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Corrosion and Protection of Steel Piles in a Natural Seawater Environment

Description: From Introduction: "This paper describes some results of the first eight years of a fifteen year program in which a variety of coating and catholic protection systems are evaluated on their ability to protect steel piles in offshore conditions at Dam Neck, Virginia. It includes a description of the methods used in the evaluation and the results found on these systems."
Date: June 1977
Creator: Escalante, E.; Iverson, W. P.; Gerhold, W. F.; Sanderson, B. T. & Alumbaugh, R. L.
Partner: UNT Libraries Government Documents Department

A correlation between EIS and salt spray proof tests for the corrosion resistance of conversion coated aluminum alloys

Description: In this study, 33 different conversion coatings were applied to 5 different Al alloy substrates. Salt spray exposure testing and EIS (electrochemical impedance spectroscopy) were conducted for comparison. A relation was developed.
Date: September 1, 1996
Creator: Buchheit, R.G.; Martinez, M.A.; Cunningham, M.; Jensen, H. & Kendig, M.W.
Partner: UNT Libraries Government Documents Department

A pipe cleaning machine: ERIP recommendation No. 571

Description: The subject invention, ``A Pipe Cleaning Machine,`` known as ``Buffy,`` is a device that strips pipeline of its coating down to the metal. The apparatus consists of a series of motor-driven metal brushes mounted on a ring structure that fits the around the pipe`s circumference. Once stripped, the pipeline may or may not be abrasive-blasted, but is then coated and wrapped, and the trench is back-filled. Present models of the Buffy can be used on pipe up to 36`` in diameter. One of the device`s unique features is its ability to operate while the pipeline remains in service.
Date: June 12, 1992
Creator: Bratcher, H. Jr.; Hinick, M.B. & Balsam, J.W.
Partner: UNT Libraries Government Documents Department


Description: The objectives of this report are: (1) To determine the effect of the crevice former on the localized corrosion damage propagation; (2) FOCUS on post initiation stage, crevice propagation and arrest processes; (3) Determine the evolution of damage--severity, shape, location/distribution, damage profile; and (4) Model of crevice corrosion propagation, i.e. the evolution of the crevice corrosion damage profile.
Date: March 1, 2006
Creator: Payer, J.H.; Landau, U.; Shan, X. & Agarwal, A.S.
Partner: UNT Libraries Government Documents Department


Description: The ability of a SS316L surface wetted with a thin electrolyte layer to serve as an effective cathode for an active localized corrosion site was studied computationally. The dependence of the total net cathodic current, I{sub net}, supplied at the repassivation potential E{sub rp} (of the anodic crevice) on relevant physical parameters including water layer thickness (WL), chloride concentration ([Cl{sup -}]) and length of cathode (Lc) were investigated using a three-level, full factorial design. The effects of kinetic parameters including the exchange current density (i{sub o,c}) and Tafel slope ({beta}{sub c}) of oxygen reduction, the anodic passive current density (i{sub p}) (on the cathodic surface), and E{sub rp} were studied as well using three-level full factorial designs of [Cl{sup -}] and Lc with a fixed WL of 25 {micro}m. The study found that all the three parameters WL, [Cl{sup -}] and Lc as well as the interactions of Lc x WL and Lc x [Cl{sup -}] had significant impact on I{sub net}. A five-factor regression equation was obtained which fits the computation results reasonably well, but demonstrated that interactions are more complicated than can be explained with a simple linear model. Significant effects on I{sub net} were found upon varying either i{sub o,c}, {beta}{sub c}, or E{sub rp}, whereas i{sub p} in the studied range was found to have little impact. It was observed that I{sub net} asymptotically approached maximum values (I{sub max}) when Lc increased to critical minimum values. I{sub max} can be used to determine the stability of coupled localized corrosion and the critical Lc provides important information for experimental design and corrosion protection.
Date: October 13, 2005
Creator: Cui, F.; Presuel-Moreno, F.J. & Kelly, R.G.
Partner: UNT Libraries Government Documents Department

Design and testing criteria for bipolar plate materials for PEM fuel cell applications

Description: Bipolar plates for proton exchange membrane (PEM) fuel cells are currently under development. These plates separate individual cells of the fuel cell stack, and thus must be sufficiently strong to support clamping forces, be electrically conducting, be fitted with flow channels for stack thermal control, be of a low permeability material to separate safely hydrogen and oxygen feed streams, be corrosion resistant, and be fitted with distribution channels to transfer the feed streams over the plate surface. To date, bipolar plate costs dominate stack costs, and therefore future materials need to meet strict cost targets. A first step in the bipolar plate development program is an assessment of design constraints. Such constraints have been estimated and evaluated and are discussed here. Conclusions point to promising advanced materials, such as conductive, corrosion resistant coatings on metal substrates, as candidates for mass production of fuel cell bipolar plates. Possible candidate materials are identified, and testing procedures developed to determine suitability of various materials.
Date: May 1, 1995
Creator: Borup, R.L. & Vanderborgh, N.E.
Partner: UNT Libraries Government Documents Department

Energy-efficient process for hot-dip batch galvanizing

Description: Hot-dip galvanizing of steel sheets, pipes, and other fabrication items is a popular method of corrosion protection. Currently, steel articles are immersed in molten zinc at 860{degrees}F, thereby forming a {open_quotes}frozen{close_quotes} metal (interfacial zinc iron intermetallic layer) on the surface. Drawbacks to the current technology include the expense of heating parts at such a high temperature and the generation of by-products such as zinc alloys, zinc oxides, and smoke. Furthermore, new federal regulations have significantly reduced acceptable lead levels in coatings, because lead from galvanized, coated steel will dissolve in water. Such dissolved lead may accumulate in human bodies with deleterious results. Additionally, the use of a molten salt layer on top of zinc (top-flux) causes kettle smoke and ash evolution. Ferro Technologies, Inc. has proposed a lead-free batch technology that will significantly improve the galvanizing process. The new Thermo Prep{trademark} process protects steel surfaces with a thermally stable flux by preheating parts to 400{degrees}F to 450{degrees}F in a separate furnace, and then immersing them in molten, lead-free zinc for a short period of time. The use of a thermally stable pre-flux would eliminate the need for top-flux, thereby reducing associated wastes.
Date: April 1, 1998
Partner: UNT Libraries Government Documents Department

Chloride content of dissolver solution from Rocky Flats scrub alloy ninth and tenth campaigns following head end treatment

Description: F-Canyon continues to obtain excellent chloride removal from Rocky Flats scrub alloy (RFSA) dissolver solution during head end treatment. One single batch of solution from the ninth RFSA campaign, dissolved in January and February of this year, and two batches from the tenth campaign, dissolved in February, have been successfully processed. Following dissolution in Tank 6.4D, chloride was precipitated with mercurous ion added as the nitrate. The precipitate, Hg{sub 2}Cl{sub 2}, was concurrently removed with the gelatin floc via centrifugation. For each of these three batches processed, a set of duplicate samples was obtained from Tank 11.2 or from Tank 13.3, containing the head end product. The samples were preanalyzed by Laboratories Department for density and acidity to ensure them to be representative of the tank`s contents prior to chloride analysis by the Separations Technology Laboratory. Previous work indicated that in order to protect downstream canyon equipment from chloride attack, the chloride content of RFSA solutions should be less than 100 ppm. All batches from these two RFSA campaigns meet this criterion.
Date: March 8, 1988
Creator: Holcomb, H.P.
Partner: UNT Libraries Government Documents Department


Description: The main objective of this research project is the formulation of processes that can be used to prepare compositionally graded alumina/mullite coatings for protection from corrosion of silicon carbide components (monolithic or composite) used or proposed to be used in coal utilization systems (e.g., combustion chamber liners, heat exchanger tubes, particulate removal filters, and turbine components) and other energy-related applications. Mullite will be employed as the inner (base) layer and the composition of the film will be continuously changed to a layer of pure alumina, which will function as the actual protective coating of the component. Chemical vapor deposition reactions of silica, alumina, and aluminosilicates (mullite) through hydrolysis of aluminum and silicon chlorides in the presence of CO2 and H2 will be employed to deposit compositionally graded films of mullite and alumina. Our studies will include the kinetic investigation of the silica, alumina, and aluminosilicate deposition processes, characterization of the composition, microstructure, surface morphology, and mechanical behavior of the prepared films, and modeling of the various deposition processes. During this six-month reporting period, the experimental work on the investigation of the deposition of alumina, silica, and aluminosilicates from mixtures of methyltrichlorosilane (MTS), aluminum trichloride, carbon dioxide, and hydrogen was continued. Experiments were also conducted on the deposition processes of the simple oxides, alumina and silica, from mixtures containing only one chloride (AlCl3 and MTS, respectively). Deposition rate data were obtained in a relatively broad range of operating conditions: temperatures in the range 800-1000 o C, 100 Torr pressure, 0.006-0.015 AlCl3 feed mole fraction, 0.011- 0.027 CH3SiCl3 feed mole fraction, and 0.004-0.07 CO2 feed mole fraction, and various positions along the axis of the deposition reactor. Since the effect of temperature had been examined in detail in the previous reporting period, our efforts were mainly concentrated on the investigation of the ...
Date: October 1, 1998
Partner: UNT Libraries Government Documents Department

Corrosion protection of metallic waste packages using thermal sprayed ceramic coatings

Description: Ceramic coated carbon steel coupons were corrosion tested in water with dissolved salts to simulate exposure to evaporation concentrated groundwater in an underground nuclear repository. Metallography revealed no corrosion at the ceramic metal interface of dense coatings, even though electrical measurements demonstrated that the coatings were slightly porous. Experimental results and a model to predict corrosion rates influenced by a porous ceramic coating and coating lifetimes are presented
Date: November 1, 1998
Creator: Farmer, J C; Hopper, R W; Shell, T E & Wilfinger, K R
Partner: UNT Libraries Government Documents Department


Description: We investigated the inhibition by chromate ions of the localized corrosion of aluminum by electrochemical transient measurements. In agreement with other work, the measurements demonstrated that chromate is a cathodic inhibitor for aluminum in open circuit. The reduction of hexavalent chromium to trivalent chromium is assumed to take place on catalyzed sites of the surface. The resulting products inhibit oxygen reduction reactions at these sites, thereby retarding pitting corrosion.
Date: September 2, 2001
Creator: SASAKI,K. & ISAACS,H.S.
Partner: UNT Libraries Government Documents Department

Pack cementation diffusion coatings for Fe-base and refractory alloys. Final report

Description: With the aid of computer-assisted calculations of the equilibrium vapor pressures in halide-activated cementation packs, processing conditions have been identified and experimentally verified for the codeposition of two or more alloying elements in a diffusion coating on a variety of steels and refractory metal alloys. A new comprehensive theory to treat the multi-component thermodynamic equilibria in the gas phase for several coexisting solid phases was developed and used. Many different processes to deposit various types of coatings on several types of steels were developed: Cr-Si codeposition for low- or medium-carbon steels, Cr-Al codeposition on low-carbon steels to yield either a Kanthal-type composition (Fe-25Cr-4Al in wt.%) or else a (Fe, Cr){sub 3}Al surface composition. An Fe{sub 3}Al substrate was aluminized to achieve an FeAl surface composition, and boron was also added to ductilize the coating. The developmental Cr-lean ORNL alloys with exceptional creep resistance were Cr-Al coated to achieve excellent oxidation resistance. Alloy wires of Ni-base were aluminized to provide an average composition of Ni{sub 3}Al for use as welding rods. Several different refractory metal alloys based on Cr-Cr{sub 2}Nb have been silicided, also with germanium additions, to provide excellent oxidation resistance. A couple of developmental Cr-Zr alloys were similarly coated and tested.
Date: March 10, 1998
Creator: Rapp, R. A.
Partner: UNT Libraries Government Documents Department

Solids Control in Sludge Pretreatment

Description: Sludge pretreatment will likely involve washing, followed by caustic or acidic leaching and washing of sludge residues after leaching. The principal goal of pretreatment is to obtain a low-volume high-activity waste stream and a high-volume low-activity waste stream. Also, some waste constituents such as chromium and phosphate can be included in glass formulations only at very low concentrations; therefore, it is desirable to remove them from high-level waste streams. Two aspects of sludge treatment and subsequent separations should be well delineated and predictable: (1) the distribution of chemical species between aqueous solutions and solids and (2) potential problems due to chemical interactions that could result in process difficulties or safety concerns.Before any treatment technology is adopted, it must be demonstrated that the process can be carried out as planned. Three pretreatment methods were considered in the Tri-Party (Washington State Ecology, U.S. Environmental Protection Agency, and U.S. Department of Energy) negotiations: (1) sludge washing with corrosion- inhibiting water, (2) Enhanced Sludge Washing, and (3)acidic dissolution with separations processes. Enhanced Sludge Washing is the baseline process. In Enhanced Sludge Washing, sludge is first washed with corrosion-inhibiting water; it is then leached with caustic (sodium hydroxide solution) and washed again with corrosion- inhibiting water. The initial concern is whether a pretreatment technique is effective in separating sludge components. This can be evaluated by bench-scale tests with sludge specimens from underground storage tanks. The results give data on the distribution of important species such as aluminum, phosphate, and radionuclides between wash and leach solutions and solid sludge residues.
Date: December 31, 1997
Creator: Beahm, E.C., Weber, C.F., Hunt, R.D., Dillow, T.A.
Partner: UNT Libraries Government Documents Department

MIL-L-87177 and CLT:X-10 Lubricants Improve Electrical Connector Fretting Corrosion Behavior

Description: We have conducted a fretting research project using MIL-L-87177 and CLT: X-10 lubricants on Nano-miniature connectors. When they were fretted without lubricant, individual connectors first exceeded our 0.5 ohm failure criteria from 2,341 to 45,238 fretting cycles. With additional fretting, their contact resistance increased to more than 100,000 ohms. Unmodified MIL-L-87177 lubricant delayed the onset of first failure to between 430,000 and over 20,000,000 fretting cycles. MIL-L-87177 modified by addition of Teflon powder delayed first failure to beyond 5 million fretting cycles. Best results were obtained when Teflon was used and also when both the straight and modified lubricants were poured into and then out of the connector. CLT: X-10 lubricant delayed the onset of first failure to beyond 55 million cycles in one test where a failure was actually observed and to beyond 20 million cycles in another that was terminated without failure. CLT: X-10 recovered an unlubricated connector driven deeply into failure, with six failed pins recovering immediately and four more recovering during an additional 420 thousand fretting cycles. MIL-L-87177 was not able to recover a connector under similar conditions.
Date: October 12, 1999
Partner: UNT Libraries Government Documents Department

MIL-L-87177 Lubricant Bulletproofs Connectors Against Chemical and Fretting Corrosion

Description: Electrical connectors corrode. Even our best SA and MC connectors finished with 50 to 100 microinches of gold over 50 to 100 microinches of nickel corrode. This work started because some, but not all, lots of connectors held in KC stores for a decade had been destroyed by pore corrosion (chemical corrosion). We have identified a MIL-L-87177 lubricant that absolutely stops chemical corrosion on SA connectors, even in the most severe environments. For commercial connectors which typically have thinner plating thicknesses, not only does the lubricant significantly retard effects of chemical corrosion, but also it greatly prolongs the fretting life. This report highlights the initial development history and use of the lubricant at Bell Labs and AT&T, and the Battelle studies and the USAF experience that lead to its deployment to stop dangerous connector corrosion on the F-16. We report the Sandia, HFM&T and Battelle development work, connector qualification, and material compatibility studies that demonstrate its usefulness and safety on JTA and WR systems. We will be applying MIL-L-87177 Connector Lubricant to all new connectors that go into KC stores. We recommend that it be applied to connectors on newly built cables and equipment as well as material that recycles through manufacturing locations from the field.
Date: May 1, 2002
Partner: UNT Libraries Government Documents Department


Description: Artificially creviced Alloy 22 (N06022) specimens may be susceptible to crevice corrosion in presence of hot chloride containing solutions. The presence of oxyanions in the electrolyte, especially nitrate, may inhibit the nucleation and growth of crevice corrosion. Constant potential tests were performed using tightly creviced specimens of Alloy 22. It was found that crevice corrosion may initiate when a constant potential above the crevice repassivation potential is applied. It was found that as the crevice corrosion nucleated, the current initially increased but later decreased. The net measured current can be converted into penetration following a power law fit of the experimental data. The average power law coefficient ''n'' was found to be 0.439, suggesting that even under constant applied potential, crevice corrosion penetration is diffusion controlled.
Date: July 1, 2005
Creator: Mon, K.G.; Gordon, G.M. & Rebak, R.B.
Partner: UNT Libraries Government Documents Department

Non-Chromate Talc Conversion Coatings for Aluminum

Description: A method was developed for applying an inorganic conversion coating on that is procedurally similar to chromate conversion coating methods; this method, however does not use or involve hazardous/toxic chemicals. The coating forms by precipitation involving Al{sup 3+} Li{sup +}, OH{sup {minus}}, CO{sub 3}{sup 2}{minus}, and possibly other anions. This polycrystalline coating is continuous, conformal and persistent in aggressive environments. Coating thicknesses range from several tenths to ten micrometers. Although the outer portions of the coating are porous, the pores do not penetrate to the substrate interface. These coatings do not match the levels of performance offered by commercially available chromate conversion coatings, but are capable of meeting many of the corrosion resistance, electrical resistivity, and paint adhesion requirements established in MIL-C-5541E ``Chemical Conversion Coatings on Aluminum and Aluminum Alloys.`` In this paper, methods for producing the talc coating on aluminum alloys 1100 and 6061-T6 are described and compared to traditional chromate conversion coating methods. Resulting coating structure and composition are described. Performance data for the talc coatings in MIL-C-5541E required tests are presented along with data commercial chromate-based coatings.
Date: January 1, 1994
Creator: Buchheit, R. G.; Drewien, C. A.; Finch, J. L. & Stoner, G. E.
Partner: UNT Libraries Government Documents Department