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材料专业学术英语——6.Corrosion of metals

材料专业学术英语——6.Corrosion of metals
材料专业学术英语——6.Corrosion of metals

To one degree or another, most materials experience some type of interaction with a large number of diverse environments. Often, such interactions impair a material’s usefulness as a result of the deterioration of its mechanical properties (e.g., ductility and strength), other physical properties, or appearance. Occasionally, to the chagrin of a design engineer, the degradation behavior of a material for some application is ignored, with adverse consequences.

Deteriorative mechanisms are different for the three material types. In metals, there is actual material loss either by dissolution (corrosion) or by the formation of nonmetallic scale or film (oxidation). Ceramic materials are relatively resistant to deterioration, which usually occurs at elevated temperatures or in rather extreme environments; the process is frequently also called corrosion. For polymers, mechanisms and consequences differ from those for metals and ceramics, and the term degradation is most frequently used. Polymers may dissolve when exposed to a liquid solvent, or they may absorb the solvent and swell; also, electromagnetic radiation (primarily ultraviolet) and heat may cause alterations in their molecular structures.

Corrosion of metals is the spontaneous chemical (oxidative) destruction of metals under the effect of their environment. Most often it follows an electrochemical mechanism, where anodic dissolution (oxidation) of the metal and cathodic reduction of an oxidizing agent occur as coupled reactions. Sometimes a chemical mechanism is observed. Corrosion (rusting) of metals is causing huge losses to the economy. This process affects the metal structures of buildings and bridges, the equipment of chemical and metallurgical plants, river and sea vessels, underground pipelines, and other structures. In the United States, for instance, corrosion-related losses approach a figure of $100 billion per year, which is almost 5% of the gross national product. Direct losses attributable to corrosion include expenditures for the replacement of individual parts, units, entire lines or plants, and for various preventive and protective tasks (such as the application of coatings for corrosion protection). Indirect losses arise when corroded equipment leads to defective products that must be rejected; they also arise during downtime required for preventive maintenance or repair of equipment. About 30% of all steel and cast iron are lost because of corrosion. Part of this metal can be reprocessed as scrap, but about 10% is

irrevocably lost.

The significance of corrosion protection has risen sharply in recent years for a number of reasons: (1) because of efforts to reduce the metal content of parts (e.g., by using thinner metallic support structures); (2) with the use of new types of equipment and processes involving expensive equipment operated under extreme conditions, such as nuclear reactors and jet and rocket engines; and (3) in connection with the development of products having extremely thin metal films, such as printed circuit boards and integrated circuits.

Corrosion phenomena can be classified according to the type of corroding medium acting on the metal. Corrosion in nonelectrolytic media is distinguished from that in electrolytic media. The former include dry hot gases, organic liquids (e.g., gasoline), and molten metals. Electrolytic media are most diverse, and include ambient air (with moisture and other components), water (seawater, tap water) and aqueous solutions (acids, alkalies, salt solutions), moist soil (for underground pipelines, piles, etc.), melts, and nonaqueous electrolyte solutions.

Corrosion phenomena can also be classified according to the visible aspects of corrosive attack (Fig. 22.1). This may be general (continuous), affecting all of the exposed surface of a metallic object, or localized. General corrosion can be uniform and nonuniform. Depending on the width and depth of the segments affected by localized corrosion, we may speak of spot, pit (large or small), or subsurface corrosion. Often, intercrystalline corrosion is encountered, which propagates in the zones between individual metal crystallites. Cracks develop between or in individual crystals in the case of stress corrosion cracking.

For metallic materials, the corrosion process is normally electrochemical, that is, a chemical reaction in which there is transfer of electrons from one chemical species to another. Metal atoms characteristically lose or give up electrons in what is called an oxidation reaction. For example, the hypothetical metal M that has a valence of n (or n

valence electrons) may experience oxidation according to the reaction

in which M becomes an n+ positively charged ion and in the process loses its n valence

electrons; is used to symbolize an electron. Examples in which metals oxidize are

The site at which oxidation takes place is called the anode; oxidation is sometimes called

an anodic reaction.

The electrons generated from each metal atom that is oxidized must be transferred to and

become a part of another chemical species in what is termed a reduction reaction. For example, some metals undergo corrosion in acid solutions, which have a high concentration of hydrogen (H+) ions; the H+ ions are reduced as follows:

and hydrogen gas (H2) is evolved.

Any metal ions present in the solution may also be reduced; for ions that can exist

in more than one valence state (multivalent ions), reduction may occur by

in which the metal ion decreases its valence state by accepting an electron. Or a

metal may be totally reduced from an ionic to a neutral metallic state according to

Some corrosion prevention methods were treated relative to the eight forms of corrosion; however, only the measures specific to each of the various corrosion types were discussed.Now, some more general techniques are presented; these include material selection, environmental alteration, design, coatings, and cathodic protection.

Perhaps the most common and easiest way of preventing corrosion is through the judicious selection of materials once the corrosion environment has been characterized. Standard corrosion references are helpful in this respect. Here, cost may be a significant factor. It is not always economically feasible to employ the material that provides the optimum corrosion resistance; sometimes, either another alloy and/or some other measure must be used.

Changing the character of the environment, if possible, may also significantly influence corrosion. Lowering the fluid temperature and/or velocity usually produces a reduction in the rate at which corrosion occurs. Many times increasing or decreasing the concentration of some species in the solution will have a positive effect; for example, the metal may experience passivation.

Inhibitors are substances that, when added in relatively low concentrations to the environment, decrease its corrosiveness. Of course, the specific inhibitor depends both on the alloy and on the corrosive environment.There are several mechanisms that may

account for the effectiveness of inhibitors. Some react with and virtually eliminate a chemically active species in the solution (such as dissolved oxygen). Other inhibitor molecules attach themselves to the corroding surface and interfere ith either the oxidation or the reduction reaction, or form a very thin protective oating. Inhibitors are normally used in closed systems such as automobile radiators and steam boilers.

Several aspects of design consideration have already been discussed, especially with regard to galvanic and crevice corrosion and erosion–corrosion. In addition, the design should allow for complete drainage in the case of a shutdown, and easy washing. Since dissolved oxygen may enhance the corrosivity of many solutions, the design should, if possible, include provision for the exclusion of air.

Physical barriers to corrosion are applied on surfaces in the form of films and coatings. A large diversity of metallic and nonmetallic coating materials are available. It is essential that the coating maintain a high degree of surface adhesion, which undoubtedly requires some preapplication surface treatment. In most cases, the coating must be virtually nonreactive in the corrosive environment and resistant to mechanical damage that exposes the bare metal to the corrosive environment. All three material types—metals, ceramics, and polymers—are used as coatings for metals.

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