Corrosion Issues Test Methods （腐蚀问题和测试方法）.pdfVIP

Corrosion Issues Test Methods Jerry Byers Cost of Corrosion to US Industries • Corrosion is the deterioration of a material (often a metal) due to interaction with its environment. • A study in 1998 estimated the direct cost of corrosion to be $275.7 Billion • Represents 3.1% of the US Gross Domestic Product • Indirect costs (lost productivity due to outages, delays, failures, and litigation) considered to be at least equal to the direct costs. Factors that Affect Corrosion Rate • Moisture (Humidity) • Temperature • Air Pollution/Contamination • Water Quality (see photo) • Lean MWF dilutions • Acids/Bases/Salts • Concentration differences across metal surface • Crevices • Contact between dissimilar metals There are just over 100 known chemical elements. About 80 are metals. Corrosion Issues – Metals Considered • Iron • Aluminum • Copper • Magnesium • Titanium Cast Iron Steel IRON (Fe) • 90% of all mining for metallic ores is for extraction of iron • Its low cost and high strength make it indispensable in engineering applications such as the construction of machinery, machine tools, automobiles, hulls of ships, and structural components for buildings. • Addition of tiny quantities of carbon to iron greatly increases its strength • Steel has lower carbon content that cast iron • The main disadvantage of most iron alloys is rust! Rust Happens! Rusted, Pitted Camshaft Caused by high chlorides high humidity Open Face Cast Iron Cylinders held overnight at 100% RH Room Temp Breakpoint: Weakest concentration that will control rust STACKED STEEL CORROSION TEST Stacking reduces fluid volume excludes oxygen Cast Iron Chip Test Comparison of Cast Iron Chip Methods