This article describes the principal cladding processes and methods for calculating properties of clad metals. It reviews the designing processes of clad metals to achieve specific requirements. The article discusses six categories of clad metal systems designed for corrosion control: noble metal clad systems, corrosion barrier systems, sacrificial metal systems, transition metal systems, complex multilayer systems, and clad diffusion alloys.

Cathodic protection (CP) is an electrochemical means of corrosion control widely used in the marine environment. This article discusses two types of CP systems: impressed current systems and sacrificial anode (passive) systems. It describes the anode materials used in these systems and the CP criteria. The article examines the design considerations and procedures involved in the CP of marine pipelines, offshore structures, and ship hulls. An illustration of sacrificial anode calculation is also provided.

Corrosion of marine- and land-based infrastructure is of major concern and its control forms an important objective. Thermal spray coatings (TSCs) are widely used for corrosion protection. This article focuses on two types of TSCs: cathodic or noble coatings and anodic or sacrificial coatings. It describes the factors affecting the performance of sacrificial TSCs in atmospheric and immersion environments. The article provides information on the applications of sacrificial TSCs, non-sacrificial coatings, and sealants/top coats, and exemplifies the use of sacrificial TSCs on structures for corrosion protection.

Cathodic protection is an electrochemical means of corrosion control in which the oxidation reaction in a galvanic cell is concentrated at the anode, which suppresses corrosion of the cathode in the same cell. This article provides a detailed discussion on the fundamentals and types of cathodic protection as well as their power sources and design considerations. The criteria for the cathodic protection and types of materials used in sacrificial anodes and impressed-current anodes are also discussed. The article provides examples selected for familiarizing the design engineer with the steps for selecting a specific corrosion control method.

This article describes the various factors that affect the extent of corrosion resulting from galvanic coupling. The factors include galvanic series, polarization behavior, and geometric relationship of metals and alloys. The article briefly discusses the various modes of attack that lead to galvanic corrosion of anodic members. It also explains the three electrochemical techniques of screening tests for predicting galvanic corrosion. The electrochemical techniques comprise of potential measurements, current measurements, and polarization measurements. The article provides a detailed discussion on the performance of alloy groupings. It concludes with information on various control methods that reduce or eliminate galvanic-corrosion effects.

Steel storage tanks are the primary means for storing large volumes of liquids and gaseous products. The stored fluid could be water, but it could also be volatile, corrosive, and flammable fluid requiring special precautions for storage as well. Corrosion is generally worst where the tank is in contact with the soil. This article describes the soil characteristics and addresses cathodic protection (CP) criteria for submerged metallic piping systems. It provides information on the data required for designing a CP system, alone or in conjunction with a protective coating system. These data are collected from predesign site assessments, tank electrical characteristics, and soil-resistivity measurements. The article addresses NACE Standard RP0169, which gives requirements and desired characteristics for coating in conjunction with CP. It also explains the methods of protecting aboveground storage tanks and underground storage tanks.

This article presents common conventions and definitions in corrosion, electrochemical cells, cathodic protection (CP), electricity, and oxidation. Evans diagrams for impressed current CP in neutral or basic environment and galvanic or sacrificial CP, in both neutral or basic environment and acidic environment, are illustrated.

This article discusses the factors affecting corrosion behavior. It describes galvanic corrosion and its protection methods. The article also provides information on coatings and inhibitors, which are used in corrosion protection.

A sacrificial coating applied to a steel substrate can add 20 years or more of life to the substrate, depending on its thickness and composition. Different techniques to apply sacrificial coatings offer various characteristics that contribute to corrosion resistance. This article discusses thermal spray, hotdipping, and electroplating processes used to apply coatings in steel structures. It describes the corrosion attributes of the resulting coatings and discusses the methods of protecting steel from corrosion using aluminum and zinc coatings.

This guide rates the compatibility of dissimilar structural materials joined together for service in seawater, marine atmosphere, or industrial atmosphere. It contains a table that indicates the material code and most generally effective surface treatment typically used to reduce corrosion of bare metals.

This article discusses the commonly encountered forms of automotive body corrosion. The corrosion forms include general or uniform corrosion, cosmetic or under-film corrosion, galvanic corrosion, crevice corrosion, poultice or under-deposit corrosion, and pitting corrosion. Corrosion-resistant sheet metals, such as electrogalvanized steel, hot dip galvanized steel, and hot dip galvannealed steel, are reviewed. The article provides information on the paint and sealant systems for corrosion control in automotive body applications.

This article describes the various environments affecting corrosion performance, corrosion protection, and corrosion control. These include freshwater environments, marine environments, and underground environments. The article provides information on corrosion in military environments and specialized environments, representing less-well-known environments with more limited applications.

This article discusses the principles of corrosion and the basis of the various prevention measures that can be taken for different corrosion modes. It describes aqueous corrosion phenomena in terms of the electrochemical reactions that occur at the metal-environment interface. The article explains the specific forms of corrosion, including general corrosion, localized attack, and environmentally assisted cracking. It provides a discussion on the engineering aspects of design that can, without due care and attention, precipitate unexpected premature failure. The article reviews ways to improve corrosion awareness and prevent corrosion/degradation. It describes a life prediction method with an example of environmental degradation in light-water nuclear reactors. The article concludes with a discussion on the validation of life-prediction algorithms and their applications.

Environmental and worker health regulations have increased the costs associated with cadmium coating application and cadmium-beating waste disposal, thus creating economic incentives for industrial users to seek cadmium plating replacements. This article presents a cadmium replacement identification matrix that includes information on the specifications, corrosion control performance, environment-assisted cracking, coating lubricity, environmental and worker health regulations, and cost and performance factors for various replacement processes.

From the standpoint of corrosion protection of iron and steel, metallic coatings can be classified into two types: noble coatings and sacrificial coatings. This article focuses on hotdipped zinc, aluminum, zinc-aluminum alloy and aluminum-zinc alloy coatings. It discusses the Sendzimir process and the Cook-Norteman process, which are the two commercial processes that are used for almost all hot-dip galvanized sheet steel in the United States. The article provides a discussion on the aqueous corrosion and atmospheric corrosion of galvanized steel and aluminized steel, as well as the intergranular corrosion of galvanized steel.

This article discusses the basic operating principles, industrial applications, and advantages as well as the parameters influencing the process of laser-induced forward transfer (LIFT) of solid materials, liquid materials, laser-absorbing layers, intact structures, and metallic 3D microstructures in additive manufacturing.

Nonferrous metals and alloys are widely used to resist corrosion. This article describes the corrosion behavior of the most widely used nonferrous metals, such as aluminum, copper, nickel, and titanium. It also provides information on several specialty nonferrous products that cannot easily be categorized by elemental base.

A tin deposit provides sacrificial protection to copper, nickel, and many other nonferrous metals and alloys. Tin also provides good protection to steel. Tin can be deposited from either alkaline or acid electrolytes. This article explains the compositions and operating conditions of these electrolytes.

The major benefit of the implementation of the corrosion-control technologies at Army installations is the extension of the service life of buildings and other structures. This article reviews the exposure of military facilities and equipment to a wide variety of environmental conditions, including soils, waters, or atmospheres of varying corrosivity. It presents the case studies illustrating typical examples of the types of corrosion problems found on military installations. The article describes the various corrosion-control technologies used in military facilities. These include protective coatings and linings, cathodic protection, advanced materials selection and design, water treatment, equipment inspection and monitoring, and below-grade moisture mitigation.