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Corrosion Prevention and Protection: Practical Solutions

ISBN: 978-0-470-02402-7
574 pages
February 2007
Corrosion Prevention and Protection: Practical Solutions (047002402X) cover image


Corrosion Prevention and Protection: Practical Solutions presents a functional approach to the various forms of corrosion, such as uniform corrosion, pitting corrosion, crevice corrosion, galvanic corrosion, stress corrosion, hydrogen-induced damage, sulphide stress cracking, erosion-corrosion, and corrosion fatigue in various industrial environments.

The book is split into two parts. The first, consisting of five chapters:

  • Introduction and Principles (Fundamentals) of Corrosion
  • Corrosion Testing, Detection, Monitoring and Failure Analysis
  • Regulations, Specifications and Safety
  • Materials: Metals, Alloys, Steels and Plastics
  • Corrosion Economics and Corrosion Management

The second part of the book consists of two chapters which present:

  • a discussion of corrosion reactions, media, active and active-passive corrosion behaviour and the various forms of corrosion,
  • a collection of case histories and practical solutions which span a wide range of industrial problems in a variety of frequently encountered environments, including statues & monuments, corrosion problems in metallurgical and mineral processing plants, boilers, heat exchangers and cooling towers, aluminum and copper alloys, galvanized steel structures as well as hydrogeological environmental corrosion

This text is relevant to researchers and practitioners, engineers and chemists, working in corrosion in industry, government laboratories and academia. It is also suitable as a course text for engineering students as well as libraries related to chemical and chemical engineering institutes and research departments.

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Table of Contents




1 Introduction and Principles of Corrosion.

1.1 Impact of Corrosion.

1.2 Preliminary Aspects of Thermodynamics and Kinetics.

1.3 Nature of Corrosion Reactions.

1.4 Oxidation and High-temperature Corrosion.

1.4.1 Oxidation of Alloys.

1.5 Corrosion Prevention.

1.6 Design Factors.

1.7 Life Prediction Analysis of Materials.

1.8 Corrosion Protection.


2 Corrosion Testing, Detection, Monitoring and Failure Analysis.

2.1 Corrosion Testing.

2.2 Corrosion Detection and Monitoring.

2.3 Failure Analysis.


3 Regulations, Specifications and Safety.

3.1 Regulations and Specifications.

3.2 Safety Considerations.


4 Materials: Metals, Alloys, Steels and Plastics.

4.1 Cast Irons.

4.2 Carbon and Low-alloy Steels.

4.3 Stainless Steels.

4.4 Aluminum and Aluminum Alloys.

4.5 Copper and Copper Alloys.

4.6 Nickel and its Alloys.

4.7 Titanium and its Alloys.

4.8 Cobalt Alloys.

4.9 Lead and Lead Alloys.

4.10 Magnesium and Magnesium Alloys.

4.11 Zinc and Zinc Alloys.

4.12 Zirconium and its Alloys.

4.13 Tin and Tin Plate.

4.15 Polymeric Materials.


5 Corrosion Economics and Corrosion Management.

5.1 Corrosion Economics.

5.2 Corrosion Management.

5.3 Computer Applications.



6 The Forms of Corrosion.

6.1 Corrosion Reactions.

6.2 Corrosion Media.

6.3 Active and Active–Passive Corrosion Behavior.

6.4 Forms of Corrosion.

6.5 Types and Modes of Corrosion.

6.6 The Morphology of Corroded Materials.

6.7 Published Corrosion Data.



7 Practical Solutions.

7.1 Cathodic Protection of Water Mains.


7.2 Internal Corrosion of Aluminum Compressed Air Cylinders.


7.3 Some Common Failure Modes in Aircraft Structures.

7.4 Premature Failure of Tie Rods of a Suspension Bridge.

7.5 Corrosion and Lead Leaching of Domestic Hot and Cold Water Loops in a Building.


7.6 Cathodic Protection of Steel in Concrete.


7.7 Corrosion of Aluminum Components in the Glass Curtain Wall of a Building.


7.8 Corrosion in a Water Cooling System.

7.9 Pitting Corrosion of 90/10 Cupronickel Chiller Tubes.


7.10 Weld Metal Overlay: a Cost-effective Solution to High-temperature Corrosion and Wear Problems.


7.11 Equipment Cracking Failure Case Studies.

7.12 Failure of a Conveyor Drive Shaft.

7.13 Failure Analysis of Copper Pipe in a Sprinkler System.

7.14 Failure of Rock Bolts.


7.15 Failure Analysis of 316L Stainless Steel Tubing of a High-pressure Still Condenser.


7.16 Failure of a Landing Gear Steel Pin.


7.17 Hydrogen-induced Cracking.


7.18 Micromechanisms of Liquid and Solid Metal-induced Embrittlement.


7.19 Nitrate SCC of Carbon Steel in the Heat Recovery Steam Generators of a Co-generation Plant.


7.20 Performance of Stainless Steel Rebar in Concrete.


7.21 Corrosion of an Oil Storage Tank.


7.22 Corrosion of a Carbon Steel Tank in a Phosphatizing Process.

7.23 Underground Corrosion of Water Pipes in Cities.

7.24 Corrosion in Drilling and Well Stimulation.



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Author Information

Edward Ghali, DSc, Dept. of Mining and Metallurgy, Laval University, Quebec City, Canada G1K 7P4

V. S. Sastri, Ph.D, Sai Ram Consultants, Ottawa, Ontario, Canada, K1J 6S7
Consulting in the fields of corrosion and corrosion control by inhibitors in sour gas systems, grinding balls, microbiological corrosion, corrosion of low-leaded copper-base alloys, hydrogen damage in high-strength and rail steels, galvanic corrosion of household plumbing solders and contamination of drinking water, surface quantification of corrosion products, electrochemical sensors for hydrogen in steels, reverse osmosis and water pollution and beneficiation of ores.

M. Elboujdaini, Ph.D., Materials Technology Laboratories, CANMET, Ottawa, Ontario, Canada, K1A 0G1
Research Scientist and Group Leader/Corrosion & Protection at Natural Resources Canada, CANMET, Materials Technology Laboratory (MTL), Ottawa, Canada.
Authority in hydrogen-induced cracking and material degradation in H2S environment; Coordinated complex and difficult tests on full-scale pipes in H2S environment for oil and gas industries; Provided critical technical information and consultative expertise to Canadian companies.

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