b Shear strength, MPa... 

FIG. 10-184 Cost of shop-fabricated tanks in mid-1980 with V4-in walls. Multiplying factors on carbon steel costs for other materials are carbon steel, 1.0 mbber-lined carbon steel, 1.5 alnminnm, 1.6 glass-lined carbon steel, 4.5 and fiber-reinforced plastic, 0.75 to 1.5. Multiplying factors on type 316 stainless-steel costs for other materials are 316 stainless steel, 1.0 Monel, 2.0 Inconel, 2.0 nickel, 2.0 titanium, 3.2 and Hastelloy C, 3.8. Multiplying factors for wall thicknesses different from V4 in are ... 

Materials of construction Relative cost per ft of tray area (based on carbon steel = 1)... 

These reactions are shown schematically near a crevice in Fig. 2.2. Many other reactions may occur at anodes and cathodes, but Reactions 2.1 and 2.2 predominate on carbon steel, for example, in near neutral pH, oxygenated water. 

Figure 5.6 Rust layer on carbon steel mill water supply pipe. Note the partially exfoliated region at the bottom of the photo.

Virtually all metallurgies can be attacked by corrosive bacteria. Cases of titanium corrosion are, however, rare. Copper alloys are not immune to bacterial attack however, corrosion morphologies on copper alloys are not well defined. Tubercles on carbon steel and common cast irons sometimes contain sulfate-reducing and acid-producing bacteria. Potentially corrosive anaerobic bacteria are often present beneath... 

Sulfides are intermixed with iron oxides and hydroxides on carbon steels and cast irons. The oxides are also produced in the corrosion process (Reaction 6.6). Although theoretical stoichiometry of 1 to 3 is often suggested between sulfide and ferrous hydroxide, empirically the ratio of iron sulfide to ferrous hydroxide is highly variable. Sulfide decomposes spontaneously upon exposure to moist air. Additionally, corrosion-product stratification is marked, with sulfide concentration being highest near metal surfaces. 

Figure 7.11 Smooth attack on carbon steel by carbonic acid. Note the vivid red color of hematite, indicating high oxygen concentrations.

The effects of some alloying elements on relative behaviour in an industrial atmosphere (Sheffield, U.K.) are shown in Table 3.21A. For comparison, data for simultaneous tests on carbon steel and some non-ferrous material are given. Results are as weight loss over a five-year period and data from... 

Rohrig, van Duzer and Fellows exposed samples in an experimental superheater fed with steam at 2-6MN/m from a power plant. Some 42 materials were tested for periods of up to 16(XX)h, attack being estimated after test by weight loss following descaling. It was concluded that at 593°C attack continues at a high rate on carbon steel, whereas the rate for most alloy steels decreases with time (Table 7.10). 

Hydrogen at high pressure and temperatures above 4(X) C has a considerable adverse effect on carbon steel, dissolving in the steels and combining with carbides to produce methane and so causing Assuring and considerable embrittlement. However, chromium stabilises the carbides and stainless steel may be safely used in hydrogen at dull red heat ... 

M. J. Franklin, D. E. Nivens, A. A. Vass, M. W. Mittelman, R. F. Jack, M. J. E. Dowling, and D. C. White. Effect of chlorine and chlorine/bromine biocide treatments on the number and activity of biofilm bacteria and on carbon steel corrosion. Corrosion, 47(2) 128-134, February 1991. 

The more expensive, corrosion-resistant, alloys are frequently used as a cladding on carbon steel. If a thick plate is needed for structural strength, as for pressure vessels, the use of clad materials can substantially reduce the cost. 

Larson JK, Buchan RM, Blehm KD, et al. 1989. Characterization of lead fume exposure during gas metal arc welding on carbon steel. Appl Ind Hyg 4 330-333. 

Integrity management processes should take into account the embrittlement effects of dry hydrogen gas on carbon steel pipeline materials and welds used to join pipe sections. 

Raeissi et al. [236, 237] showed that temperature, pH, and current density affected the morphology and texture, as well as the nucleation mechanism of the zinc deposits on carbon steel electrode. 

Cd on carbon steel as cathode emulsion with water... 

These products derived from DuPont research consist of two or more flat metals joined metallurgically to yield clad plates fully meeting ASTM ASME codes. The expin-bonding process permits manuf of a wide variety of Detaclad products, ranging from a combination of more conventional metals and alloys, such as stainless steel and nickel on carbon steel, to noble metals on steel, stainless steel or other metals... 

Where corrosive conditions do exist, equipment is protected in sulfuric acid units by the use of stainless steel and in hydrofluoric acid units by the use of Monel. Both acids build up a thin layer of iron salt on carbon steel even in the cold. Such a layer of salt causes any moving parts to stick in time, and, therefore, most valves and pumps are protected with alloy trim under normal conditions and are solid alloy under severe conditions. Both types of units will have very little corrosion if properly designed and operated. 

The EHD method with a RDE has been applied to the characterisation of porous layers of corrosion products formed on carbon steel [110], for the characterisation of salt films formed on copper [90, 111, 112] and iron [113], and for biofilms developed in natural seawater [114]. Corrosion inhibition films formed by an organic surfactant acting on the surface of pure iron have been characterised in this way, too [115]. An effect of a... 

Data is shown in Figs. 7a and 7b for oxygen reduction on carbon steel in room temperature 0.6M NaCl. iL increases with co0 5 as predicted. Hence if the corrosion rate is determined by the mass transport of oxygen to the disk surface to support oxygen reduction, then the corrosion rate will increase as a function of the rotation rate, co, raised to the 0.5 power and linearly with dissolved oxygen concentration. The diffusion boundary layer thickness, 8d, may be calculated from Fick s first law after iL is determined. Recall that 8 = nFDCJiL for one dimensional diffusion at the steady state. This leads to the following expression for the diffusional boundary layer thickness ... 

The results obtained from tests on carbon steel and stainless steels on exposure to 0.5 and 2% chloride for period of two years at 80% relative humidity are noted in Table 7.13. It is obvious from the data that carbon steel failed in 2% chloride along with severe cracking of the concrete sample. The stainless steels did not corrode and the concrete also remained intact without cracking. 

High solids (carbonates and bicarbonates) BFW will result in significant formation of carbon dioxide. The resulting carbon dioxide-laden condensate causes erosion-corrosion attack on carbon steel. Failure occurs by deep pitting, furrowing, or channeling. Corrosion inhibitors can be added to minimize this attack. 

Figure 4.5 Relationship between pH, carbon dioxide partial pressure, and estimated corrosion rate on carbon steel at 100°F (38°C)Z...

A CA of Vfc in. (3 mm) should be used on carbon steel exchangers since it is standard for TEMA Class... 

MR0175, For carbon steeft the hardness limit shoiid be 200 Srlneil Rockwell B 95 see NACE Standard RP0472) p4] Avoid use of cement linings or Monel 400 for sour water. See Number 14 for corrosion allowance on carbon steel exposed to sour water. 

---