This chapter covers the engineering aspects of corrosion inhibitors and their effect on corrosion reactions. It explains how different metallic salts and heterocyclic compounds influence chemical reactions on metal surfaces exposed to corrosive media or environments. It describes how to evaluate inhibition efficiency through weight loss measurements, linear polarization resistance tests, electrochemical impedance spectroscopy, electrochemical noise monitoring, and surface analysis. It demonstrates the use of potentiodynamic polarization curves, Tafel extrapolations, equivalent circuit models, and various methods for characterizing corrosion damage and protective surface films. It also discusses typical applications, industry trends, and the emerging role of high-throughput experimentation, quantitative modeling, and machine learning in the development of cleaner and more effective corrosion inhibitors.

This chapter contains sample problems with worked solutions pertaining to the application of corrosion inhibitors. Correct answers require an understanding of potentiodynamic polarization scan (PDS) curves, the determination of corrosion current and inhibitor efficiency, and the development of a test plan to evaluate the long-term corrosion protection of a potential inhibitor.

This chapter covers the different types of wear encountered in metalworking processes. It discusses the mechanisms involved in adhesive, abrasive, chemical, and fatigue wear and key contributing factors, including the composition and structure of tool and workpiece materials, the characteristics of contact surfaces, and loading forces imposed by the process. It describes the nature of metal transfer between tool and workpiece surfaces and the role of lubricants, coatings, and textures. It also discusses the use of wear maps, the effects of adhesion, and material-lubricant interactions.

This chapter reviews the basic theory of lubrication in the context of metal forming applications. It discusses the rheological properties of fluids and their effect on fluid-film thickness at pressures, temperatures, and loading conditions typical of metal working processes. It describes the three lubrication regimes (boundary, mixed, and hydrodynamic) of a Stribeck curve and the forces that maintain surface separation. It also discusses mixed, elastohydrodynamic, plastohydrodynamic, and solid or semi-solid lubrication, the effects of starvation and frictional instabilities, and the role of elastic deflection and ultrasonic vibration.

This chapter describes the properties and attributes of various classes of metalworking lubricants, including mineral oils; natural oils, fats, derivatives, and soaps; synthetic fluids (olefins, esters, polyglycols, ionic liquids); compounded lubricants (oils, greases, fats); aqueous lubricants (emulsions, synthetics, solutions); and a wide range of coatings and carriers. It also discusses solid-film lubricants (oxide films, polymer films, layer-lattice compounds) and environmental and safety concerns.

Rolling is unique in that it cannot be conducted without friction. Friction draws the workpiece into the roll gap and facilitates its passage through the deformation zone. This chapter provides an overview of the mechanics and tribology of flat rolling processes and explains how various aspects of the theory apply to shape rolling as well. It derives numerous equations and models to help quantify the forces, torque, and power involved in rolling operations and the associated heating, slip, strain distribution, and deformation in both the workpiece and rolls. It describes the friction and wear that occur in hot and cold rolling under hydrodynamic and mixed-film lubrication; the influence of viscosity, film thickness, rolling speed, interface pressure, pass reduction, and lubricant breakdown; and the effect of surface finish and defects. The chapter also provides best practices for evaluating, applying, and treating lubricants for industrially important materials including iron-base, nickel-base, and aluminum alloys.

Drawing is a bulk deformation process that involves significant surface generation and high pressures. This chapter provides an overview of the mechanics and tribology of wire, bar, tube, and shape drawing. It presents important equations for calculating stresses, forces, friction, heat, strain, and distortion for different tooling configurations and geometries. It explains how to select and apply lubricants based on drawing speed, die design, and other factors and how to maintain sufficient film thickness for hydrodynamic, mixed, and solid-film lubrication conditions. It also discusses the use of vibrating dies, the influence of surface finish and defects, and lubrication practices for specific materials.

This chapter deals with the mechanics and tribology associated with the extrusion of bars, sections, and tubes. It covers direct and indirect extrusion processes in detail and demonstrates the use of important equations, relationships, and measurements for determining pressure, force, material flow, friction, die wear, heat generation, and lubrication requirements. The chapter also provides information on hydrostatic, friction-assisted, and severe plastic deformation extrusion processes, discusses the cause of instabilities and defects, and explains how to select and apply lubricants to minimize friction and die wear when extruding steel, aluminum, copper, and refractory metals.

Forging is a deformation process achieved through the application of compressive stresses. During the stroke, pressures and velocities are continuously changing and the initial lubricant supply must suffice for the duration of the operation. Lubricant residues and pickup products also change with time, further complicating the analysis of friction and wear. This chapter provides a qualitative and quantitative overview of the mechanics and tribology of forging in all of its forms. It discusses the effects of friction, pressures, forces, and temperature on the deformation and flow of metals in open-die, closed-die, and impression-die forging and in back extrusion and piercing operations. It presents various ways to achieve fluid-film lubrication in upset forging processes and examines the cause of barreling, defect formation, and folding in the upsetting of cylinders, rings, and slabs. It also explains how to evaluate lubricants, friction, and wear under hot, cold, and warm forging conditions and how to extend die life and reduce defects when processing different materials.

This chapter covers the mechanics and tribology of sheet metalworking processes, including shearing, bending, spinning, stretching, deep drawing, ironing, and hydroforming. It explains how to determine friction, wear, and lubrication needs based on process forces, temperatures, and strains and the effects of strain hardening on workpiece materials. It presents test methods for evaluating process tribology, describes lubrication and wear control approaches, and discusses the factors, such as surface roughness, lubricant breakdown, and adhesion, that can lead to galling and other forms of wear. It also provides best practices for selecting, evaluating, and applying lubricants for specific materials, including steels, stainless steels, and aluminum and magnesium alloys.

In contrast to most plastic deformation processes, the shape of a machined component is not uniquely defined by the tooling. Instead, it is affected by complex interactions between tool geometry, material properties, and frictional stresses and is further complicated by tool wear. This chapter covers the mechanics and tribology of metal cutting processes. It discusses the factors that influence chip formation, including tool and process geometry, cutting forces and speeds, temperature, and stress distribution. It reviews the causes and effects of tool wear and explains how to predict and extend the life of cutting tools based on the material of construction, the use of cutting fluids, and the means of lubrication. It presents various methods for evaluating workpiece materials, chip formation, wear, and surface finish in cutting processes such as turning, milling, and drilling. It also discusses the mechanics and tribology of surface grinding and other forms of abrasive machining.

This chapter covers the tribological properties of different types of oil, greases, solid lubricants, and metalworking and traction fluids. It explains how lubricants are made, how they work, and how they are applied and tested. It also discusses the fundamentals of lubrication and friction control, the relationship between viscosity and breakaway friction, and the factors that affect load-carrying capacity and service life.

This chapter provides a detailed account of crevice corrosion of metals. It begins by describing various critical factors influencing crevice corrosion. This is followed by a section presenting selected examples of crevice corrosion of stainless steel, nickel alloys, aluminum alloys, and titanium alloys in different environments. Methods that have been developed for differentiating and ranking the resistance of alloys toward crevice corrosion are then reviewed. The chapter concludes by discussing various strategies for the prevention of crevice corrosion, namely design awareness, use of inhibitors, and potential control methods.

The basic concept for most methods of corrosion protection is to remove one or more of the electrochemical cell components so that the pure metal or metal alloy of interest will not corrode. Another widely used corrosion protection approach is to change the nature of the anode so that it becomes the cathode (cathodic protection). This chapter briefly reviews these methods of corrosion protection. The factors affecting corrosion behavior are covered. In addition, the chapter provides information on coatings and inhibitors, which are used in corrosion protection.

This chapter provides a detailed account of corrosion inhibitors for oil and gas production. It begins by discussing some of the demands of competitive industry on inhibitor formulations. It then describes the varying characteristics of oil wells, gas wells, water injection systems, and pipelines. The following sections provide information on the factors influencing corrosivity of produced fluids and the methods of inhibitor application. The chapter discusses the primary causes of corrosion problems and inhibition in waterfloods and provides an overview of bacteria-induced corrosion. Various laboratory testing methods of corrosion inhibitors and the methods used to monitor corrosion rates and inhibitor effectiveness are also presented. The chapter ends by providing information on quality control of inhibitors and computerization of inhibitor treating programs.

This chapter describes various units and process streams that are often susceptible corrosion inhibitors in crude oil refineries, discusses the types and applications of corrosion inhibitors, and provides some information on corrosion monitoring techniques used at refineries.

This chapter discusses the particular corrosion problems encountered and the methods of control used in petroleum production and the storage and transportation of oil and gas up to the refinery. It begins by describing those aspects of corrosion that tend to be unique to corrosion as encountered in applications involving oil and gas exploration and production. This is followed by a section reviewing the methods of corrosion control, namely the proper selection of materials, protective coatings, cathodic protection systems, use of inhibitors, use of nonmetallic materials, and control of the environment. The chapter ends with a discussion on the problems encountered and protective measures that are based on the state-of-the-art as practiced daily by corrosion and petroleum engineers and production personnel.