corrosion resistance of steels, nickel alloys and zinc in ... · from the ecole nationale...

www.wiley-vch.de

Schütze · Roche

Bender (Eds.)

Corrosion R

esistance of Steels, N

ickel Alloys and Z

inc in Aqueous M

edia

Corrosion of metals in the presence of water is a common problem across many industries. Understanding how to protect materials against attack by water is paramount to extending component lifetimes and reducing maintenance. The materials selection process can sometimes become complex; usually involving multiple factors such as high strength requirements, operating temperature, high corrosion resistance, availability and cost. The present handbook compiles new and updated information on the corrosion behavior of virtually all types of steels and other iron-based alloys as well as nickel alloys and zinc in contact with aqueous media such as seawater, brackish water, industrial waste water, municipal waste water, drinking water, and high-purity water. This compilation is an indispensable tool for all materials scientists, mechanical, civil and chemical engineers working with steels, iron-, nickel- or zinc-based materials exposed to aqueous environments.

Edited by Michael Schütze, Marcel Roche, and Roman Bender

Corrosion Resistance of Steels, Nickel Alloys and Zinc in Aqueous Media

Michael Schütze, born in 1952, studied materials sciences at the University of Erlangen-Nürnberg from 1972 to 1978, then joined the Karl Winnacker Institute of the DECHEMA as a research associate. He received his doctorate in engineering sciences from the RWTH (Technical University) in Aachen in 1983, completed his habilitation in 1991, becoming a member of the external teaching staff of the RWTH. Since 1998, he holds a professorship there. He was appointed director of the Karl Winnacker Institute in 1996 and Chairman of the executive board of DECHEMA Forschungsinstitut in 2012. He is recipient of the Friedrich-Wilhelm-Prize, the Rahmel-Schwenk medal, the Otto-von-Guericke Prize, the Cavallaro medal, the U.R. Evans Award, the Khwarizmi Award and the UNIDO Award, past Chairman of the Gordon Conference on Corrosion, editor of the journal Materials and Corrosion, Past-President of the European Federation of Corrosion, Past-President of the World Corrosion Organization and Chairman of the Working Party Corrosion by Hot Gases and Combustion Products of the European Federation of Corrosion.

Marcel Roche, born in 1945, received his diplomas in Chemical Engineering from the Institut National des Sciences Appliquées of Lyon in 1967 and in Refi ning and Chemical Engineering from the Ecole Nationale Supérieure du Pétrole et des Moteurs in 1968. He worked as a corrosion engineer for the Institut Français de Pétrole and Technip Engineering from 1970 to 1979, when he moved to the Corrosion Department of Elf Aquitaine. He spent the remainder of his career in the fi eld of Corrosion, Inspection and Materials in this Group which became TotalFinaElf and fi nally Total. He retired in June 2008 and became a corrosion consultant. Since July 2011, he is President of CEFRACOR, the French Corrosion Society, and of its department Conseil Français de la Protection Cathodique. He is a member of the Scientifi c and Technical Advisory Committee of the European Federation of Corrosion and a member of its Board of Administrators, representing France. He has been active in several European and international standardisation working groups, including CEN TC219 WG3 for cathodic protection in marine applications for which he has been Convenor from 2009 to 2014.

Roman Bender, born in 1971, studied chemistry at the Justus Liebig University of Giessen from 1992 to 1997. After he received his diploma he joined the Karl Winnacker Institute of the DECHEMA in Frankfurt (Main) as a research associate. Since 2000 he is head of the group materials and corrosion at the DECHEMA and editor in chief of the world’s largest corrosion data collection, the DECHEMA Werkstofftabelle, and the Corrosion Handbook. In 2001 he received his doctorate in natural sciences from the Technical University of Aachen (RWTH Aachen). In 2008 Dr. Bender was appointed chief executive offi cer of the GfKORR – The Society for Corrosion Protection. As well, in 2013 he has been appointed as the Scientifi c Secretary of the European Federation of Corrosion.

the prime source of corrosion expertise

Waste Water, Seawater, Drinking Water, High-Purity Water

Corrosion Resistance of Steels, Nickel Alloys

and Zinc in Aqueous Media

Edited by Michael Sch�tze,

Marcel Roche

and Roman Bender

Corrosion Resistanceof Steels, Nickel Alloysand Zinc in Aqueous Media

Editors

Prof. Dr.-Ing. Michael Sch�tzeDECHEMA-ForschungsinstitutChairman of the Executive BoardTheodor-Heuss-Allee 2560486 Frankfurt am MainGermany

Marcel RochePresident of CEFRACORFrench Corrosion Society28 rue Saint Dominique75007 ParisFrance

Dr. rer. nat. Roman BenderChief Executive of GfKORR e. V.Society for Corrosion ProtectionTheodor-Heuss-Allee 2560486 Frankfurt am MainGermany

Cover IllustrationSource: DECHEMA-Forschungsinstitut,Frankfurt (Main), Germany

Warranty Disclaimer

This book has been compiled from literature datawith the greatest possible care and attention.The statements made only provide generaldescriptions and information.

Even for the correct selection of materials and correctprocessing, corrosive attack cannot be excluded in acorrosion system as it may be caused by previouslyunknown critical conditions and influencing factorsor subsequently modified operating conditions.

No guarantee can be given for the chemical stabilityof the plant or equipment. Therefore, the giveninformation and recommendations do not includeany statements, from which warranty claims canbe derived with respect to DECHEMA e.V. or itsemployees or the authors.

The DECHEMA e.V. is liable to the customer,irrespective of the legal grounds, for intentional orgrossly negligent damage caused by their legalrepresentatives or vicarious agents.

For a case of slight negligence, liability is limited tothe infringement of essential contractual obligations(cardinal obligations). DECHEMA e.V. is not liablein the case of slight negligence for collateral damageor consequential damage as well as for damage thatresults from interruptions in the operations or delayswhichmay arise from the deployment of this book.

n This book was carefully produced. Nevertheless,editors, authors and publisher do not warrant theinformation contained therein to be free of errors.Readers are advised to keep in mind that statements,data, illustrations, procedural details or other itemsmay inadvertently be inaccurate.

Library of Congress Card No.: Applied for.

British Library Cataloguing-in-Publication Data:A catalogue record for this book is available from theBritish Library.

Bibliographic information published by

Die Deutsche BibliothekDie Deutsche Bibliothek lists this publication in theDeutsche Nationalbibliografie; detailed bibliographicdata is available in the Internet at<http://dnb.ddb.de>.

� 2016 DECHEMA e.V., Society for ChemicalEngineering and Biotechnology, 60486 Frankfurt(Main), Germany

All rights reserved (including those of translationinto other languages). No part of this book may bereproduced in any form – nor transmitted or trans-lated into machine language without written permis-sion from the publishers. Registered names, trade-marks, etc. used in this book, even when notspecifically marked as such, are not to be consideredunprotected by law.

Printed in the Federal Republic of Germany

Printed on acid-free paper

Typesetting K�hn & Weyh, Satz und Medien,FreiburgPrinting and Binding Strauss GmbH, MçrlenbachCover Design Graphik-Design Schulz, Fußgçnheim

ISBN: 978-3-527-34069-9

Preface IX

How to use the Handbook XI

Warranty disclaimer 1

High Purity Water 3

Introduction 3

Physical and chemical properties 4

Unalloyed and low alloyed steels/Cast steel 6

Non-alloyed cast iron 21

High-alloyed cast iron 22

Ferritic chromium steels with < 13% Cr 22

Ferritic chromium steels with ‡ 13% Cr 24

High-alloyed multiphase steels 26

Austenitic CrNi steels 27

Austenitic CrNiMo(N)steels 52

Nickel 56

Nickel-chromium alloys 56

Nickel-chromium-iron alloys (without Mo) 56

Nickel-chromium-molybdenum alloys 67

Nickel-copper alloys 67

Nickel-molybdenum alloys 68

Zinc 68

Bibliography 69

Contents

V

Drinking Water 81

Introduction 82

Unalloyed steels and cast steel 87

Unalloyed cast iron 102

Structural steels with up to 12% chromium 104

Ferritic chromium steels with more than 12% chromium 104

Ferritic-austenitic steels with more than 12% chromium 104

Austenitic chromium-nickel steels 104

Austenitic chromium-nickel-molybdenum steels 104

Austenitic chromium-nickel steels with special alloying additions 104

Zinc 112

Bibliography 147

Seawater 155

Introduction 155

Unalloyed and low-alloyed steels/cast steel 193

Unalloyed cast iron and low-alloy cast iron 224

High-alloy cast iron 226

Ferritic chromium steels with < 13% Cr 228

Ferritic chromium steels with ‡13% Cr 229

High-alloy multiphase steels 235

Ferritic/pearlitic-martensitic steels 235

Ferritic-austenitic steels/duplex steels 235


Austenitic CrNiMo(N) steels 239

Austenitic CrNiMoCu(N) steels 244

Nickel 260





Nickel-molybdenum alloys 270

Other nickel alloys 270

Zinc 270

Bibliography 273

ContentsVI

Waste Water (Municipal) 289

Introduction 290

Unalloyed steels and cast steel 292

Unalloyed cast iron 294

Ferritic chromium steels with more than 12% chromium 299

Ferritic austenitic steels with more than 12% chromium 299



Austenitic CrNiMoCu(N)-steels 299

Zinc 305

Bibliography 307

Waste Water (Industrial) 311

Introduction 311

Unalloyed steels and low-alloy steels/cast steel 312

Unalloyed cast iron and low-alloy cast iron 316

High-alloy cast iron 316

Silicon cast iron 316

Ferritic chromium steels with < 13 % Cr 320

Ferritic chromium steels with ‡ 13 % Cr 320

High-alloy multiphase steels 320

Ferritic/pearlitic-martensitic steels 320

Ferritic-austenitic steels/duplex steels 320



Austenitic CrNiMoCu(N) steels 323





Zinc 343

Bibliography 344

Key to materials compositions 351

Index of materials 391

Subject index 401

Contents VII

Practically all industries face the problem of corrosion – from the micro-scale ofcomponents for the electronics industries to the macro-scale of those for the chemi-cal and construction industries. This explains why the overall costs of corrosion stillamount to about 2 to 4% of the gross national product of industrialised countriesdespite the fact that billions of dollars have been spent on corrosion research duringthe last few decades.

Much of this research was necessary due to the development of new technologies,materials and products, but it is no secret that a considerable number of failures intechnology nowadays could, to a significant extent, be avoided if existing knowledgewere used properly. This fact is particularly true in the field of corrosion and corro-sion protection. Here, a wealth of information exists, but unfortunately in mostcases it is scattered over many different information sources. However, as far backas 1953, an initiative was launched in Germany to compile an information systemfrom the existing knowledge of corrosion and to complement this information withcommentaries and interpretations by corrosion experts. The information system,entitled “DECHEMA-WERKSTOFF-TABELLE” (DECHEMA Corrosion Data Sheets),grew rapidly in size and content during the following years and soon became anindispensable tool for all engineers and scientists dealing with corrosion problems.This tool is still a living system today: it is continuously revised and updated bycorrosion experts and thus represents a unique source of information. Currently, itcomprises more than 12,000 pages with approximately 110,000 corrosion systems(i.e., all relevant commercial materials and media), based on the evaluation of over100,000 scientific and technical articles which are referenced in the database.

Increasing demand for an English version of the DECHEMA WERKSTOFF-TABELLE arose in the 1980’s; accordingly the first volume of the DECHEMA Corro-sion Handbook was published in 1987. This was a slightly condensed version of theGerman edition and comprised 12 volumes. Before long, this handbook had spreadall over the world and become a standard tool in countless laboratories outsideGermany. The second edition of the DECHEMA Corrosion Handbook was pub-lished in 2004. Together the two editions covered 24 volumes.

Water is commonly described either in terms of its nature, usage, or origin. Theimplications in these descriptions range from being highly specific to very general.The present handbook compiles new and updated information on the corrosionbehaviour of iron, nickel, zinc and their alloys in contact with the following water

Preface

IX

grades: drinking water, sea water, industrial and municipal waste water and highpurity water.

All water contains some dissolved oxygen and is therefore somewhat corrosive.The rate of corrosion depends on many factors including the water’s pH, electricalconductivity, oxygen concentration, and temperature. In addition to corrosion, metalsdissolve when the water is extremely low in dissolved salts and in the presence ofcertain water-borne ions.

Understanding how to improve the corrosion resistance of iron, nickel, zinc andtheir alloys used in construction, transport and storage vessels and structuresagainst this omnipresent chemical is crucial for all industries involved. This book istherefore an indispensable tool for all mechanical, civil and chemical engineers,material scientists and chemists working with these materials.

This handbook highlights the limitations of iron, nickel, zinc and their alloys invarious water grades and provides vital information on corrosion protection mea-sures. The chapters are arranged by the media leading to individual corrosion reac-tions, and a vast number of alloys are presented in terms of their behaviour in thesemedia. The key information consists of quantitative data on corrosion rates coupledwith commentaries on the background and mechanisms of corrosion behind thesedata, together with the dependencies on secondary parameters, such as flow-rate,pH, temperature, etc. Where necessary this information is complemented by moredetailed annotations and by an immense number of references listed at the end ofeach chapter.

An important feature of this handbook is that the data was compiled for industrialuse. Therefore, particularly for those working in industrial laboratories or for indus-trial clients, the book will be an invaluable source of rapid information for day to dayproblem solving. The handbook will have fulfilled its task if it helps to avoid thefailures and problems caused by corrosion simply by providing a comprehensivesource of information summarising the present state of the art. Last but not least, incases where this knowledge is applied, there is a good chance of decreasing thecosts of corrosion significantly.

Finally the editors would like to express their appreciation to Dr. Rick Durhamand Dr. Horst Massong for their admirable commitment and meticulous editing ofa work that is encyclopaedic in scope.

Michael Sch�tze, Marcel Roche and Roman Bender

X Preface

XI

How to use the Handbook

The Handbook provides information on the chemical resistance and the corrosionbehaviour of iron, nickel, zinc and their alloys in contact with the following watergrades: drinking water, sea water, industrial and municipal waste water and high-purity water.

The user is given information on the range of applications and corrosion protec-tion measures.

Research results and operating experience reported by experts allow recommenda-tions to be made for the selection of materials and to provide assistance in the assess-ment of damage.

The objective is to offer a comprehensive and concise description of the behaviourof these materials in contact with a particular aqueous medium.

The information on resistance is given as text, tables, and figures. The literatureused by the authors is cited at the corresponding point. There is an index of materi-als as well as a subject index at the end of the book so that the user can quickly findthe information given for a particular keyword.

The Handbook is thus a guide that leads the reader to materials that have alreadybeen used in certain cases, that can be used or that are not suitable owing to theirlack of resistance.

The resistance is labeled with three evaluation symbols in view of concise presen-tation. Uniform corrosion is evaluated according to the following criteria:

Symbol Meaning Area-related mass loss ratex

Corrosion ratey

g/m2 h g/m2 d mm/a

+ resistant £ 0.1 £ 2.4 £ 0.1

+ moderately resistant > 0.1 to £ 1.0 > 2.4 to £ 24.0 > 0.1 to £ 1.0

– not resistant > 1.0 > 24.0 > 1.0

The evaluation of the corrosion resistance of metallic materials is given

. for uniform corrosion or local penetration rate, in: mm/a and mpy

. or if the density of the material is not known, in: g/m2 h or g/m2 d.

How to use the Handbook

Pitting corrosion, crevice corrosion, and stress corrosion cracking or non-uniformattack are particularly highlighted.

The following equations are used to convert mass loss rates, x, into the corrosionrate, y:

from x1 in g/m2 h from x2 in g/m2 d where

x1� 365 � 24r � 1;000

= y (mm/a)x2� 365

r � 1;000= y (mm/a) x1: value in g/m2 h

y: value in mm/ax2: value in g/m2 dd: daysr: density of material in g/cm3

h: hours

In those media in which uniform corrosion can be expected, if possible, isocorrosioncurves (corrosion rate y = 0.1 mm/a) are given.

Unless stated otherwise, the data was measured at atmospheric pressure androom temperature.

The resistance data should not be accepted by the user without question, and thematerials for a particular purpose should not be regarded as the only ones that aresuitable. To avoid wrong conclusions being drawn, it must be always taken intoaccount that the expected material behaviour depends on a variety of factors that areoften difficult to recognise individually and which may not have been taken deliber-ately into account in the investigations upon which the data is based. Under certaincircumstances, even slight deviations in the chemical composition of the medium,in the pressure, in the temperature or, for example, in the flow rate are sufficient tohave a significant effect on the behaviour of the materials. Furthermore, impuritiesin the medium or mixed media can result in a considerable increase in corrosion.

The composition or the pretreatment of the material itself can also be of decisiveimportance for its behaviour. In this respect, welding should be mentioned. Thesuitability of the component’s design with respect to corrosion is a further pointwhich must be taken into account. In case of doubt, the corrosion resistance shouldbe investigated under operating conditions to decide on the suitability of the selectedmaterials.

XII

1

Warranty disclaimer

This book has been compiled from literature data with the greatest possible care andattention. The statements made in this book only provide general descriptions andinformation.

Even for the correct selection of materials and correct processing, corrosive attackcannot be excluded in a corrosion system as it may be caused by previouslyunknown critical conditions and influencing factors or subsequently modified oper-ating conditions.

No guarantee can be given for the chemical stability of the plant or equipment.Therefore, the given information and recommendations do not include any state-ments, from which warranty claims can be derived with respect to DECHEMAe.V.or its employees or the authors.

The DECHEMA e.V. is liable to the customer, irrespective of the legal grounds,for intentional or grossly negligent damage caused by their legal representatives orvicarious agents.

For a case of slight negligence, liability is limited to the infringement of essentialcontractual obligations (cardinal obligations). DECHEMA e.V. is not liable in thecase of slight negligence for collateral damage or consequential damage as well asfor damage that results from interruptions in the operations or delays which mayarise from the deployment of this book.

corrosion resistance of steels, nickel alloys and zinc in ... · from the ecole nationale...

Documents