UHLIG’S CORROSION HANDBOOK

THE ELECTROCHEMICAL SOCIETY SERIES

ECS-The Electrochemical Society

65 South Main Street

Pennington, NJ 08534-2839

http://www.electrochem.org

Corrosion HandbookEdited by Herbert H. Uhlig

Modern Electroplating, Third Edition

Edited by Frederick A. Lowenheim

Modern Electroplating, Fifth Edition

Edited by Mordechay Schlesinger and Milan Paunovic

The Electron Microprobe

Edited by T. D. McKinley, K. F. J. Heinrich, and D. B.Wittry

Chemical Physics of Ionic Solutions

Edited by B. E. Conway and R. G. Barradas

High-Temperature Materials and TechnologyEdited by Ivor E. Campbell and Edwin M. Sherwood

Alkaline Storage Batteries

S. Uno Falk and Alvin J. Salkind

The Primary Battery (in Two Volumes)

Volume I Edited by George W. Heise and N. Corey Cahoon

Volume II Edited by N. Corey Cahoon and George W. Heise

Zinc-Silver Oxide Batteries

Edited by Arthur Fleischer and J. J. Lander

Lead-Acid Batteries

Hans Bode

Translated by R. J. Brodd and Karl V. Kordesch

Thin Films-Interdiffusion and Reactions

Edited by J. M. Poate, M. N. Tu, and J. W. Mayer

Lithium Battery Technology

Edited by H. V. Venkatasetty

Quality and Reliability Methods for Primary BatteriesP. Bro and S. C. Levy

Techniques for Characterization of Electrodes andElectrochemical Processes

Edited by Ravi Varma and J. R. Selman

Electrochemical Oxygen Technology

Kim Kinoshita

Synthetic Diamond: Emerging CVD Science and

Technology

Edited by Karl E. Spear and John P. Dismukes

Corrosion of Stainless Steels

A. John Sedriks

Semiconductor Wafer Bonding: Science and Technology

Q.-Y. Tong and U. G€oscle

Uhlig’s Corrosion Handbook, Second Edition

Edited by R. Winston Revie

Atmospheric Corrosion

Christofer Leygraf and Thomas Graedel

Electrochemical Systems, Third Edition

John Newman and Karen E. Thomas-Alyea

Fundamentals of Electrochemistry, Second Edition

V. S. Bagotsky

Fundamentals of Electrochemical Deposition, Second

Edition

Milan Paunovic and Mordechay Schlesinger

Electrochemical Impedance Spectroscopy

Mark E. Orazem and Bernard Tribollet

Fuel Cells: Problems and Solutions

Vladimir S. Bagotsky

UHLIG’S CORROSION HANDBOOK

THIRD EDITION

Edited by

R. WINSTON REVIE

CANMET Materials Technology LaboratoryOttawa, Ontario, Canada

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Library of Congress Cataloging-in-Publication Data:

Uhlig’s corrosion handbook / edited by R. Winston Revie–3rd ed.

p. cm. –(The ECS series of texts and monographs)

Includes index.

ISBN 978-0-470-08032-0

Printed in the United States of America

eBook ISBN: 978-0-470-87285-7

oBook ISBN: 978-0-470-87286-4

10 9 8 7 6 5 4 3 2 1

Herbert H. UhligMarch 3, 1907–July 3, 1993

This Handbook is dedicated to the memory of Herbert H. Uhlig.

Herbert Uhlig began his career at MIT in 1936 where, with the exception of the

interruption caused by World War II, he remained until his retirement nearly 40 years

later, bringing the MIT Corrosion Laboratory to a level of international prominence that

it retains to this day as a major center of excellence. He helped to establish the Corrosion

Division of The Electrochemical Society in 1942 and served as President of the Society

in 1955–1956. His characteristics as an uncompromising innovator and meticulous

scientist who insisted on reliable data and on achieving results led to the success of his

many endeavors as educator and mentor, including the Corrosion Handbook, published in

1948, that he conceived, organized, and edited.

EDITORIAL ADVISORY BOARD

Robert Baboian

RB Corrosion Service

Greenville, Rhode Island

Donald L. Jordan

Ford Motor Company

Dearborn, Michigan

Russell D. Kane

iCorrosion LLC

Houston, Texas

Martin Kendig

Rockwell International Science Center

Thousand Oaks, California

Pradip R. Khaladkar

E.I. DuPont de Nemours & Co., Inc.

Wilmington, Delaware

Ronald M. Latanision

Exponent-Failure Analysis Associates, Inc.

Natick, Massachusetts

Barry MacDougall

National Research Council of Canada

Ottawa, Ontario, Canada

Tomomi Murata

Japan Science and Technology Agency

Saitama, Japan

Srdjan Ne�si�cOhio University

Athens, Ohio

Howard W. Pickering

The Pennsylvania State University

University Park, Pennsylvania

Pierre R. Roberge

Royal Military College of Canada

Kingston, Ontario

Canada

Guenter A. Schmitt

Iserlohn University of Applied Sciences

Iserlohn, Germany

Roger W. Staehle

University of Minnesota and Industrial Consultant

North Oaks, Minnesota

Graham Wood

University of Manchester

Manchester, UK

CONTENTS

Foreword xvii

Foreword to the Second Edition xix

Preface xxi

Contributors xxiii

Introductory Notes on Climate Change, Life-Cycle Design,

and Corrosion of Steel

xxvii

T. Murata

PART I BASICS OF CORROSION SCIENCE AND ENGINEERING

1 Corrosion Failure Analysis with Case Histories 3

L. E. Eiselstein and R. Huet

2 Cost of Metallic Corrosion 15

J. Kruger

3 Economics of Corrosion 21

E. D. Verink, Jr.

4 Lifetime Prediction of Materials in Environments 31

R. W. Staehle

5 Estimating the Risk of Pipeline Failure Due to Corrosion 75

M. Nessim

6 Designing to Prevent Corrosion 83

E. D. Verink, Jr.

7 Simplified Procedure for Constructing Pourbaix Diagrams 93

E. D. Verink, Jr.

ix

8 Pourbaix Diagrams for Multielement Systems 103

W. T. Thompson, M. H. Kaye, C. W. Bale, and A. D. Pelton

9 Computation of Pourbaix Diagrams at Elevated Temperature 111

M. H. Kaye and W. T. Thompson

10 Galvanic Corrosion 123

X. G. Zhang

11 Dealloying 145

R. Heidersbach

12 Passivity 151

J. Kruger

13 Localized Corrosion of Passive Metals 157

H. Bohni

14 Stress Corrosion Cracking 171

R. N. Parkins

15 Hydrogen-Induced Cracking and Sulfide Stress Cracking 183

M. Elboujdaini

16 Corrosion Fatigue 195

Y.-Z. Wang

17 Flow Effects on Corrosion 203

K. D. Efird

18 Erosion–Corrosion in Single- and Multiphase Flow 215

J. Postlethwaite and S. Nesic

19 Carbon Dioxide Corrosion of Mild Steel 229

S. Nesic

20 High-Temperature Oxidation 247

C. A. C. Sequeira

21 Thermochemical Evaluation of Corrosion Product Stabilities

for Alloys in Gases at High Temperature

281

W. T. Thompson, R. C. John, and A. L. Young

22 A Procedure to Compute Equilibrium Gas-Phase Speciation forUse with Predominance Diagrams

287

M. H. Piro, B. J. Lewis, and W. T. Thompson

23 Atmospheric Corrosion 299

P. R. Roberge

x CONTENTS

24 Atmospheric Corrosion in Cold Regions 327

G. A. King

25 Corrosion by Soils 333

T. R. Jack and M. J. Wilmott

26 Microbial Degradation of Materials: General Processes 351

J.-D. Gu, T. E. Ford, and R. Mitchell

27 Corrosion Probability and Statistical Evaluation of Corrosion Data 365

T. Shibata

PART II NONMETALS

28 Corrosion of Refractories and Ceramics 387

M. Rigaud

29 Corrosion of Glass 399

B. Grambow

30 Microbiological Degradation of Polymeric Materials 421

J.-D. Gu, T. E. Ford, D. B. Mitton, and R. Mitchell

31 Durability of Concrete 439

V. M. Malhotra

32 Microbiological Corrosion of Concrete 451

J.-D. Gu, T. E. Ford, and R. Mitchell

33 Microbial Degradation of Wood 461

P. I. Morris

34 Use of Chemicals to Prevent Degradation of Wood 469

J. N. R. Ruddick

PART III METALS

35 Metal–Matrix Composites 481

L. H. Hihara

36 Environmental Degradation of Engineered Barrier Materials

in Nuclear Waste Repositories

503

R. B. Rebak

37 Corrosion Behavior of Electrodeposited Nanocrystals 517

U. Erb

38 Corrosion of Shape Memory and Superelastic Alloys 529

L. E. Eiselstein

CONTENTS xi

39 Microbiological Corrosion of Metallic Materials 549

J.-D. Gu, T. E. Ford, and R. Mitchell

40 Electronic Materials, Components, and Devices 559

R. P. Frankenthal and L. F. Garfias-Mesias

41 Corrosion of Electronics: Lead-Free Initiatives 565

M. Reid and L. F. Garfias-Mesias

42 Metastable Alloys 571

K. Hashimoto

43 Carbon Steel—Atmospheric Corrosion 579

I. Matsushima

44 Carbon Steel—Corrosion in Freshwaters 589

I. Matsushima

45 Carbon Steel—Corrosion by Seawater 601

I. Matsushima

46 Carbon Steel—Corrosion by Soils 609

I. Matsushima

47 Localized Corrosion of Iron and Steel 615

I. Matsushima

48 Weathering Steel 621

T. Murata

49 Corrosion of Steel in Concrete 633

J. P. Broomfield

50 Ethanol Stress Corrosion Cracking of Carbon Steels 649

J. Beavers, F. Gui, and N. Sridhar

51 Austenitic and Ferritic Stainless Steels 657

M. A. Streicher, Revised by J. F. Grubb

52 Duplex Stainless Steels 695

M.-L. Falkland, M. Glaes, and M. Liljas

53 Martensitic Stainless Steels 707

J. F. Grubb

54 Aluminum and Aluminum Alloys 715

E. Ghali

55 Cobalt Alloys 747

P. Crook and W. L. Silence

xii CONTENTS

56 Copper and Copper Alloys 757

C. A. C. Sequeira

57 Lead and Lead Alloys 787

F. E. Goodwin

58 Magnesium and Magnesium Alloys 809

E. Ghali

59 Nickel and Nickel Alloys 837

D. C. Agarwal and N. Sridhar

60 Tin and Tinplate 853

T. P. Murphy

61 Titanium and Titanium Alloys 861

J. Been and J. S. Grauman

62 Zinc 879

X. G. Zhang

63 Zirconium Alloy Corrosion 893

B. Cox

PART IV CORROSION PROTECTION

64 Controlling Flow Effects on Corrosion 903

K. D. Efird

65 Erosion–Corrosion: Recognition and Control 907

J. Postlethwaite and S. Nesic

66 Using Plastics, Elastomers, and Composites for Corrosion Control 915

P. R. Khaladkar

67 Corrosion Control of Steel by Organic Coatings 971

C. H. Hare

68 Selection and Use of Coatings for Underground

or Submersion Service

985

R. Norsworthy

69 Engineering of Cathodic Protection Systems 1001

J. H. Fitzgerald III

70 Stray-Current Analysis 1013

J. H. Fitzgerald III

71 Corrosion Inhibitors 1021

S. Papavinasam

CONTENTS xiii