 Selection of Materials for Corrosion Resistance

 Corrosive Medium Parameters

 Design Parameters
 Material Parameters
 Coatings for Protection against Corrosion
 Metallic Coatings
 Organic Coatings
 Vitreous Enamels

 Selection of Materials for Wear Resistance

 Metals
 Plastic
 Ceramics
 Coatings
 SELECTION OF 1. Chemical composition and presence of

MATERIALS FOR 2.
impurities.
Physical state whether solid, liquid, gas, or
CORROSION 3.
combinations
Aeration, oxygen content, and ionization.
RESISTANCE 4. Bacteria content.

CORROSIVE MEDIUM
PARAMETERS
 • Metallic materials for atmospheric

CORROSIVE corrosionaqueous electrolyte?????(by condensation of

moisture).
• Hot and dry or cold and icy  <attack than wet

MEDIUM conditions.
• Clean atmosphere <<industrial or marine
atmospheres (containing sulfur dioxide and

PARAMETERS salt).
• Direction of exposure to the sun, wind, and sources of
pollution can also affect the rate of atmospheric
(FOR METALLIC MATERIALS) corrosion.
 • Porous–wet media  More corrosion.

CORROSIVE • Porosity  aerobic bacteria.

• Destruction of organic coating

MEDIUM • Production of H2S

• Dry, sandy, or chalky soils of high electric resistance
<<<<< heavy clays (wet) or saline soils.

PARAMETERS
(BURIED STRUCTURES)
 GOOD mechanical properties and low
cost. NOT highly corrosion resistant
 Low-carbon steels have adequate
resistance to scaling in air up to about
500°C (ca. 930°F),
 The addition of chromium in amounts of
about 3% increases the resistance to both
oxidation and sulfide scaling.
 Cr additions also improve resistance to
atmospheric corrosion.
 Ni is also added to improve
the resistance to NaOH.
 Stainless steels do not resist all corrosive
environments.
 SCC is present in Cl- environments.
 Manufacturing issues may cause corrosion.
(intergranular corrosion, SCC, crevice,
pitting)
 ↑Cr  ↑corrosion resistance. (thin film of
hydrous oxide). The material is passivated.
 The film must be continuous, nonporous, self-
healing, and insoluble in the corrosive
medium.
 X passive film stainless steels could get
pitting, crevice corrosion, intergranular
corrosion, or SCC.
 Mo strengthens the passive film and
improves resistance to pitting in seawater.
 ↑ Cu, ↑ Al, ↑ Si  ↑corrosión resistance
 ↑↑↑corrosive resistance.
 Inconel, (78/16/6 Ni–Cr–Fe), is resistant
to many acids and has outstanding
resistance to nitriding at high
temperatures.
 Nimonic alloys (80/20 Ni–Cr), ↑σ,
↑corrosive resistance at high
temperatures.
 Monel alloys, (70/30 Ni–Cu) similar
resistance to pure nickel but cheaper
 GOOD for seawater and brackish waters at
high fluid velocities.
 GOOD for hydrofluoric acid.
 GOOD for Nonoxidizing acids.
 NOT GOOD for nitric acid, ferric chloride,
sulfur dioxide, and ammonia(oxidizing
media).
 Pure copper is a noble metal 
↑↑↑corrosive resistance.
 Cu is alloyed with > 15%Zn
dezincifcation may occur
 1%Sn ↓corrosion
 Tin bronzes are resistant to a variety of
atmospheres, waters, and soils.
 Al bronzes, (10% Al) ↑resistant to
chloride–potash solutions, nonoxidizing
mineral acids, and many organic acids.
 Cupronickels are widely used in
saltwater
 GOOD SCC.
 Sn is nontoxic and it provides a good
base for organic coatings.
 Use in coating the steel cans, tin cans,
 food products and beverages
 Tin is also resistant to relatively
pure water and dilute mineral acids in
the absence of air.
 NOT GOOD for strong mineral acids and
alkalis
 Al is reactive but its oxide it’s not.
 The oxide is ↑ acid solutions organic
compounds, (inc.fatty acids);↓in alkalis.
 Heat-treatable alloys (2000 and 7000) are
less resistant that Pure Al and Heat-
treatable alloys.
 Similar to Al but stronger oxide film.

 Titanium is immune to seawater (Cl gas as

well) and to hot strong oxidizing solutions.
 It also has very high resistance to erosion
corrosion in seawater.
 Hydrofluoric acid attack Ti (the film)

 An addition of alloying elements can affect

corrosion resistance if they alter the
properties of the oxide film.
 Because of their corrosion resistance,
plastics and composites have replaced
metals.
 Crystalline thermoplastics (fluorocarbons,
Teflon, and nylon), have superior chemical
stability than amorphous types like
polycarbonate.
 PTFE, are among the most chemically inert
materials available.
 GOOD for nitric acids, hydrofluoric acid, and
most organic solvents.
 Epoxies represent the best combination of
corrosion resistance and mechanical
properties .
 GOOD resistance to chemicals (excepting HF)
 Glasses are among the most chemically stable materials,
 Exceptionally good resistance to attack by water, aqueous
solutions of most acids, alkalis, and salts.
 Borosilicate and silica glasses show much higher
resistance to boiling water and hot dilute acid
solution than do soda-lime and lead-alkali glasses.
 Enamels, which are made of silicate and borosilicate
glass with the addition of
fluxes to promote adhesion, are highly resistant to
corrosion and are widely used to
protect steels and cast irons.
 1. Metallurgical variables, including hardness,
toughness, chemical composition, and
microstructure.
2. Service variables, including contacting
SELECTION OF materials, contact pressure, sliding
speed, operating temperature, surface fnish,
lubrication, and corrosion.
MATERIALS  Material hardness could be a clue to select a

FOR WEAR material but it doesn’t tell the whole story.

 For metal-to-metal sliding, increasing the hardness
increases wear resistance as a result of decreasing

RESISTANCE penetration, scratching, and deformation.

 Increasing toughness also increases wear resistance
by making it more difficult to tear off small particles of
deformed metal.
 Mild steels have poor wear resistance. If this
type of steel is needed to support abrasion, it
must be mated with a sacrifice material, such as
babbit (tin-based alloy), white bronzes (Cu-Sn-
Zn) or avoid dry sliding (improve lubrication).
 Surface-hardenable carbon or low-alloy steels is
another solution for wear resistance. They can be
surface hardened by carburizing, cyaniding, or
carbonitriding (higher cost).
 Nitriding medium-C–Cr or medium-C Cr–Al
steels
 Surface hardening high-carbon–high Cr steels.
 Precipitation-hardened stainless steels can be
used in applications involving wear, elevated
temperature, and corrosion.
 Austenitic manganese steels (1.2% C and 12%
Mn) have superior toughness at moderate cost.
 excellent resistance to metal-to-metal wear(rails,
and castings for railway track work,conveyors and
chains subjected to abrasion and used for carrying
heavy loads)
 As-cast gray cast iron (GCI) has adequate
wear resistance (machine tools and
similar sliding members).
 White pearlitic and martensitic
irons(chilled iron rolls and grinding
balls).
 White irons.
 Aluminum bronzes
 Non self-lubricated
 high loads and moderate to low speeds.

 Be-Cu alloys (1.9% Be, 0.2% Co)

 Non self-lubricated
 load-carrying capacity
 excellent corrosion resistance (marine
atmospheres)
 Co-based alloys.
 Good resistance to impact
 Thermal shock,
 Oxidation
 Corrosion
 High hot hardness
 Bearings, cams, and gear.
 Why???
 Easy to manufacture
 Self-Lubricating properties
 Silicone and PTFE are usually added to
thermoplastics to improve their performance
at high speeds and pressures

 Less maintenance.

 Drawbacks
 Operating temperatures
 Plastic-to plastic contact
 Sensitivity to surface roughness
 Type of contact surface.
 In general, as the grain size and porosity
of the ceramic material increases, wear
increases
 Surface films of water and oils, can affect
adhesion and wear.
 SiC against lubricated steel has lower
friction than chilled cast iron, which makes
it suitable for engine valves, train
components, and bearing