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Corrosion Prevention and Protection: Practical Solutions

Edward Ghali, V. S. Sastri, M. Elboujdaini

ISBN: 978-0-470-02402-7 February 2007 574 Pages


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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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.