The Science and Engineering of Materials, 4th ed

Donald R. Askeland Pradeep P. Phul

Chapter 22 Corrosion and Wear

Objectives of Chapter 22
To introduce the principles and mechanisms by which corrosion and wear occur under different conditions. To give summary of different technologies that are used to prevent or minimize corrosion and wear associated problems.

Corrosion
Oxidation Wet corrosion Chemical corrosion Electrochemical corrosion

Oxidation and Other Gas Reactions

One of the requirement of a material is that it should resist attack by gases in particular that it should resist oxidation Oxidation - Reaction of a metal with oxygen to produce a metallic oxide. This normally occurs most rapidly at high temperatures. Excessive attack of this sort is obviously undesirable in such a highly stressed component. Which materials best resist oxidation, how can the resistance to gas attack can be improved?

material is constants

oxygen turbine important conditions

Figure 22.16 The standard free energy of formation of selected oxides as a function of temperature. A large negative free energy indicates a more stable oxide.

The important thing about the oxide film is that it acts as a barrier and cuts down the rate at which these atoms react to form more oxide. For example, the rate of Al oxide layer 2.5 time higher than Fe oxide layer, but the oxide layer on Al is much more effective barrier than oxide film on iron is.

Pilling-Bedworth ratio - Describes the type of oxide film that forms on a metal surface during oxidation.

R=
M D d m n

M .d n.m.D

: Molar weight of oxide : Density of oxide layer : Density of Metal : Atomic weight of metal : The number of metal atom in the oxide

P-B oran < 1 Figure 22.17 Three types of oxides may form, depending on the volume ratio between the metal and the oxide: (a) magnesium produces a porous oxide film, (b) aluminum forms a protective, adherent, nonporous oxide film, and (c) iron forms an oxide film that spills off the surface and provides poor protection.
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1<P-B oran<1.5

P-B oran>1.5

Unproductive films: Possesses high diffusion coefficients and thus low melting points and conductivity for electron pass. Thus Al2O3, Cr2O3, SiO2 are protective and FeO, Cu2O are not protective. Some oxides evaporates at oxidation temperature and so are not protective: MoO3, WO3.

3.

If the volume of oxide film much less than metal layer, oxide film cracks to relieve strain (oxide film usually brittle) and so oxidation continues. If the volume of oxide film much greater than metal layer, film tends to release the strain energy by breaking adhesion between metal and oxide and springing away. Thus oxidation continues

4.

Example 22.12

Pilling-Bedworth Ratio

The density of aluminum is 2.7 g/cm3 and that of Al2O3 is about 4 g/cm3. Describe the characteristics of the aluminumoxide film. Compare with the oxide film that forms on tungsten. The density of tungsten is 19.254 g/cm3 and that of WO3 is 7.3 g/cm3. Example 22.12 SOLUTION For 2Al + 3/2O2 Al2O3, the molecular weight of Al2O3 is 101.96 and that of aluminum is 26.981.

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Example 22.12 SOLUTION For tungsten, W+ 3/2O2 WO3. The molecular weight of WO3 is 231.85 and that of tungsten is 183.85:

Since P-B ~ 1-1,5 for aluminum, the Al2O3 film is nonporous and adherent, providing protection to the underlying aluminum. However, P-B > 1,5-2 for tungsten, so the WO3 should be non adherent and non protective.

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Example 22.13 Parabolic Oxidation Curve for Nickel

At 1000oC, pure nickel follows a parabolic oxidation curve given by the constant k = 3.9 10-12 cm2/s in an oxygen atmosphere. If this relationship is not affected by the thickness of the oxide, calculate the time required for a 0.1cm nickel sheet to oxidize completely. Example 22.13 SOLUTION Assuming that the sheet oxidizes from both sides:

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consists right which is this hours integral its

Solution