Table of Contents

Table of Contents

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1. Introduction to Corrosion
	1.1 Historical Background
	1.2 Definition of Corrosion
	1.3 Corrosive Environment
	1.4 Consequences of Corrosion
	1.5 Costs of Corrosion
	1.6 Contributors to Corrosion Research
	1.7 Functional Aspects of Corrosion
	1.8 Health, Safety, Environment and Product Life Top
2. Understanding Corrosion
	2.1 Why Metals Corrode
	2.2 Corrosion Components
	2.3 Electromotive Series
	2.4 Mechanism of Corrosion
	2.5 Free Energy Potentials
		2.5.1 Relationship between 'Free Energy' and 'Equilibrium Constant'
		2.5.2 Derivation of Nernst Equation
		2.5.3 Electric double layer
		2.5.4 Exchange current density
	2.6 A Look at Polarization
	2.7 Activation Polarization
	2.8 Concept of Concentration Polarization
	2.9 Resistance Polarization Top
3. Faraday's Laws and Rate of Corrosion
	3.1 The I and II Laws
	3.2 Determination of Corrosion Rates in Metals and Alloys
		Example: Calculation of weight loss
	3.3 Penetration Rate
		Example: Calculation of corrosion rate in mdd Top
4. Forms of Corrosion
	4.1 Introduction
	4.2 Uniform Corrosion
	4.3 Galvanic Corrosion
	4.4 Pitting Corrosion
	4.5 Intergranular Corrosion
	4.6 Stress Corrosion Cracking
	4.7 Hydrogen Blistering
	4.8 Hydrogen Induced Cracking
	4.9 Sulphide Stress Corrosion Cracking
	4.10 Caustic Cracking
	4.11 Crevice Corrosion Top
5. Cathodic Protection
	5.1 Introduction
	5.2 How Cathodic Protection Works
	5.3 Cathodic Protection Systems
		5.3.1 Galvanic Anode (Sacrificial Anode) System
		5.3.2 Impressed Current System
			- Current requirement for coated pipes
			- Current requirement for bare structures
	5.4 Important Measurements in Cathodic Protection
		5.4.1 Measurement of Soil Resistivity
		5.4.2 Measurement of Structure-to-Soil Potential
	5.5 Soil Resistivity Survey
	5.6 Criteria for Cathodic Protection
	5.7 Cathodic Protection Interference
	5.8 Stray Current Corrosion
	5.9 Ground Bed Design
	5.10 Anode-to-Earth Resistance
	5.11 Design Curves
	5.12 Comparison of Galvanic Anode and Impressed Current Systems
	Top
6. Coating Principles
	6.1 Introduction
	6.2 Paints
	6.3 Coating Systems
	6.4 Binders
	6.5 Pigments, Extenders and Additives
	6.6 Solvents
	6.7 Coatings and Corrosion
	6.8 Engineering Applications of Corrosion
	6.9 Glossary of Special Terms Top
7. Coating Failures
	7.1 Introduction
	7.2 Factors Contributing to Coating Failures
	7.3 Systems and Coatings
	7.4 Types of Failures
		7.4.1 Formulation related failures
			- Chalking
			- Checking
			- Alligatoring
			- Cracking
			- Mud Cracking
		7.4.2 Substrate related failures
			- Major Contaminants
		7.4.3 Design related failures
			- Failures at Edges
			- Failures at Corners
			- Failures at Welded Areas
			- Nuts and Bolts
			- Faying Surfaces
		7.4.4 Adhesion related failures
			- Blistering
			- Flaking
		7.4.5 Application related failures
			- Holidays
			- Pinholes
			- Cratering
			- Dry spray
			- Sagging
			- Orange peel
	7.5 Rules for Longer Coating Life Top

8. Prevention by Design
	8.1 Introduction
	8.2 Service Life of Equipment
	8.3 Causes of Failure in the Context of Design
	8.4 Corrosive Environment
	8.5 Stages in Design Process
	8.6 Areas Requiring Consideration at Design Stage
	8.7 Design for Liquid Containers
a	8.8 Summary Top