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HT/LT systems
Indirectly;
Lead to caustic attack be increasing the OH- ion concentration
Galvanic Action
Corrosion within cooling systems can occur if the coolant, i.e. water, has not been properly treated. The corrosion can take the form of acid attack with resultant loss of metal from a large area of the exposed surface, or by Oxygen attack characterized by pitting. A primary motive force for this corrosion is Galvanic action The metals closer to the anodic end of the list corrode with preference to the metals towards the cathode end. A galvanic cell can occur within an apparently Homogeneous material due to several processes on of which is differential aeration where one area is exposed to more oxygen than another. The area with less oxygen becomes anodic and will corrode.
Brasses Nickel Stainless-Steel 18-8 (Active) Stainless Steel 18-8-3 (Active) Chromium Iron (Active) Chromium-Nickel-Iron (Active) Cadmium Iron
Gold and Platinum Titanium Silver Silver solder Chromium-Nickel-Iron (Passive) Chromium-Iron (Passive) Stainless Steel (Passive) Copper Monel 70/30 Cupro-Nickel 67-33 Nickel-Copper
Steel
Cast Iron Chromium Zinc
12
13 14 15 16
Hydrogen
lead Tin 2-1 Tin lead Solder Bronzes
Aluminum
Aluminum Alloys
Magnesium
Anode
Metals closer to the anodic end of the list corrode with preference to the metals towards the cathode end
Galvanic Action
Galvanic action within metal
This situation can exist in cooling water systems with complex layout of heat exchangers and passage ways within the diesel engine. Systems containing readily corrodible metals such as zinc, tin and lead alloys can complicate and intensify problems by causing deposit formations
Differential Aeration
-Where only a single metal exists within a system corrosion can still take place if the oxygen content of the electrolyte is not homogenous. Such a situation can occur readily in a jacket water system as regions of stagnant flow soon have the oxygen level reduced by the oxidation of local metal. The metal adjacent to water with reduced levels of oxygen become anodic to metals with higher oxygen content electrolyte in contact with it.. Generally, the anodic metal is small in comparison the cathode i.e. the area of stagnant flow is small compared to the area of normal flow of electrolyte, and high rates of corrosion can exist. One clear case of this is the generation of deep pits below rust scabs.
Water treatment
To remove the risk of corrosion it is necessary to isolate the metal surface form the electrolyte. One method would be by painting, but this is impractical for engine cooling water passages. A better solution would be a system which not only search out bare metal, coating it with a protective barrier, but also repair any damage to the barrier. For corrosion to occur four conditions must be met; There must be an Anode There must be a cathode An electrolyte must be present An electron pathway should exits
Corrosion inhibitors are classified on how they affect the corrosion cell and are placed into three categories; Anodic Inhibitors Cathodic Inhibitors Combination inhibitors/organic inhibitors
Common Corrosion Inhibitors
Corrosion Inhibitors
Anodic Inhibitors
Nitrite (NO2- )- These are the most commonly used form of treatment and operate by oxidizing mild steel surfaces with a thin, tenacious layer of corrosion product (magnetite Fe3O4). Relatively high volumes of treatment chemical are required so this method is only viable on closed systems Sodium Nitrite- (sometimes with Borate added)-effective with low dosage, concentration non-critical. It is non toxic, compatible with anti freezes and closed system cooling materials. It does not polymerize or breakdown. However protection for non-ferrous materials is low. An organic inhibitor is thus required. Although will not cause skin disease it will harm eyes and skin. Approved for use with domestic fresh water systems. Sodium Nitrite is a passivator which chemically produce an insulating layer on the metal surface. Whenever corrosion takes place the corrosion products including bubbles of gas, are released from the metal surfaces. Passivating chemicals act on the corrosion products preventing release from the metal surface and thus stifling further corrosion. If the insulating layer becomes damaged, corrosion begins again and the passivator acts on the new products to repair the layer. Sodium Chromate which was an excellent inhibitor. Not allowed. Due to its toxicity. Sometimes used as a biocide in such places as brine in large Reefer plants.
Anodic Inhibitors
Silicates- react with dissolved metal ions at the anode. The resultant ion/silicate complex forms a gel that deposits on anodic sites. This gel forms a thin, adherent layer that is relatively unaffected by pH in comparison to other inhibitors. The inhibiting properties increase with temperature and pH, normal pH levels are 9.5 to 10.5. Care should be taken with the use of silicates, which are often used for the protection of systems containing alumiinium. In the event of boiling increased concentrations and lead to aggressive corrosion due to the high pH. Orthophosphate Forms an insoluble complex with dissolved ferric ions that deposit at the anodic site. It is more adherent and less pH sensitive than other anodic inhibitors. The film forms in pH of 6.5 to 7.0. Dosage is typically 10ppm in neutral water
Cathodic Inhibitors
Cathodic Inhibitors Polyphosphate- Forms complexes with Calcium, Zinc and other divalent ions, this creates positively charged colloidal particles. These will migrate to the cathodic site and precipitate to form a corrosion inhibiting film. The presence of calcium is required at a typical minimum concentration of 50ppm. Extreme variations in pH can upset the film and a reversion to orthophosphate will occur with time and temperature. Positively charged zinc ions migrate to the cathodic site and react with the free hydroxyl ions to form a zinc hydroxide stable film at pH 7.4 to 8.2. If the water is too acidic the film will dissolve and not reform. If it is too alkaline the zinc hydroxide will precipitate in bulk and not at the cathodic site. Phosphonates Initially introduced as scale inhibitors to replace polyphosphates, they exhibit absorption at the metal surface especially in alkaline hard water. Generally used with other inhibitor types
Modern treatment
Nitrite-Borate treatment is most effective with a high quality water base. This treatment has no scale prevention properties and its effectiveness is reduced by high quantities of dissolved solids. A modern treatment will be a Nitrite -Borate base, with a complex blend of organic and inorganic scale and corrosion inhibitors plus surfactants, alkali adjusters, dispersants and foam suppressers. A high quality water supply is still strongly recommended.
Electrolytic protection for the whole system by the use of sacrificial anodes is impractical. Parameters such as water temperature, relative surface area of anode and cathode, activity of metals in system and relative positions in galvanic series come into play. Anodic protection has become out of favor for cooling water systems as it can lead to local attack, causes deposits leading to flow disturbance and it has no scale protection
Piston cooling
Piston crowns attain a running temperature of about 450oC and in this zone there is a need for high strength and minimum distortion in order to maintain resistance to gas loads and maintain the attitude to the rings in relation to the liner. The heat flow path from the crown must be uniform otherwise thermal distortion will cause a non-circular piston resulting in reduced running clearance or even possible contact with the liner wall. Efficient cooling is required to ensure the piston retains sufficient strength to prevent distortion. For medium and high speed engines the weight of the material becomes important to reduce the stresses on the rotating parts. The high thermal conductivity of aluminum alloys allied to its low weight makes this an ideal material. To keep thermal stresses to a reasonable level cooling pipes may be cast into the crown, although this may be omitted on smaller engines. Where cooling is omitted, the crown is made thicker both for strength and to aid in the heat removal from the outer surface.
Piston cooling
Water Cooled High specific heat capacity therefore removes more heat per unit volume Requires chemical conditioning treatment to prevent scaling Larger capacity cooling water pump or separate piston cooling pump and coolers although less so than with oil Special piping required to get coolant to and from piston without leak Coolant drains tank required to collect water if engine has to be drained. Pistons often of more complicated design Oil Cooled Low specific heat capacity
Does not require chemical treatment but requires increased separate and purification plant
Larger capacity Lube oil pump, sump quantity and coolers No special means required and leakage not a problem with less risk of hammering and bubble impingement. Increased capacity sump tank required Thermal stresses in piston generally less in oil cooled pistons Large volumes of oil required to keep oxidation down and extended cooling period required after engine stopped to prevent coking of oil
Pistons may be cooled by oil or water. Oil has the advantage that it may be supplied simply from the lubrication system up the piston rod. Its disadvantage are that maximum temperatures is relatively low in order to avoid oxidized deposits which build up on the surfaces. In addition the heat capacity of oil is much lower than that of water thus a greater flow is required and so pumps and pipe work must be larger. Also, if the bearing supply oil is used as is mainly the case a greater capacity sump is required with more oil in use. Water does not have these problems, but leakage into the crankcase can cause problems with the oil (such as Microbial-Degradation). The concave or dished piston profile is used for most pistons because it is stronger than the flat top for the same section thickness
Naval brass end plate (alpha-beta brass containing tin) End covers cast iron (unprotected suffers graphitization) Shell CI or MS
PHE
Corrugation promotes turbulence and good heat transfer due to breaking of boundary layer Corrugation makes the plates stronger The corrugation increases plate area Titanium and SS plates are the most common based on duties. Nitrile rubber is found suitable up to 110C, retightening as advised by makers are very important as this can damage rubber, plate etc.
Corrosion
alpha-beta brass - a brass that has more zinc and is stronger than alpha brass; used in making castings and hot-worked products
2. Air Admixture
the total oil quantity is such that it circulates 15-18 times per hr.
3. Catalytic action
due to copper, iron, varnish, lacquer rust etc being present in oil