Chapter 5 - Metal Alloys

7/25/2019 Chapter 5 - Metal Alloys

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DJJ3213 MATERIAL SCIENCECHAPTER 5 METAL ALLOYS

MOHD HAFIZ BIN ALIJABATAN KEJURUTERAAN MEKANIKAL

POLITEKNIK KOTA KINABALU


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Alloy s!!ls "#! $#o%&'"#(o% "lloys) o *+$'+ "lloy$%,!l!-!%s "#! "..!. *$+ " /0#/os! o $-/#o! +!s!!ls /#o/!#$!s "s 'o-/"#!. o +! '"#(o% s!!ls

Co%"$% -o#! +"% 14 o o+!# !l!-!%s $%s!". o

F! "%. CP0#/os! o "lloy$%, I%'#!"s! +"#.!%"($l$y I-/#o! s#!%,+ " o#.$%"#y !-/!#"0#! I-/#o! -!'+"%$'"l /#o/!#$!s " !$+!# +$,+ o# lo*

!-/!#"0#!s I-/#o! o0,+%!ss " "%y -$%$-0- +"#.%!ss o# s#!%,+ I%'#!"s! *!"# #!s$s"%'! I%'#!"s! 'o##os$o% #!s$s"%'! I-/#o! -",%!$' /#o/!#$!s

ALLOY STEELS


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FERROUS AND NONFERROUSALLOYS


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Classifcation. Three types o errous alloys:

I#o%6 l!ss +"% 7 * 4 C $% 89!##$! " #oo- T

S!!ls6 7 & 21: * 4 C ;0s0"lly < 1 * 4 = 8&!##$! >F!3C " #oo- T ;C+"/!# 12=

C"s $#o%6 21: & ?@ * 4 ;0s0"lly < :5 * 4=

TYPES OF FERROUS ALLOYS


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CARBON STEELS

C"#(o% s!!ls "#! ,#o0/(y +!$# /!#'!%",! o'"#(o% 'o%!% /!#*!$,+ T+! +$,+!# +!

'"#(o% 'o%!% +!,#!"!# +! +"#.%!ss)s#!%,+ "%. *!"##!s$s"%'! "!# +!"#!"-!%

Low-carbon steel, "lso'"ll!. -$l. s!!ls) +"s

l!ss +"% 34 '"#(o%Us!. $% !!#y."y$%.0s#$"l /#o.0's l$!(ols) %0s) s+!!) /l"!"%. 0(!s High Carbon Steel

Nails


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CARBON STEELS

Medium-carbon steel+"s 34 o ?4 '"#(o%Us!. o# o(s #!0$#$%, +$,+!# s#!%,+ s0'+ "s-"'+$%!#y) "0o-o$! !0$/-!% /"#s) "%.-!"l*o#$%, !0$/-!%

High-carbon steel+"s -o#! +"% ?4 '"#(o%Us!. /"#s +" #!0$#! +! +$,+!s s#!%,+)+"#.%!ss) "%. *!"# #!s$s"%'! O%'! -"%0"'0#!.+!y "#! +!" #!"!. "%. !-/!#!.


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STAINLESS STEELS

tainless steels "#!/#$-"#$ly %o* o#

+!$# 'o##os$o%#!s$s"%'!) +$,+s#!%,+) "%..0'$l$y "%.'+#o-$0- 'o%!%


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STAINLESS STEELS

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'+#o-$0- 'o%!% o 14 o 124 (y *!$,+


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STAINLESS STEELS

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STAINLESS STEELSUs$%, s"$%l!ss s!!ls "s #!$%o#'$%, ("#s) +"s

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'o%'#!! $s!l

Rebar

corrosion inconcrete


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OERIEG OF CAST IRON

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IRON CARBON DIARAM

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> F!3C

> L

>

L > F!3C

@23C

1C

4 74 24 34

> F!3CC"s I#o%

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TYPES OF CAST IRON

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REY CAST IRON


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NODULAR;DUCTILE= IRON

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MICROSTRUCTURE

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PROPERTIES

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APPLICATIONS

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MALLEABLE CAST IRON

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MICROSTRUCTURE

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PROPERTIES

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APPLICATIONS

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GHITE CAST IRON


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CHARACTERISTICS ANDAPPLICATION OF NONFERROUS

ALLOY MATERIALS


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TITANIUM

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TITANIUM

Us!. $%A!#os/"'! /"#sR"'$%, '"#s) -oo#'y'l!s "%. ($'y'l!sP$/!*o# "%. +!" !'+"%,!#s $% '+!-$'"l /l"%s "%.

o$l $%s"ll"$o%s


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T$"%$0- +!"&!'+"%,!#s


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WHAT IS CORROSION?

Corrosion is the oxidation of a metal due to anELECTROCHEMICAL reaction. The oxidizing agent ismost often O2 atmos!heric corrosion" or H

# chemical

corrosion" or $oth.

Why is it a problem?%inancial & '()* +illion ,ollar Annual -ro$lem in ./.0.2)1 of 3-" ,e!artment of ,efense s!ends '4 5

6 +illion


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RECIPE FORCORROSION

Acti7e metal

8ater

Ox9genatmos!hericcorrosion"

Acidchemicalcorrosion"

/alt

Hightem!erature

Corrosion

Triangle

Electrolyte

Metal Oxidize


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3:

Electrochemical corrosion- Corrosion produced by thedevelopment of a current in an electrochemical cell thatremoves ions from the material.

Electrochemical cell- A cell in which electrons and ions

can flow by separate paths between two materials,producing a current which, in turn, leads to corrosion orplating.

Oxidation reaction- The anode reaction by whichelectrons are given up to the electrochemical cell.

eduction reaction- The cathode reaction by whichelectrons are accepted from the electrochemical cell.

El!'#o'+!-$'"l Co##os$o%


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35

2003 Brooks /Cole, a division of Thomson Learning, Inc. Thomson Learningis a trademark sed herein nder license.

!igure "".# The components in an electrochemical cell: $a% asimple electrochemical cell and $b% a corrosion cell between asteel water pipe and a copper ftting.


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3?

2003 Brooks/ Cole, a division of Thomson Learning, Inc. Thomson Learningis a trademark sed herein nder license.

!igure "".& The anode and cathode reactions in typicalelectrolytic corrosion cells: $a% the hydrogen electrode, $b% theo'ygen electrode, and $c% the water electrode.


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TYPES OF CORROSION

:

Co##os$o% $s +! /#$-"#y -!"%s (y*+$'+ -!"ls .!!#$o#"! Mos -!"ls

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s0l0# 'o%"$%$%, ,"s!s


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Corrosion Mechanism :Co##os$o% M!'+"%$s- $s +! .!s#0'$!

""') o# .!!#$o#"$o%) o " -!"l (y'+!-$'"l o# !l!'#o'+!-$'"l #!"'$o% *$+ $s

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Uniform Corrosion


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UNIFORM CORROSION

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Pitting


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PITTIN CORROSION

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Erosion-Corrosion


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EROSION CORROSION

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s0(!' o +$s y/! o""'


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Fretting Corrosion


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Fretting corrosion ) *+$'+ #!s0ls #o- sl$,+ #!l"$!-o$o% ;"s $% $(#"$o%= o *o s0(s"%'!s $% 'o%"')o%! o# (o+ (!$%, -!"ls) 0s0"lly l!".s o " s!#$!s o/$s " +! -!"l $%!#"'! M!"l & o$.! .!(#$s0s0"lly lls +! /$s so +" o%ly "!# +! 'o##os$o%/#o.0's "#! #!-o!. .o +! /$s (!'o-! $s$(l!


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Cavitation Erosion


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Selective Corrosion


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Intergranular Corrosion


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Corrosion Fatigue


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Galvanic Corrosion


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Crevice Corrosion


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SELECTIE CORROSION

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Methods to Control Corrosion

There are five methods to control corrosion:

material selection

coatings

changing the environment

changing the potential

design

HOG TO AOID ;OR


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HOG TO AOID ;ORCONTROL= CORROSIONWM"!#$"l S!l!'$o%X R!-!-(!# !%$#o%-!% !y

Loo " /o!%$"l /H .$",#"-sXXXEl$-$%"! "%y o%! o +! : #!-!%s o# 'o##os$o%X"l"%$' & Ao$. 0s$%, .$ss$-$l"# -!"ls O# 'los! o,!+!# "s /oss$(l! O# !l!'#$'"lly $sol"! o%! #o- +! o+!# O# MAKE ANODE BIXXX

HOG TO AOID ;OR


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HOG TO AOID ;ORCONTROL= CORROSIONWP$$%,C#!$'!6 G"'+ o# s",%"! *"!# !l!'#oly! Us! ,"s!s Us! ,oo. *!l.$%, /#"'$'!s

I%!#,#"%0l"# *"'+ ,#"$% s$Q!) !%$#o%-!%)

!-/!#"0#!) !' C"#!0l *$+ S"$%l!ss S!!ls "%.AL

HOG TO AOID ;OR


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HOG TO AOID ;ORCONTROL= CORROSIONW

Co%s$.!# o#,"%$' 'o"$%, ;/"$%)'!#"-$') '+#o-!) !'= DANER IF ITETS SCRACTHEDXX

OR BETTER YET) 'o%s$.!# '"+o.$'/#o!'$o%6 s0'+ "s Q$%' ;o# ,"l"%$Q!.= /l"$%, o% s!!lM, s"'#$'$"l "%o.! o% s!!l (o" +0ll I-/#!ss!. '0##!%) !'


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CORROSION CONTROL6

Anodic Protection Zinc coating of steel. KNOW OW T!" WO#K"$$


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%&"!'N for Corrosion


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%&"!'N for Corrosion

(rac)et easier

to replace thanpipe$


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SURFACE TREATMENT ;COATINS=

O#,"%$' /"$%sChromating and phosphating:

T+! P#o'!ss & '+#o-"$ %, "%. /+os/+"$%, "#! s0# "'!&'o"$%, /#o'!ss!s +"!%+"%'! +! 'o##os$o% #!s$s"%'! o -!"ls Bo+ $%ol! so"$%, +! 'o-/o%!% $% "+!"!. ("+ ("s!. o% '+#o-$' o# /+os/+o#$' "'$.s T+! "'$. #!"'s *$+ +! s0#"'!)

.$ssol$%, so-! o +! s0#"'! -!"l "%. .!/os$$%, " +$% /#o!'$! l"y!# o'o-/l! '+#o-$0- o# /+os/+o#o0s 'o-/o0%.s

A%o.$Q$%, ;"l0-$%0-) $"%$0-= T+! P#o'!ss & Al 0-$%0- $s " #!"'$! -!"l) y! $% !! #y."y o(!'s $ .o!s %o

'o##o.! o# .$s'olo# T+" $s (!'"0s! o " +$% o$.! l- & Al2O3 & +" o#-ss/o%"%!o0sly o% $s s0#"'!) "%. +$s l-) +o0,+ $%$s$(l!) $s +$,+ly /#o!'$! T+! l- '"% (! +$'!%!. "%. $s s#0'0#! 'o%#oll!. (y +! /#o'!ss o "%o.$Q$%, T+!

/#o'!ss $s !l!'#oly$' +! !l!'#oly!) y/$'"lly) $s .$l0! ;154= s0l0#$' "'$.A%o.$Q$%, $s -os ,!%!#"lly "//l$!. o "l0-$%0-) (0 -",%!s$0-) $"%$0-) Q$#'o%$0-"%. Q$%' '"% "ll (! #!"!. $% +$s *"y T+! o$.! o#-!. (y "%o.$Q$%, $s +"#.)"(#"s$o% #!s$s"% "%. #!s$ss 'o##os$o% *!ll T+! l-&s0#"'! $s -$'#o&/o#o0s)"llo*$%, $ o "(so#( .y!s) ,$$%, -!"ll$' #!!'$$y *$+ "% "#"'$! ,ol.) $#$.$"%)"Q0#! o# #os!&'olo#!. s+!!% "%. $ '"% (! /"!#%!. T+! /#o'!ss $s '+!"/) "%$-/"#s (o+ 'o##os$o% "%. *!"# #!s$s"%'! o +! s0#"'!


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SURFACE TREATMENT ;COATINS=

El!'#o&/l"$%, T+! P# o'!ss &M!" l 'o"$%, /#o '!ss *+!#! $% " +$% -!" ll $' 'o" $s .!/o s$!. o% +! *o#/$!'! (y-!"%s o "% $o%$Q!. !l!'#oly$' sol0$o% T+! *o#/$!'! ;'"+o.!= "%. +! -!"ll$Q$%, so0#'!-"!#$"l ;"%o.!= "#! s0(-!#,!. $% +! sol0$o% *+!#! " .$#!' !l!'#$'"l '0##!% '"0s!s +!-!"ll$' $o%s o -$,#"! #o- +! so0#'! -"!#$"l o +! *o#/$!'! T+! *o#/$!'! "%. so0#'!-!"l "#! s0s/!%.!. $% +! $o%$Q!. !l!'#oly$' sol0$o% (y $%s0l"!. #o.s T+o#o0,+ s0#"'!'l!"%$%, /#!'!.!s +! /l"$%, o/!#"$o% Pl"$%, $s '"##$!. o0 o# -"%y #!"so%s6 'o##os$o%#!s$s"%'!) $-/#o!. "//!"#"%'!) *!"# #!s$s"%'!) +$,+!# !l!'#$'"l 'o%.0'$$y) (!!# !l!'#$'"l'o%"') ,#!"!# s0#"'! s-oo+%!ss "%. (!!# l$,+ #!!'"%'!

Bl0$%, (luing $s " /"ss$"$o%/#o'!ss $% *+$'+ s!!l $s /"#$"lly /#o!'!. ","$%s #0s) "%. $s %"-!.

"!# +! (l0!&(l"' "//!"#"%'! o +! #!s0l $%, /#o!'$! %$s+ T#0! ,0%(l0$%, $s "%!l!'#o'+!-$'"l 'o%!#s$o% 'o"$%,#!s0l $%, #o- "% o$.$Q$%, '+!-$'"l #!"'$o% *$+ $#o% o% +!s0#"'! s!l!'$!ly o#-$%, -",%!$! ;F! 3O:=) +! (l"' o$.! o $#o%) *+$'+ o''0/$!s +! s"-!ol0-! "s %o#-"l $#o% Do%! o# (ols '"ll!. (l"'!%$%,V

Ho&.$/ Co"$%, ;$! ,"l"%$Q$%,= Ho .$//$%, $s " /#o'!ss o # 'o" $%, " -!"l ) -"$%ly ! ##o0s -!"ls) *$+ lo* -!l $%, /o$% -!"ls 0s0"l ly Q $%' "%.

$s "l loys T+! 'o-/o%!% $s #s .!,#!"s!. $% " '"0s $' ("+) +!% /$'l!. ;o #!-o! #0s "%. s'"l!= $% " s0l 0# $'"'$. ("+) $--!#s!. ;.$//!.= $% +! l $0$. -!"l "%.) "!# l $ $%, o0 ) $ $s 'ool!. $% " 'ol. "$ # s#!"- T+! -ol!%-!"l "l loys *$+ +! s0#"'! o +! 'o-/o%!%) o#-$%, " 'o% $%0o0s +$% 'o" $%, G+!% +! 'o" $%, $s Q $%' "%.+! 'o-/o%!% $s s!!l ) +! /#o'!ss $s %o*% "s ,"l"%$Q $%,

T+! /#o '! ss $s !#y !#s" $l ! "%. '"% (! "//l $! . o 'o-/o %!%s o "%y s+"/!) "%. s$Q !s 0/ o 3 - 2 - : -T+! 'os $s 'o-/"#"(l! *$ + +" o /"$% $% ,) (0 + ! /#o ! '$ o% o !#! . (y ,"l"%$ Q $%, $s -0'+ ,#! "! # ) (!'"0s! $ +! 'o" $%, $s s'#"'+!. $ $s +! Q $%' %o +! 0%.!# ly$%, s!!l +" 'o##o.!s ;[,"l"%$' /#o!' $o%[= P#o/!# ly,"l"%$Q!. s!!l *$ l l s0#$! o0.oo#s o# 3&: y!"#s *$+o0 0#+!# #!"-!%

%isc*ss and sho+ (olts$$$
http://en.wikipedia.org/wiki/Passivationhttp://en.wikipedia.org/wiki/Rusthttp://en.wikipedia.org/wiki/Gunhttp://en.wikipedia.org/wiki/Gunhttp://en.wikipedia.org/wiki/Conversion_coatinghttp://en.wikipedia.org/wiki/Magnetitehttp://en.wikipedia.org/wiki/Iron_oxidehttp://en.wikipedia.org/wiki/Ironhttp://en.wikipedia.org/wiki/Ironhttp://en.wikipedia.org/wiki/Iron_oxidehttp://en.wikipedia.org/wiki/Magnetitehttp://en.wikipedia.org/wiki/Conversion_coatinghttp://en.wikipedia.org/wiki/Gunhttp://en.wikipedia.org/wiki/Rusthttp://en.wikipedia.org/wiki/Passivation


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MATERIAL SELECTION6

)mportance o *'ide flms

T+! 0%."-!%"l #!s$s"%'! o s"$%l!ss s!!l o'o##os$o% o''0#s (!'"0s! o $s "($l$y o o#- "%o$.! /#o!'$! 'o"$%, o% $s s0#"'! T+$s +$%

'o"$%, $s $%$s$(l!) (0 ,!%!#"lly /#o!'s +!s!!l $% o$.$Q$%, !%$#o%-!%s ;"$# "%. %$#$'"'$.= Ho*!!#) +$s l- los!s $s /#o!'$!%!ss$% !%$#o%-!%s s0'+ "s +y.#o'+lo#$' "'$. "%.'+lo#$.!s I% s"$%l!ss s!!ls) l"' o oy,!% "lso#0$%s +! 'o##os$o% /#o!'$! o$.! l-)+!#!o#! +!s! .!(#$s #$..!% o# s",%"%#!,$o%s "#! s0s'!/$(l! o 'o##os$o%

CATHODIC PROTECTION ;CP=


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CATHODIC PROTECTION ;CP=

Cathodic protection ;C+= $s " !'+%$0! o 'o%#ol +!'o##os$o%o " -!"l s0#"'! (y -"$%, $ *o# "s " '"+o.!o"% !l!'#o'+!-$'"l '!ll T+$s $s "'+$!!. (y /l"'$%, $% 'o%"'*$+ +! -!"l o (! /#o!'!. "%o+!# -o#! !"s$ly 'o##o.!.-!"l o "' "s +! "%o.! o +! !l!'#o'+!-$'"l '!ll C"+o.$'

/#o!'$o% sys!-s "#! -os 'o--o%ly 0s!. o /#o!' s!!l)*"!# o# 0!l /$/!l$%!s"%. so#",! "%s) s!!l /$!# /$l!s) s+$/s)os+o#! o$l /l"o#-s"%. o%s+o#! o$l *!ll'"s$%,s
http://en.wikipedia.org/wiki/Corrosionhttp://en.wikipedia.org/wiki/Cathodehttp://en.wikipedia.org/wiki/Electrochemical_cellhttp://en.wikipedia.org/wiki/Electrochemical_cellhttp://en.wikipedia.org/wiki/Steelhttp://en.wikipedia.org/wiki/Pipeline_transporthttp://en.wikipedia.org/wiki/Storage_tankhttp://en.wikipedia.org/wiki/Pileshttp://en.wikipedia.org/wiki/Oil_platformhttp://en.wikipedia.org/wiki/Oil_wellhttp://en.wikipedia.org/wiki/Oil_wellhttp://en.wikipedia.org/wiki/Oil_platformhttp://en.wikipedia.org/wiki/Pileshttp://en.wikipedia.org/wiki/Storage_tankhttp://en.wikipedia.org/wiki/Pipeline_transporthttp://en.wikipedia.org/wiki/Steelhttp://en.wikipedia.org/wiki/Electrochemical_cellhttp://en.wikipedia.org/wiki/Electrochemical_cellhttp://en.wikipedia.org/wiki/Cathodehttp://en.wikipedia.org/wiki/Corrosion


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Ty/!s o CP6 s"'#$'$"l "%o.!s Q$%') -",%!s$0- o# "l0-$%0- T+! s"'#$'$"l

"%o.!s "#! -o#! "'$! ;-o#! %!,"$! /o!%$"l= +"% +! -!"lo +! s#0'0#! +!y#! .!s$,%!. o /#o!' T+! "%o.! /0s+!s+! /o!%$"l o +! s!!l s#0'0#! -o#! %!,"$! "%. +!#!o#!+! .#$$%, o#'! o# 'o##os$o% +"ls T+! "%o.! 'o%$%0!s o'o##o.! 0%$l $ #!0$#!s #!/l"'!-!%)

I-/#!ss!. '0##!% CP .o%! o# l"#,! s#0'0#!s ;/$/!s) os+o#!/l"o#-s) !'= *+!#! " ,"l"%$' ;o# s"'#$'$"l= "%o.! '"% %o!'o%o-$'"lly .!l$!# !%o0,+ '0##!%

"l"%$Q!. s!!l ","$%) s!!l $s 'o"!. *$+ Q$%' "%. $ +! Q$%''o"$%, $s s'#"'+!. "%. s!!l !/os!.) +! s0##o0%.$%, "#!"s o

Q$%' 'o"$%, o#- " ,"l"%$' '!ll *$+ +! !/os!. s!!l "%./#o!'s $% #o- 'o##o.$%, T+! Q$%' 'o"$%, "'s "s " s"'#$'$"l"%o.!


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"ee &,,on Mo-il e,ample


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Al*mini*manodes mo*nted on a steel

ac)et str*ct*re *sing galvanic corrosion

for corrosion control$ Called cathodic

protection /a)a sacrificial anode0
http://en.wikipedia.org/wiki/Aluminiumhttp://en.wikipedia.org/wiki/Steelhttp://en.wikipedia.org/wiki/Steelhttp://en.wikipedia.org/wiki/Aluminium


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T\

Chapter 5 - Metal Alloys

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Transcript of Chapter 5 - Metal Alloys