Introduction 1. Aqueous Corrosion 2. Environments and Application Examples 3. high-Temperature Corrosion 4. Modeling, Life Prediction, and Computer Applications 5. Corrosion Failures 6. Corrosion Maintenance Through Inspection And Monitoring 7. Acceleration and Amplification of Corrosion Damage 8. Materials Selection 9. Protective Coatings 10. Corrosion Inhibitors 11. Cathodic Protection 12. Anodic Protection

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Handbook of Corrosion Engineering

High temperature corrosion of coatings and boiler steels below chlorine-containing salt deposits

High temperature corrosion tests were performed on ferritic and austenitic boiler steels, five high velocity oxy-fuel (HVOF) coatings, laser-melted HVOF coating, and diffusion chromized steel. Synthetic atmosphere simulating biofuel combustion was created for the tests. The tests were performed in oxidizing atmosphere containing 500 vppm HCl, 20% H2O, 3% O2, and Ar as a balance. The test temperature was 550 °C and the test duration was 1000 h. The corrosion resistance of steels was determined by alloy content. Homogeneous and dense coatings with high chromium content performed well and protected the substrate material. Corrosive species were able to penetrate through some of the HVOF coatings and attack the substrate via interconnected network of voids and oxides at splat boundaries.

High temperature corrosion of coatings and boiler steels in oxidizing chlorine-containing atmosphere

Unacceptably high corrosion rates are often experienced, when chlorine-containing fuels are combusted. Reducing conditions that may occur in various boilers accelerate corrosion even further. Protective oxide scales are not formed on low-alloy steels if partial pressure of oxygen is too low. Materials rich in oxide formers, such as chromium and aluminum, are needed to resist corrosion in reducing combustion atmospheres, but processibility of such bulk alloys is very limited. Various coating technologies are considered as potential solution for corrosion problems in high temperature combustion environments with low partial pressure of oxygen. High temperature corrosion tests were performed on one ferritic boiler steel, one austenitic boiler steel, five high velocity oxy-fuel (HVOF) coatings, one laser-melted HVOF coating, and one diffusion chromized steel. Synthetic atmosphere simulating reducing conditions in combustion of chlorine-containing fuels was created for the tests. The test atmosphere contained 500 ppm HCl, 600 ppm H 2 S, 20% H 2 O, 5% CO, and Ar as a balance. The test temperature was 550 °C and the test duration was 1000 h. Corrosion resistance of steels and homogeneous coatings was mainly determined by chromium content. Homogeneous and dense coatings with high chromium content performed well and were able to protect the substrate. Some of the HVOF coatings were attacked by corrosive species through interconnected network of voids and oxides at splat boundaries.

High temperature corrosion of coatings and boiler steels in reducing chlorine-containing atmosphere

High temperature corrosion tests were performed on dissimilar friction weldment of low alloy steel and austenitic stainless steel. Test conditions simulated the environment of a biofuel fired boiler. The samples were exposed to synthetic salt containing 40 wt-%K2SO4, 40 wt-%Na2SO4, 10 wt-%KCl and 10 wt-%NaCl. In the present paper, hot corrosion behaviour of friction welded AISI 4140 and AISI 304 dissimilar materials in molten salt environments at 500, 550 and 600°C was studied. Corrosion was extremely severe on the interface of the dissimilar weldment in molten salt environment. Comparative evaluation was based on the effect of burn-off length and temperature of exposure on hot corrosion behaviour of the dissimilar weldment. Even the interface was attacked through chromium rich phases in hot corrosion environment. The metals formed on the weldment were non-protective.

Hot corrosion studies on dissimilar friction welded low alloy steel and austenitic stainless steel under chlorine containing salt deposits under cyclic conditions

The results of two surveys (conducted in 1981 and 1984) of users of corrosion monitoring equipment are described. The benefits to be obtained from a well-designed corrosion monitoring system, especially if a corrosion control program is used, are outlined together with the difficulties and barriers that can obstruct successful application. Developing methods such as AC impedance, electrochemical noise, and thin layer activation are discussed in view of the comments received from the surveys.

Effective corrosion monitoring

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Effective corrosion monitoring