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corrosion rate
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in Corrosion Failure of the Rocky Point Viaduct
> ASM Failure Analysis Case Histories: Buildings, Bridges, and Infrastructure
Published: 01 June 2019
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Published: 01 December 2019
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Published: 01 December 2019
Fig. 14 Corrosion rate of Monel 400 exposed to a 5 wt.% HCl solution, as a function of temperature. Source: Ref 7
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Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.modes.c9001013
EISBN: 978-1-62708-234-1
... by the corrosive, high velocity gas flow. The corrosion rate of either the inhibited or uninhibited gas stream was too high for equipment in high pressure gas service. Type 410 (12% Cr) stainless steel was recommended for the choke bodies because other equipment such as valves made of type 410 showed no evidence...
Abstract
A wall section of a carbon steel choke body in gas service at 4400 psig blew out three months after the use of a corrosion inhibitor was stopped. Corrosion damage occurred in ripples, leaving both smoothly polished and unattacked areas. The corrodent in condensate wells was principally carbon dioxide dissolved in water condensed from the gas stream, with organic acids possibly an aggravating factor. A gas analysis showed no other corrosive agents. No metallurgical or fabrication defects were found in the carbon steel part. The mode of attack was corrosion-erosion, caused by the corrosive, high velocity gas flow. The corrosion rate of either the inhibited or uninhibited gas stream was too high for equipment in high pressure gas service. Type 410 (12% Cr) stainless steel was recommended for the choke bodies because other equipment such as valves made of type 410 showed no evidence of corrosion damage after three years' exposure. This change was made five years ago and there have been no failures since.
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.aero.c9001560
EISBN: 978-1-62708-217-4
... may have occurred. A study was made for stress-corrosion cracking susceptibility of 4340 steel in a paste made of the residues collected from used breech chambers. The constant extension rate test (CERT) technique was employed and SCC susceptibility was demonstrated. The residues, which contained both...
Abstract
Military aircraft use a cartridge ignition system for emergency engine starts. Analysis of premature failures of steel (AISI 4340) breech chambers in which the solid propellant cartridges were burned identified corrosion as one problem with an indication that stress-corrosion cracking may have occurred. A study was made for stress-corrosion cracking susceptibility of 4340 steel in a paste made of the residues collected from used breech chambers. The constant extension rate test (CERT) technique was employed and SCC susceptibility was demonstrated. The residues, which contained both combustion products from the cartridges and corrosion products from the chamber, were analyzed using elemental analysis and x-ray diffraction techniques. Electrochemical polarization techniques were also utilized to estimate corrosion rates.
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.chem.c9001525
EISBN: 978-1-62708-220-4
... then evaluated for polarization resistance and corrosion rate when immersed in the mildly alkaline product that is stored in the tanks. The tanks were all studied at ambient temperature. Electrochemical Impedance Electrochemical corrosion test cells were assembled to expose the surface of each panel...
Abstract
Welded steel storage vessels used to hold mildly alkaline solution were produced in exactly the same manner from deep-drawn aluminum-killed SAE 1006 low-carbon steel sheet. After the cylindrical shell was drawn, a top low-carbon steel closure was welded to the inside diameter. The containers were then filled with the slightly alkaline solution, pressurized, and allowed to stand under ambient conditions. A small number, less than 1%, were returned because they began to leak in service. Inspection revealed general corrosion and pitting on the inner surfaces. However, other tanks that experienced the same service conditions developed no corrosion. Corrosion was linked to forming defects that provided sites for localized corrosion, and to lack of steam drying after cleaning, which increased susceptibility to general corrosion.
Series: ASM Failure Analysis Case Histories
Volume: 3
Publisher: ASM International
Published: 01 December 2019
DOI: 10.31399/asm.fach.v03.c9001779
EISBN: 978-1-62708-241-9
... , mg/l NH 3 , mg/l O 2 , mg/l Feed water 0.52 1.3 9 5< 18.7 808 5 Prescribed water 0.3 Max 0.7 Max 9 ± 1 5 Max 15 800 20 Electrochemical data Table 6 Electrochemical data I Corr , μA Corrosion rate, mpy Distilled water 6.237 2.859 Feed water...
Abstract
Material samples collected from failed booster pumps were analyzed to determine the cause of failure and assess the adequacy of the materials used in the design. The pumps had been in service at a power plant, transporting feedwater from a deaerator to a main turbine boiler. Samples from critical areas of the pump were examined using optical and scanning electron microscopy, electrochemical analysis, and tensile testing. Based on microstructure and morphology, estimated corrosion rates, and particle concentrations in the feedwater, it was concluded that cavitation and erosion were the dominant failure mechanisms and that the materials and processes used to make the pumps were largely unsuited for the application.
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.marine.c9001720
EISBN: 978-1-62708-227-3
... would have no effect on corrosion rate under aerobic conditions that may occur in local areas on the hull. In the part of the ship from which samples for this report were obtained, high temperatures above 1340 deg F did not occur. Hull plate samples from the submerged wreckage are not yet available...
Abstract
Metallographic studies found that steel used to fabricate the U.S.S. Arizona battleship during original construction, 1913-1915 and reconstruction, 1929-1931 were consistent with the best materials available during each time period. Due to the force of the forward magazine detonation, the best steel available today would not have had any impact on the outcome. Heavy banding in steels from both periods could adversely affect the corrosion resistance under anaerobic conditions that prevail during a corrosion cycle that has developed under hard biofouling layers for over 58 years. Banding would have no effect on corrosion rate under aerobic conditions that may occur in local areas on the hull. In the part of the ship from which samples for this report were obtained, high temperatures above 1340 deg F did not occur. Hull plate samples from the submerged wreckage are not yet available. These samples will be important to confirm findings to this time and determine the remaining thickness of the hull plate and, indirectly, the integrity of the fuel oil tanks.
Series: ASM Handbook Archive
Volume: 11
Publisher: ASM International
Published: 01 January 2002
DOI: 10.31399/asm.hb.v11.a0003549
EISBN: 978-1-62708-180-1
... and the reduction of oxygen. Since the rates of oxidation and reduction must be equal, increasing the total reduction rate increases the rate of zinc solution. Therefore, acid solutions containing dissolved oxygen normally will be more corrosive than air-free acids. Oxygen reduction simply provides another means...
Abstract
This article provides an overview of the electrochemical nature of corrosion and analyzes corrosion-related failures. It describes corrosion failure analysis and discusses corrective and preventive approaches to mitigate corrosion-related failures of metals. These include: change in the environment; change in the alloy or heat treatment; change in design; use of galvanic protection; use of inhibitors; use of nonmetallic coatings and liners; application of metallic coatings; use of surface treatments, thermal spray, or other surface modifications; corrosion monitoring; and preventive maintenance.
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in Analysis of Hot Rolled Steel Transit Damage
> ASM Failure Analysis Case Histories: Improper Maintenance, Repair, and Operating Conditions
Published: 01 June 2019
Fig. 13 Prior Corrosion: Examination of this shipment of steel from Poland revealed that the corrosion was so severe it could not have occurred during the voyage. That is, the corrosion rate would have been in excess of that possible, even if it had been wet for the entire voyage. It was found
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Book Chapter
Series: ASM Handbook Archive
Volume: 11
Publisher: ASM International
Published: 01 January 2002
DOI: 10.31399/asm.hb.v11.a0003548
EISBN: 978-1-62708-180-1
... Corrosion-Related Failures.” The rate, extent, and type of corrosive attack that can be tolerated in an object vary widely, depending on the specific application and initial design. Whether the observed corrosion behavior was normal for the metal used in the given service conditions helps determine...
Abstract
This article addresses the forms of corrosion that contribute directly to the failure of metal parts or that render them susceptible to failure by some other mechanism. It describes the mechanisms of corrosive attack for specific forms of corrosion such as galvanic corrosion, uniform corrosion, pitting and crevice corrosion, intergranular corrosion, and velocity-affected corrosion. The article contains a table that lists combinations of alloys and environments subjected to selective leaching and the elements removed by leaching.
Series: ASM Handbook
Volume: 11
Publisher: ASM International
Published: 15 January 2021
DOI: 10.31399/asm.hb.v11.a0006783
EISBN: 978-1-62708-295-2
.... The rate, extent, and type of corrosive attack that can be tolerated in an object vary widely, depending on the specific application and initial design. Whether the observed corrosion behavior was normal for the material used in the given service conditions helps determine what inspection and maintenance...
Abstract
Corrosion is the electrochemical reaction of a material and its environment. This article addresses those forms of corrosion that contribute directly to the failure of metal parts or that render them susceptible to failure by some other mechanism. Various forms of corrosion covered are galvanic corrosion, uniform corrosion, pitting, crevice corrosion, intergranular corrosion, selective leaching, and velocity-affected corrosion. In particular, mechanisms of corrosive attack for specific forms of corrosion, as well as evaluation and factors contributing to these forms, are described. These reviews of corrosion forms and mechanisms are intended to assist the reader in developing an understanding of the underlying principles of corrosion; acquiring such an understanding is the first step in recognizing and analyzing corrosion-related failures and in formulating preventive measures.
Book Chapter
Series: ASM Handbook Archive
Volume: 11
Publisher: ASM International
Published: 01 January 2002
DOI: 10.31399/asm.hb.v11.a0003567
EISBN: 978-1-62708-180-1
... corrosion was not dominant. When slurries are recycled in a closed slurry pot system, the wear rate can decrease dramatically with time ( Ref 13 , 14 , 15 ). This is due to the microscopic rounding of the abrasive particles. The difference in wear rates for recycled and flow-through slurries is shown...
Abstract
This article focuses on the corrosion-wear synergism in aqueous slurry and grinding environments. It describes the effects of environmental factors on corrosive wear and provides information on the impact and three-body abrasive-corrosive wear. The article also discusses the various means for combating corrosive wear, namely, materials selection, surface treatments, and handling-environment modifications.
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in Failure Analysis of Welded Low-Carbon Steel Storage Tank
> ASM Failure Analysis Case Histories: Chemical Processing Equipment
Published: 01 June 2019
Fig. 3 Cyclic polarization test curve from a typical panel that had not been steam dried. The corrosion rate was measured to be 67 mils (170 µm) per year.
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Image
in Failure Analysis of Welded Low-Carbon Steel Storage Tank
> ASM Failure Analysis Case Histories: Chemical Processing Equipment
Published: 01 June 2019
Fig. 4 Cyclic polarization test plot from a typical panel that had been steam dried. The corrosion rate was determined to be less than 0.1 mil (2.5 µm) per year.
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Series: ASM Failure Analysis Case Histories
Volume: 3
Publisher: ASM International
Published: 01 December 2019
DOI: 10.31399/asm.fach.v03.c9001775
EISBN: 978-1-62708-241-9
... The cracked part of the tube, containing two parallel through-thickness cracks Fig. 3 Collage of photographs showing the observed cracks as viewed from (a) the internal (gas–side) and (b) the external surface of the tube Fig. 13 Corrosion rate of Monel 400 as a function of HCl...
Abstract
A bent Ni-Cu Monel 400 alloy tube, which operated as part of a pipeline in a petrochemical distillery, failed by through-thickness cracking. The pipeline was used to carry a stream of gaseous hydrocarbons containing hydrochloric acid (HCl) into a reaction tower. The tower provided a caustic solution (NaOH) to remove HCl from the stream, before the latter was directed to a burner. Metallographic examination showed that the cracks were intergranular and were frequently branched. Although nominal chemical composition of the component was found within the specified range, energy dispersive x-ray analysis (EDXA) indicated significant segregation of sulfur and chlorine along the grain boundaries. Failure was attributed to hypochlorous-acid (HClO)-induced stress-corrosion cracking (SCC). The HClO was formed by the reaction of HCl with atmospheric O 2 that entered the tube during shutdowns and startups. Residual stresses, originating from in situ bend forming of the tube during assembly of the line, provided a driving force for crack growth, and the segregation of sulfur on grain boundaries made the material more susceptible to cracking.
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.bldgs.c9001702
EISBN: 978-1-62708-219-8
.... 1995 - New Rocky Point Viaduct open for use. Experimental The evaluation of the state of the corrosion of beam A1 was done by considering the beam condition survey, beam physical properties, half-cell potential survey, chloride distribution, corrosion rate survey, aggregate characterization...
Abstract
The Rocky Point Viaduct, located near Port Orford, OR, was replaced after only 40 years of service. A beam from the original viaduct was studied in detail to determine the mechanisms contributing to severe corrosion damage to the structure. Results are presented from the delamination survey, potential and corrosion mapping, concrete chemistry, and concrete physical properties. The major cause of corrosion damage appears to have been the presence of both pre-existing and environmentally-delivered chlorides in the concrete.
Series: ASM Handbook
Volume: 11
Publisher: ASM International
Published: 15 January 2021
DOI: 10.31399/asm.hb.v11.a0006788
EISBN: 978-1-62708-295-2
... location. In concentration cells, the position of the anode and cathode are determined by differences in chemistry and therefore electrical potential on different parts of a metal surface. The rate of corrosion is controlled by the slowest half-reaction in the electrochemical cell. In the anaerobic...
Abstract
This article focuses on the mechanisms of microbiologically influenced corrosion as a basis for discussion on the diagnosis, management, and prevention of biological corrosion failures in piping, tanks, heat exchangers, and cooling towers. It begins with an overview of the scope of microbial activity and the corrosion process. Then, various mechanisms that influence corrosion in microorganisms are discussed. The focus is on the incremental activities needed to assess the role played by microorganisms, if any, in the overall scenario. The article presents a case study that illustrates opportunities to improve operating processes and procedures related to the management of system integrity. Industry experience with corrosion-resistant alloys of steel, copper, and aluminum is reviewed. The article ends with a discussion on monitoring and preventing microbiologically influenced corrosion failures.
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in Biologically Influenced Corrosion of Stainless Steel Welds by Water
> ASM Failure Analysis Case Histories: Failure Modes and Mechanisms
Published: 01 June 2019
Fig. 11 Preferential corrosion of filler material in MIC attack area. Rates of attack on ferrite and austenite phases differ. 200×.
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Series: ASM Handbook
Volume: 11
Publisher: ASM International
Published: 15 January 2021
DOI: 10.31399/asm.hb.v11.a0006782
EISBN: 978-1-62708-295-2
...: the evolution of hydrogen and the reduction of oxygen. Because the rates of oxidation and reduction must be equal, increasing the total reduction rate increases the rate of zinc solution. Therefore, acid solutions containing dissolved oxygen are typically more corrosive than air-free acids. Oxygen reduction...
Abstract
Corrosion is the deterioration of a material by a reaction of that material with its environment. The realization that corrosion control can be profitable has been acknowledged repeatedly by industry, typically following costly business interruptions. This article describes the electrochemical nature of corrosion and provides the typical analysis of environmental- and corrosion-related failures. It presents common methods of testing of laboratory corrosion and discusses the processes involved in the prevention of environmental- and corrosion-related failures of metals and nonmetals.
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