The corrosion behavior of a metal or alloy is determined by its composition and structural features, the environment and stresses to which it is exposed, and the behavior of any corrosion products generated. This article provides a detailed discussion on the fundamentals of pure metals, impure metals, and alloys. It highlights the ways in which the metallurgical variables, namely, composition and structure, influence the corrosion properties of metals and alloys in aqueous environment.

This article provides an overview of the degradation of metals and alloys in aqueous systems. The importance of the hydrogen ion lies in its ability to interact with an alloy surface. The article describes the effects of various conditions of pH on corrosion including strongly acid conditions, near-neutral conditions, and strongly basic conditions as well as the effects of temperature on corrosion. The influence of the fluid flow rate on corrosion depends on the alloy, fluid components, fluid physical properties, geometry in which the fluid is contained, and corrosion mechanism. The article discusses the influence of fluid flow rate through specific examples. It concludes with information on how the concentration of dissolved species works with other variables to influence corrosion behavior.

This article provides a general introduction to the kinetics of aqueous corrosion with an emphasis on electrochemical principles. It describes the thermodynamic basis for corrosion by determining the equilibrium potentials of electrochemical reactions from the Nernst equation. A corrosion process can be controlled by the electronic conductivity of passive films when the cathodic reaction occurs on the surface of the film and by activation control of corrosion. Passivation becomes thermodynamically possible when the corrosion potential exceeds the potential corresponding to the equilibrium between a metal and one of its oxides/hydroxides. The article schematically illustrates a current-potential or polarization curve for an anodic process.

Corrosion of metallic materials is governed by electrochemical kinetics, so that the general concepts developed for studying electrochemical reaction mechanisms may be applied to corrosion. This article presents the fundamental aspects of electrode kinetics. The processes of charge transfer taking place at the electrode interface within the double layer and of mass transport at the vicinity of the electrode surface are discussed. The article describes the corrosion processes, which involve anodic and cathodic reactions at specific electrode sites. Some experimental methods for devising a reliable reaction model are detailed. The article explains some reaction mechanisms for cathodic and anodic processes to illustrate the great variety of reaction mechanisms occurring at the electrode interface.

This article describes the methods of wear measurements and a model of corrosive wear in mill atmospheres. It explains the polarization curves of pyrrhotite and high-carbon low-alloy steel in a quartzite slurry with examples. The surfaces of pyrrhotite in contact with mild steel or stainless steel affected by galvanic interaction are discussed. The article contains a table that lists the results of laboratory marked ball wear tests for three types of steel balls in wet grinding of magnetic taconite. It also provides information on the mechanism of electrochemical interaction and relative significance of corrosion and abrasion in wear. Galvanic interactions in multielectrode systems are reviewed. The article presents a case history on the material selection for grinding balls to minimize corrosion loss and the adverse effect on flotation.

This article addresses electrochemical methods for instantaneous rate determination and threshold determination as well as nonelectrochemical methods that can determine incremental or cumulative rates of corrosion. Electrochemical methods for the study of galvanic corrosion rates and localized corrosion and evaluation of corrosion rates under paints are also discussed. The article describes nonelectrochemical methods that can determine incremental or cumulative rates of corrosion. Methods presented include polarization methods, polarization resistance methods, electrochemical impedance methods, frequency modulation methods, electrochemical noise resistance, potential probe methods, cyclic potentiodynamic polarization methods, potentiostatic and galvanostatic methods, electrochemical noise (EN) methods, scratch-repassivation method, and electrochemical impedance spectroscopy (EIS) techniques. Gravimetric determination of mass loss, electrical-resistance methods, magnetic methods, quartz crystal microbalance method, solution analysis methods, and metrological methods are nonelectrochemical methods. The article presents an electrochemical test that examines the susceptibility of stainless steel alloys to intergranular corrosion.

This article provides a general technical description of thermal spray coatings used for corrosion protection in atmospheric and aqueous environments. It further discusses two basic coating approaches of corrosion protection, namely, the sacrificial coating of thermal spray aluminum (TSA) and thermal spray zinc (TSZ), and the barrier-type coating of corrosion-resistant materials. The emphasis is on sacrificial coatings. The article describes the steps involved in the application of TSA and TSZ: surface preparation, coating deposition, and postspray treatment. It discusses their field exposure tests and application history. The article also contains helpful information on the dense barrier coatings by high-velocity spraying processes along with their corrosion performance.

This article reviews the corrosion behavior of intermetallics for the modeling of the corrosion processes and for devising a strategy to create corrosion protective systems through alloy and coating design. Thermodynamic principles in the context of high-temperature corrosion and information on oxidation; sulfidation; hot corrosion of NiAl-, FeAl-, and TiAl-based intermetallics; and silicides are included. The article explores the thermodynamic consideration, ordering influencing kinetics, stress-cracking corrosion, and hydrogen embrittlement of aqueous corrosion. It also explains the practical issues dealing with the corrosion problems.