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corrodes to this:
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Size?
Length, breadth and thickness before
What about after?
Volume before, volume after .. by liquid displacement .
Sensitive enough?
Mass?
Weigh before, weigh after (if piece small enough for reasonable
balance note that measuring weight losses to a fraction of
a mg in a few grams is the norm in corrosion testing).
To be of any use, a weight loss measurement has to be scaled to
the size of the specimen corrosion is a surface related
phenomenon.
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Because corrosion is a surface phenomenon, weight loss is related
to surface area (SA)
For example:
a metal coupon having a total surface area of 10 cm 2 loses 1 mg
when exposed to a particular environment for a month;
1 mg
total corrosion
10 cm 2
mg cm 2 mg
0.1 2 100 2
10 2
10 mdm
cm month dm dm month
BUT even though mdms give reasonable numbers for
most corrosion situations, the month is a bad unit Why?
mg
dm 2 day
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If we know the metal density, we can convert the weight
loss to penetration:
for in g/cm3:
x mg cm 3 1g dm 2 x 5
10 cm / day
dm day
2
g 1000 mg 100 cm 2
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However, we note that 1 cm = 104 m, thus:
x 5 cm x m day x m
10 0.1 365 36.5
day day yr yr
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Scaled (e.g., oxidized) specimens often experience a
weight gain thus, the high-temperature oxidation of
iron proceeds
NOW WHAT?
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Consider the scaling process
Weight before = Wo g
Surface area = A dm2
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We can only be sure that the remaining metal provides an
unequivocal reference, so
Descale
Descaled weight = W2 g
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( W0 W2 ) 1000 mg mg
Total corrosion 2
A 1 g dm
(divided by for rate mdd)
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How do we descale?
employ an inhibitor
use a blank
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A blank is a bare specimen put into the descaling solution along with the
specimen;
Wb mg
weight loss of blank 1000 2
A b dm
we apply this blank correction to the specimen measurement
DRAWBACKS? DISCUSS
EXAMPLE.
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Note: such corrosion measurements and units are useful for general
or uniform corrosion but they dont work for localized corrosion
(e.g. pitting or cracking). A component can fail by stress corrosion
cracking (SCC) with no detectable weight loss
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For these situations, we use concepts such as crack
propagation rate or pit propagation rate.
For example:
percent through-wall for tubes, pipes, vessels, etc.;
m mm
propagation rate , etc.
year year
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Examples of Corrosion
General corrosion .
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Stress Corrosion
Stress corrosion of stainless steel type 304 autoclave. (Mallinckrodt Chemical Works)
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How would you measure (estimate) the corrosion of
plant components?
For example:
pressure vessels or pressure tubes;
feeder pipes
steam generator tubes;
feedwater pipes and heaters;
etc.
DISCUSS
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Methods involve
Non-Destructive Evaluation (NDE) or
Non-Destructive Testing (NDT)
and include
Ultrasonic Testing (UT);
Eddy Current;
Acoustic Emission;
etc.
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Some useful conversion factors:
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