Corrosion of Aluminium (eBook)

Front Cover 1
Corrosion of Alluminium 4
Copright Page 5
Contents 16
Foreword 8
Foreword to the Original French Edition 10
Introductory Remark 12
Preface to the Original French Edition 14
Acknowledgements 15
Part A: Aluminium and Its Alloys 34
CHAPTER A.1. THE ADVANTAGES OF ALUMINIUM 42
1.1. Lightness 42
1.2. Thermal Conductivity 44
1.3. Electrical Conductivity 45
1.4. Resistance to Corrosion 45
1.5. Suitability for Surface Treatments 46
1.6. The Diversity of Aluminium Alloys 46
1.7. The Diversity of Semi-Products 47
1.8. The Functionality of Castings and Extrusions 48
1.9. The Ease of Use 48
1.10. Recycling 48
References 49
CHAPTER A.2. PHYSICAL PROPERTIES OF ALUMINIUM 52
CHAPTER A.3. THE METALLURGY OF ALUMINIUM 56
3.1. Alloy Series 56
3.2. Casting Alloys 61
3.3. Wrought Alloys 65
Reference 90
CHAPTER A.4. THE MOST COMMON WROUGHT ALUMINIUM ALLOYS 94
4.1. The 1000 Series 94
4.2. The 3000 Series 94
4.3. The 5000 Series 95
4.4. The 8000 Series 98
4.5. The 2000 Series 98
4.6. The 6000 Series 100
4.7. The 7000 Series 101
References 102
CHAPTER A.5. SELECTION CRITERIA FOR ALUMINIUM ALLOYS 106
5.1. Selection Criteria 106
5.2. Selecting an Alloy 107
5.3. Principal Applications of Aluminium and Its Alloys 108
Part B: The Corrosion of Aluminium 110
CHAPTER B.1. THE CORROSION OF ALUMINIUM 114
1.1. Short Historical Introduction 114
1.2. The Electrochemical Basis of Metal Corrosion 115
1.3. The Electrochemical Reactions in the Corrosion of Aluminium 119
1.4. The Standard Potential of a Metal 121
1.5. Dissolution Potentials 124
1.6. Electrochemical Equilibrium (Pourbaix) Diagrams 129
1.7. The Electrochemical Behaviour of Aluminium 134
1.8. Aluminium as a Passive Metal 134
References 141
CHAPTER B.2. TYPES OF CORROSION ON ALUMINIUM 146
2.1. Uniform Corrosion 146
2.2. Pitting Corrosion 146
2.3. Transgranular and Intergranular (Intercrystalline) Corrosion 155
2.4. Exfoliation Corrosion 160
2.5. Stress Corrosion 161
2.6. Filiform Corrosion 167
2.7. Water Line Corrosion 170
2.8. Crevice Corrosion 171
2.9. Cavitation 173
2.10. Erosion 174
2.11. Microbiological Corrosion 174
2.12. Corrosion Products 175
References 177
CHAPTER B.3. GALVANIC CORROSION 182
3.1. Aluminium and Galvanic Corrosion 182
3.2. Definition of Galvanic Corrosion 183
3.3. Form of Galvanic Corrosion 183
3.4. Principle of a Battery 184
3.5. Conditions of Galvanic Corrosion 186
3.6. Galvanic Corrosion Parameters 187
3.7. Practical Aspects of Galvanic Corrosion 188
3.8. The Influence of the type of Metal in Contact with Aluminium in Emerged Assemblies 190
3.9. Contact Between Aluminium Alloys 192
3.10. Predicting Galvanic Corrosion 193
3.11. Prevention of Galvanic Corrosion 194
References 197
CHAPTER B.4. TESTING METHODS 200
4.1. Types of Tests 200
4.2. Goal of Corrosion Testing Methods 201
4.3. Expression of Results 203
4.4. Standardisation of Corrosion Testing Methods 205
4.5. Electrochemical Test Methods 206
References 214
CHAPTER B.5. PROTECTION AGAINST CORROSION 218
5.1. Boehmite Coatings 219
5.2. Chemical Conversion Treatments 220
5.3. Anodising 223
5.4. Paint and other Organic Coatings 226
5.5. Cathodic Protection 227
5.6. Cladding 230
5.7. Zinc Coating 232
5.8. Inhibitors 233
References 237
CHAPTER B.6. THE CORROSION BEHAVIOUR OF ALUMINIUM ALLOYS 244
6.1. Factors Related to the Environment 244
6.2. Factors Related to the Metal 248
6.3. Factors Related to Conditions of Use 250
6.4. The Corrosion Resistance of Aluminium Alloys 251
References 262
Part C: Atmospheric Corrosion of Aluminium 264
CHAPTER C.1. ATMOSPHERIC CORROSION 268
1.1. The Nature of Atmospheric Corrosion 269
References 269
CHAPTER C.2. THE PARAMETERS OF ATMOSPHERIC CORROSION 274
2.1. Relative Humidity 274
2.2. Rain 277
2.3. Fog 279
2.4. Condensation 279
2.5. Temperature 281
2.6. Gaseous Pollutants 281
2.7. Dust 287
2.8. Alternating Periods of Dampness and Dryness 289
References 290
CHAPTER C.3. TYPES OF ATMOSPHERES 294
3.1. The Classic Typology 294
3.2. Standardised Typology 294
3.3. The Predictive Approach 297
References 299
CHAPTER C.4. THE VARIOUS FORMS OF ATMOSPHERIC CORROSION 302
4.1. Pitting Corrosion 302
4.2. Galvanic Corrosion 302
4.3. Filiform Corrosion 305
4.4. Tarnishing Due to Water Staining 305
4.5. Water Staining Due to Storage of Semi-products 305
References 307
CHAPTER C.5. THE RESISTANCE OF ALUMINIUM TO ATMOSPHERIC CORROSION 310
5.1. The Dome of San Gioacchino Church, a 100-year-old Experience 310
5.2. Atmospheric Corrosion of Aluminium Over Time 311
5.3. Weathering Resistance of Wrought Alloys 314
5.4. Weathering of Casting Alloys 318
5.5. Weathering Resistance of Anodised Semi-products 319
References 323
Part D: Corrosion in Water 326
CHAPTER D.1. FRESHWATER 332
1.1. The Physical Chemistry of Water 332
1.2. The Analysis of Water 333
1.3. Typology of Waters 335
1.4. The Various Forms of Aluminium Corrosion in Natural Waters 337
1.5. Blackening of Aluminium 339
1.6. The Action of Water on Aluminium 341
1.7. The Influence of Temperature 347
1.8. The Influence of Oxygen Dissolved in Water 351
1.9. The Influence of pH 352
1.10. The Influence of Water Movement and Flow Speed 353
1.11. Predicting the Resistance of Aluminium in Freshwater 354
1.12. Examples for the Use of Aluminium in Contact with Freshwater 355
1.13. Distilled Water 358
References 358
CHAPTER D.2. BRACKISH WATERS AND WASTEWATER 364
2.1. Brackish Waters 364
2.2. Wastewater 364
References 365
CHAPTER D.3 SEAWATER 368
3.1. Characteristics of Seawater 369
3.2. Marine Environments 374
3.3. Forms of Corrosion in Seawater 375
3.4. Marine Applications of Aluminium 379
References 383
Part E: The Action of Inorganic Products 386
CHAPTER E.1. OXIDES AND PEROXIDES 390
1.1. Oxygen 390
1.2. Ozone 391
1.3. Metal Oxides 391
1.4. Oxides of Copper CuO, Cu2O, Silver Ag2O, Mercury HgO and Lead PbO, Pb2O 392
1.5. Carbon Monoxide CO and Carbon Dioxide CO2 393
1.6. Sulphur Dioxide SO2 394
1.7. Sulphuric Anhydride SO3 395
1.8. Nitrogen Oxides NO2, N2O4 395
1.9. Peroxides 395
1.10. Oxychlorides 397
References 398
CHAPTER E.2. HYDROGEN, NITROGEN, AND NOBLE GASES 402
2.1. Hydrogen H2 402
2.2. Nitrogen 403
2.3. Noble Gases: Argon Ar, Helium He, Krypton Kr, Neon Ne, and Xenon Xe 403
Reference 404
CHAPTER E.3. METALLOIDS AND HALIDES 408
3.1. Phosphoros P, Arsenic As, and Antimony Sb 408
3.2. Carbon C, Silicon Si, and Boron B 408
3.3. Sulphur S 409
3.4. Halogens 410
3.5. Halogen Derivatives 412
3.6. Sulphides 413
References 415
CHAPTER E.4. INORGANIC BASES 418
4.1. Sodium Hydroxide NaOH 418
4.2. Potassium Hydroxide KOH 420
4.3. Lithium Hydroxide LiOH 420
4.4. Calcium Hydroxide Ca(OH)2 421
4.5. Barium Hydroxide Ba(OH)2·8H2O 422
4.6. Ammonia NH3 422
4.7. Ammonia Water NH4OH 423
4.8. Hydrazine N2H4 425
4.9. Urea NH2CONH2 425
References 426
CHAPTER E.5. INORGANIC ACIDS 430
5.1. Hydracids 430
5.2. Oxacids 433
References 447
CHAPTER E.6. INORGANIC SALTS 450
6.1. Fluorides 452
6.2. Chlorides 454
6.3. Chlorates and Perchlorates 458
6.4. Hypochlorites 459
6.5. Bromides and Iodides 460
6.6. Sulphates 461
6.7. Sulphites and Hydrogen Sulphites 464
6.8. Sodium Thiosulphate Na2S2O3·5H2O 464
6.9. Sulphides 464
6.10. Persulphates 465
6.11. Nitrates 465
6.12. Nitrites 467
6.13. Phosphates 468
6.14. Arsenates and Arsenites 469
6.15. Carbonates 470
6.16. Silicates and Metasilicates 471
6.17. Borates, Perborates and Tetraborates 471
6.18. Cyanides, Cyanates and Thiocyanates 472
6.19. Chromates and Dichromates 472
6.20. Permanganates 473
6.21. Carbamates and Sulphamates 473
References 473
Part F: The Action of Organic Products 476
CHAPTER F.1. HYDROCARBONS 480
1.1. Alkanes 480
1.2. Alkenes 481
1.3. Alkynes 482
1.4. Arenes or Aromatic Hydrocarbons 482
1.5. Terphenyls 483
1.6. Cyclic, Non-Benzenic Hydrocarbons 483
1.7. Fuel for Engines 484
1.8. Petroleum Industry 485
1.9. Drilling Sludge 486
References 486
CHAPTER F.2. HALOGEN DERIVATIVES 490
2.1. Derivatives of Acyclic Hydrocarbons 491
2.2. Derivatives of Aromatic Hydrocarbons 498
2.3. Halogen Derivatives of Acids and Phenols 500
CHAPTER F.3. ALCOHOLS, ETHERS, THIOLS AND PHENOLS 506
3.1. The Action of Boiling Alcohols and Dehydrated Phenols on Aluminium 507
3.2. Acyclic Saturated Alcohols 507
3.3. Acyclic Unsaturated Alcohols 509
3.4. Aromatic Alcohols 510
3.5. Other Alcohols 510
3.6. Polyalcohols 511
3.7. Ethers 513
3.8. Thiols and Their Derivatives 516
3.9. Phenols 517
References 519
CHAPTER F.4. AMINES 524
4.1. Acyclic Amines 525
4.2. Alcohol Amines 526
4.3. Aromatic Amines 529
4.4. Derivatives of Aromatic Amines 530
4.5. Aminophenols 531
4.6. Amino Acids 531
References 532
CHAPTER F.5. ALDEHYDES AND KETONES 536
5.1. Aliphatic Aldehydes 536
5.2. Cyclic Aldehydes 538
5.3. Aromatic Aldehydes 539
5.4. Ketones 539
References 542
CHAPTER F.6. CARBOXYLIC ACIDS AND THEIR DERIVATIVES 546
6.1. Acyclic Hydrocarbon Acids 547
6.2. Acid Anhydrides 557
6.3. Salts of Organic Acids 559
6.4. Esters 563
6.5. Amides 571
6.6. Nitriles and Nitrous Derivatives 572
References 573
CHAPTER F.7. OTHER ORGANIC PRODUCTS 578
7.1. Alkaloids and Heterocyclic Compounds 578
7.2. Glucides 579
Reference 579
Part G: The Effect of Other Environments 580
CHAPTER G.1. CORROSION IN SOIL 584
1.1. Types of Soil 584
1.2. The Influence of the Nature of Soil on the Corrosion Behaviour of Aluminium 585
1.3. Form of Aluminium Corrosion in Soils 587
1.4. Aluminium Corrosion Resistance in Soils 587
1.5. Protection Against Corrosion in Soil 588
References 588
CHAPTER G.2. THE EFFECT OF STRAY CURRENTS AND ALTERNATING CURRENT 592
2.1. Stray Currents 592
2.2. Alternating Currents 592
References 595
CHAPTER G.3. FERTILISERS AND HERBICIDES 598
3.1. Fertilisers 598
3.2. Plant-Care Products 600
References 600
CHAPTER G.4. CONSTRUCTION MATERIALS 604
4.1. The Effect of Concrete 604
4.2. The Effect of Plaster 606
4.3. The Effect of Wood 607
4.4. The Effect of Polymers 608
References 609
CHAPTER G.5. FOOD INDUSTRY 612
5.1. Aluminium and Health 612
5.2. Food Compatibility of Aluminium: European Standardisation 614
5.3. Applications of Aluminium in Contact with Foodstuffs 616
5.4. The Resistance of Aluminium in Contact with Foodstuffs 617
References 618
CHAPTER G.6. CLEANING OF ALUMINIUM 622
6.1. Cleaning of Metallic Surfaces 622
6.2. The Choice of Cleaning Products 623
6.3. Compatibility with Aluminium 623
6.4. Cleaning Materials Used with Food 624
6.5. Cleaning Anodised Surfaces 625
6.6. Sand Blasting 625
6.7. Cleaning by Projection of Ice or Carbonic Ice 625
References 626
CHAPTER G.7. BEHAVIOUR IN FIRE 630
7.1. Fire Resistance 630
7.2. Reaction to Fire 632
7.3. The Classification of Aluminium Alloys 634
References 634
PRODUCTS THAT MAY BE DANGEROUS IN CONTACT WITH ALUMINIUM 636
General References 640
Glossary 642
Index 650