The Treatment of Durability in CES EduPack A white paper

The Treatment of Durability in CES EduPack A white paper Mike Ashby, Cambridge UK March 2009 Introduction Durability is a key material attribute, one central to the safety and economy of products It is one of the more difficult attributes to characterize, quantify and use for selection because • • • It is a function not just of the material but of the environment in which it operates There are many mechanisms, some general, some peculiar to particular materials and environments Material combinations (as in galvanic corrosion) and configuration (as in crevice corrosion) play a role Figure shows some of the considerations involved The central players are Materials and Environments But the fact that a given material is resistant to a given environment is not enough – there are many other considerations, some of them listed on the Figure First there is the Industrial sector in which the material is to be used: some are limited to material lightweight materials, some to non-flammable materials, some to biocompatible materials Second, there are many Mechanisms of attack, some general, some appearing only under special conditions Third, there are Protection methods, some generally applicable (like painting), some specific to particular combinations of material and environment (such as inhibitors) And finally there are issues of Design, often specific to a given industry Thus there are preferred material choices for use in a given environment – those that, through experience, best meet both the primary constraint of resisting attack and the secondary constraints of stiffness, strength, cost, and the like Figure CES EduPack records deal explicitly with materials and environments The other information is captured, as far as possible, in Notes attached to the each environment field, in the way shown in Figure This White Paper describes the way in which Durability is treated in CES EduPack Section lists the environments Section describes the data organisation and information provision in CES EduPack Section illustrates how the database is used Appendix A reviews currently available software for durability selection Appendix B gives examples of the data The materials and the environments The material set is that of the CES EduPack Level database It contains records for 97 materials, organized under the headings shown in Table The records contain a description and image of the material, data for general, mechanical, thermal and electrical properties, properties relating to the impact of their use on the natural environment, design guide-lines, technical notes, typical uses and trade names Table The material families and classes Family Class Metals and alloys Ferrous Non ferrous Polymers and elastomers Elastomers Thermoplastics Thermosets Ceramics and glasses Cement and concrete Fired clay Glasses Minerals and stone Technical ceramics Hybrids Composites Foams Natural materials Table lists the 53 environments – it is a subset of a longer list of the kind found in the Chemical Resistance tables of CES EduPack or the compilation by Schweitzer (1995) or that used by NACE, expanded by the addition of Built Environments (to include use in Architecture) and Thermal Environments (giving a way to select materials for use at high temperatures) Table The 53 environments Chemical environments Water & Aqueous Solutions Water (fresh) Water (salt) Soils, acidic (peat) Soils, alkaline (clay) Alcohols, aldehydes, keytones Wine Acetaldehyde Acetone Acids Ethyl alcohol (ethanol) Acetic acid (10%) Ethylene glycol Acetic acid (glacial) Formaldehyde (40%) Citric acid (10%) Glycerol Hydrochloric acid (10%) Methyl alcohol (methanol) Hydrochloric acid (36%) Hydrofluoric acid (40%) Halogens and gases Nitric acid (10%) Chlorine gas (dry) Nitric acid (70%) Fluorine (gas) Phosphoric acid (10%) Oxygen (gas) Phosphoric acid (85%) Sulfur dioxide, SO2 Sulfuric acid (10%) Built environments Sulfuric acid (70%) Industrial atmosphere Alkalis Marine atmosphere Sodium hydroxide (10%) Rural atmosphere Sodium hydroxide (60%) UV radiation (sunlight) Flammability Fuels, oils and solvents Amyl acetate Thermal environments Carbon tetrachloride Cryogenic (down to -273 C) Chloroform Tolerance to 150 C Crude oil Tolerance to 250 C Diesel oil Tolerance to 450 C Lubricating oil Tolerance to 850 C Paraffin oil (kerosene) Tolerance above 850 C Petroleum (gasoline) Silicone fluids Toluene Turpentine Vegetable oils White spirit 3 The way Durability is treated in CES EduPack When CES EduPack is opened in Browse or Select mode, the user has the ability to choose a selection template One of the options under EduPack Level is Materials with Durability, as shown in Figure This presents, under the heading Durability, the 53 environments, grouped under eight headings: Water & Aqueous solutions, Acids, Alkalis etc as listed in Table Each material is given a ranking in each environment, using a point scale: Excellent (A), Satisfactory (B), Doubtful (C), Unsatisfactory (D) Table B3 of Appendix B lists a subset (about one third of the total) of the materials and environments with their ranking on this scale File Edit Browse Table: View Select Tools… Search Select MaterialUniverse MaterialUniverse Subset: Edu EduLevel Level22 Edu Level Edu Level Edu Level with durability Edu Level with eco props Edu Level 2…… Figure Opening the CES EduPack data base with durability attributes Materials to resist a given environment are best selected using a Limit stage Figure shows part the display for environments under the heading of Acids Ticking the box for Excellent, or those for Excellent and for Satisfactory, for a chosen environment, limits the selection to materials that carry these rankings This, however, may not always be the best way to select materials for durability because there are other issues involved Durability can be achieved by choosing a material that does not corrode or react in a given environment But it can also be achieved by protection with corrosion inhibitors, by coatings, or – when corrosion is uniform rather than localised – simply by providing sufficient section that the loss over the design life does not compromise the integrity of the component The preferred choice of material or coating may, for economic reasons, not be the one most resistant to attack, but a cheaper one that is still satisfactory in its performance This information, and more, is contained in sets of Notes, accessed by double clicking on the group name (e.g on “Acids”) or on the name of the environment (e.g “Hydrochloric acid”) Figure illustrates the two sorts of notes that are accessed by double clicking on the headings and environment names These are described next Figure The way information on Durability information is stored and accessed in CES EduPack Opening a LIMIT stage reveals a list of the environments, each with a 4-point check box for material selection Each heading is linked to pages of Science notes, and each environment name is linked to Environmental notes pages like those shown here, listing information relating to the other factors shown in Figure Science notes The headings (Water and Aqueous solutions, Acids, Alkalis etc) are linked to Science notes that outline the underlying science – the chemical reactions, the rate of attack etc – associated with the subject of the heading Thus “Acids” in Figure is linked to pages of Science notes about the nature of acid attack They parallel the Science notes attached to the mechanical, thermal, electrical and optical properties in the database Environment notes The environments (Acetic acid, Citric acid, Hydrochloric acid etc) are linked to Notes of a different kind Their purpose is to capture some of the peripheral information suggested by Figure Each Environmental note is headed by the environment name and chemical formula The first item in the Note (“where found”) lists the circumstances under which this environment in encountered Table B1 of Appendix B lists some of these The second lists the industrial sectors in which it is commonly encountered, drawn from the list in Table The third describes the problems caused by a given environment, particularly the classes of material that are most vulnerable to it This introductory information is followed by a list of the preferred materials and coatings used when the design requires resistance to that environment (Table B4 of Appendix B lists a subset) The purpose is to direct the user to the Metals, Polymers and Ceramics and Glasses most commonly used to contain, transport or process the environment The choice is influenced both by resistance to attack and by the economics of its use, and for that reason is not always the most obvious one Materials for which records can be found in CES EduPack Level are shown without brackets Those that are not in Level 2, but for which properties can be found in Level are shown in brackets Below this are two further notes The first lists inhibitors that slow the rate of attack by the environment, though they seldom prevent it entirely (Table B2 of Appendix B gives examples) Inhibitors are materialspecific – thus the inhibitors for HCl attack of iron differ from those for HCl attack of aluminium or titanium The metal to which a given inhibitor applies is shown in brackets after the inhibitor name The second note simply indicates the underlying mechanism, more fully described in the Science notes attached to the headings Table Industrial sectors Industry Particular environments Petroleum Petroleum, oils, solvents, sulphuric acid, sulphur, salt and fresh water, soil Food processing Acetic acid, citric acid, sulphur dioxide, vegetable oils, fresh and salt water, wine Chemical engineering Acids, alkalis, halogen gases, oils Engineering manufacture Industrial fluids, Fuels and oil Construction (housing, industrial building Soils, Built environments (Industrial, marine, rural) Radiation, Energy conversion (ic engines, steam and gas turbines) Thermal environments: Hot liquids and gasses Marine engineering (shipping, off-shore engineering) Salt water, industrial solvents Aerospace (airframes) Fresh and salt water, radiation Bio-engineering Fresh and salt water, body fluids Domestic (cooking, cleaning) Fresh and salt water, dilute acids and alkali, vegetable and animal fats Using the Durability data in CES EduPack The use of the database is best illustrated by examples In each example the CES system has been opened in Level Materials with Durability Example The waste stream of a fertilizer plant includes dilute sulfuric acid The dilute acid is stored in surface tanks some distance from the plant It is suggested that the ducting to carry the acid to the tanks could, most economically, be made of wood Is this a totally crazy suggestion? • Browse: opening the records for Hardwood:oak or for Softwood: pine we find: Softwood: pine Durability: acids Sulfuric acid (10%) Acceptable Sulfuric acid (70%) Unacceptable The suggestion should be taken seriously, provided the strength of the acid is below 10% Example A polymer coating is sought to protect components of a microchip processing unit from attack by hydrogen fluoride (HF) Results of Limit stage • Tree stage: limit the selection to Polymers Ionomer (I) • Limit stage: require Excellent in Hydroflouric acid (40%) The results are shown in the box Polychloroprene (Neoprene, CR) Polyethylene (PE) • Opening the Environmental notes for Hydrofluoric acid (40%) confirms that fluorocarbon polymers give good protection, and provides information about inhibitors, suggesting that steel components can be protected by doping the HF solution with one of these Polypropylene (PP) Polytetrafluoroethylene (PTFE) Hydrofluoric acid (40%), HF Preferred materials and coatings Metals Lead Copper Stainless Steel Carbon Steels (Monel) (Hastelloy C) (Platinum, Gold, Silver) Polymers and composites PTFE Fluorocarbon polymers Rubber Ceramics and glasses Graphite Inhibitors Thiourea, arsenic oxide, sodium arsenate (all for Fe) Example A food processing plant uses dilute acetic acid for pickling onions The acid is piped to and from holding tanks Select a suitable material for the pipes and tanks, given that, to have sufficient strength and toughness to tolerate external abuse they must be made of a metal • Tree stage: limit the selection to metals • Limit stage: require Excellent in Acetic acid (10%) The results are shown in the box Results of Limit stage Commercially pure lead Commercially pure titanium Titanium alloys Nickel-based superalloys Nickel-chromium alloys Stainless steel Tin • Opening the Notes for Acetic acid (10%) gives the following information about preferred materials and coating Acetic acid (10%), CH3COOH: Metals Aluminum Stainless steel Nickel Nickel alloys Titanium (Monel) Preferred materials and coatings Polymers and composites HDPE PTFE Ceramics and glasses Glass (Porcelain) (Graphite) The metals are essentially the same as those found by the limit search – the only difference is the inclusion of aluminum But the other two columns suggest an alternative approach: that of making the pipe work out of a cheap steel and either lining it with HDPE or PTFE, or enameling it to give a glass surface These are attractive alternatives since, in food processing, any leaching of metal ions into the product is unacceptable Example Metal pipe work on an oil rig must carry hydrochloric acid solution to acidify the well Use the database to explore ways of providing and protecting the pipe • Results of Limit stage Tree stage: limit the selection to metals • Limit stage: require Excellent in Hydrochloric acid (10%) The results are shown in the box HCl is a particularly aggressive acid Only three alloys survive Commercially pure lead Stainless steel Titanium alloys • Opening the Notes for Acetic acid (10%) we learn that HCl is a particularly aggressive acid, difficult to contain and transport The preferred material and coating, and the inhibitors are listed Hydrochloric acid (10%), HCl Preferred materials and coatings Metals Copper Nickel and nickel alloys Titanium (Monel) (Molybdenum) (Tantalum) (Zirconium) (Platinum, Gold, Silver) Polymers and composites HDPE PP GFRP Rubber Ceramics and glasses Glass Inhibitors Ethylaniline, mercaptobenzotriazole, pyridine and phenylhydrazine, ethylene oxide (all used for Fe), phenylacridine (Al), napthoquinone (Al), thiourea (Al), chromic acid (Ti), copper sulphate (Ti) Titanium would appear to be the best, though expensive, choice: its inherent resistance to attack by HCl is high, and inhibitors exist that give added protection The alternative, suggested by the table, is that the pipe work is lined with HDPE or enameled Example An auto maker is concerned about the consequences of the introduction of bio-methanol, CH3OH or bio-ethanol C2H5OH into auto fuels The particular concerns are (a) Corrosion of aluminum components, particularly the engine block, by methanol or ethanol (b) Possible damage to GFRP or CFRP body panels of some models by spillage of methanol or ethanolcontaining bio-fuels Are the concerns justified? What can be done if they are? • Browse: opening the records for Cast aluminum alloys and for Sheet molding compound (SMC) yields the information shown in the boxes Clicking on the environment name brings up the Notes pages, also useful Cast aluminum alloys are “Acceptable” in both alcohols – not the highest rating, so some corrosion is possible The problem, as the Note explains, is the take up of water, which, if allowed, brings the risk of electro-chemical corrosion Lobbying for the inclusion of inhibitors in the Cast Al-alloys Durability: alcohols, aldehydes, ketones Ethyl alcohol (ethanol) Acceptable Methyl alcohol (methanol) Acceptable Inhibitors for aluminum Potassium dichromate, alkali carbonates or lactates (Al), fuel might be justified SMC (and also CFRP) gets a more severe rating of “Limited use” This is a cause for concern – prolonged exposure to either of the two alcohols, if present in large concentration in the fuel, could result in degradation of the body panels It will be necessary to explore alcoholresistant surface coatings if the use of bio-fuels becomes widespread Sheet molding compound, SMC Durability: alcohols, aldehydes, ketones Ethyl alcohol (ethanol) Limited use Methyl alcohol (methanol) Limited use Example As a materials consultant you are asked to prepare a survey of the strength and resistance of materials to strong sodium hydroxide, NaOH The client, the manager of a paper-making plant that uses NaOH in one step of the paper-making process, is interested in metals, polymers and polymer based composites as alternatives for parts of the pipe work, valves and pumps • Select: Custom – define you own subset Create a database that contains only the materials of interest to the client: metals, polymers and polymer-matrix composites • Graph stage: make a Graph with Yield strength on the y-axis and Sodium hydroxide (60%) on the xaxis • Label the materials by clicking on the bars Where the name is too long or for some other reason you want to edit it, click twice, slowly, on the label When it turns blue you can edit it To reformat the color, type face or size, right-click on the label and select Format at the bottom of the menu that appears It lets you change the font and its size and color • Add a title by clicking on the A in the tool bar above the chart • Open the Environmental Notes for Sodium Hydroxide (60%) The resulting chart, shown below, provide an overview at the CES Level of strength of materials and their durability in strong NaOH of materials The Notes, also shown, give further information about where the environment is encountered and the materials that are most resistant to it Figure A chart made with the CES EduPack Level with durability properties, surveying the durability of chosen material classes in NaOH Sodium hydroxide (60%) (caustic soda), NaOH Where found Sodium hydroxide of this concentration is found in drain cleaners as a 50% solution, is used to produce alumina, paper and bio diesel, and is used to clean and etch aluminum Industrial sectors Chemical engineering, domestic, petroleum, engineering manufacture The problem The strong alkalis NaOH, KOH (potassium hydroxide), and NH4OH (ammonium hydroxide) are all corrosive and toxic Vapors are dangerous Preferred materials and coatings Metals Polymers and composites Ceramics and glasses Nickel and its alloys PVC Glass Stainless steels LDPE Graphite HDPE PTFE (PE-CTFE) Underlying mechanisms Basic attack; stress corrosion cracking Figure The Environmental notes for Sodium hydroxide (60%) 10 References ASM (2008) “Handbooks on line”, Vol 13a, b, c, ASM International, Metal s Park, Ohio, USA Bradford, S.A (1993) “Corrosion control”, Van Nostrand Reinhold, New York, NY, USA ISBN 0-442-010885 (Excellent introduction to the practical side of corrosion control with tables of materials to withstand a range of environments.) CORROSION DATA for Brass, Carbon Steel, 316 Stainless Steel and coatings www.lancevalves.com/pdfs/corrosiondata.pdf Copper Development Association (2008) Corrosion data for bronze, copper, brass, copper-nickel and gun metals http://www.hghouston.com/coppers/corrosion_cu.html DECHEMA Corrosion Handbook (2004) Corrosive Agents and their Interaction with Materials : Methanol alkanols acetic acid, acetates, sodium hydroxide, formic acid, alkaline earth chlorides, aliphatic amines Elsevier, Oxford, UK ISBN: 0-444-50833-3 (The DECHEMA Corrosion Handbook is an Englishlanguage compendium of corrosion data based on the DECHEMA-WERKSTOFF-TABELLE) DeRenzo, D.J (1985) “Corrosion resistant materials handbook”, 4th edition, William Andrew Publishing/Noyes ISBN 978-0-8155-1023-9 (A handbook of commercially available corrosion resistant materials for a specific environments) Fontana, M.G (1986) “Corrosion engineering” McGraw Hill, St Louis, USA ISBN 0-07-021463-8 Fluoropolymer Chemical Resistant Charts (2008) http://www.texloc.com/closet/cl_chemical_resistance_chart.html Fontana, M.G and Greene, N.D (1967) “Corrosion engineering” McGraw Hill, St Louis, USA Library of Congress Number 67-19901 NACE (1983) “Corrosion Guide”, 2nd Edition edited by K M Pruett, Compass Publications (An extensive tables and guidelines for the oxidation and corrosion characteristics of metals and polymers.) Nibco (2008) “Chemical resistance guide for plastic and metal valves and fittings”, www.nibco.com ProFlow Dynamics chemical resistance selector (2008) http://www.proflowdynamics.com/viewcorrosion.aspx Rabold, E (1968) “Corrosion guide”, 2nd edition, Elsevier, Amsterdam, Holland Library of Congress No 6719853 Schweitzer, P.A (1983), editor, Corrosion and corrosion protection handbook”, Marcel Dekker, NY, USA ISBN 0-8247-1705-8 Schweitzer, P.A (1998) “Encyclopaedia of corrosion technology”, Marcel Dekker, New York, USA ISBN 08247-0137-2 (A curious compilation, organized alphabetically, that mixes definitions and terminology with tables of data.) Schweitzer, P.A.(2004) “Corrosion resistance tables”, 5th edition, Marcel Dekker, NY, USA ISBN 0-82475673-8, 5674-6, 5675-4 and 5676-2 (A four-volume compilation of tables of of the corrosion resistance of a limited set of polymers, metals and non-metals in some 800 different industrial fluids and chemicals.) Speller, F.N (1951) “Corrosion causes and prevention”, 3rd edition, MeGraw Hill, New York, NY, USA (p157 et seq) Tretheway, K.R and Chamberlain, J (1995) “Corrosion for science and engineering” 2nd edition, Longman Scientific and Technical, Harlow, UK ISBN 0-582-238692 (An unusually readable introduction to Corrosion Science, filled with little bench-top experiments to illustrate principles.) Uhlig, H.H (1948) “The corrosion handbook”, Wiley and Sons, New York, NY, USA (A vast compendium of corrosion information, ordered by material, the life’s work of one of the fathers of the field, but now, inevitably, rather dated.) Waterman, N.A and Ashby, M.F (1991) “Elsevier Materials Selector”, Elsevier, Oxford, UK ISBN 1-85-166605-2 and, in the CRC edition, ISBN 0-8493-7790-0 (A 3-volume compilation of materials data for design, 11 Appendix A Software for durability selection Most texts and existing software systems focus on the materials and environments that are associated with a particular industrial sector (the oil industry, food processing, aerospace ) Few attempt a broader sweep, as we here, seeking to cover a many materials and sectors Existing software for corrosion selection is listed in Table The first two come closest to the methods we develop here Those that were accessible are reviewed on the next page Table A1 Software for corrosion information and selection Company Software Web address DeZurik Materials Selection Guide http://www.dezurik.com/ ProFlow Dynamics Corrosion Database http://www.proflowdynamics.com/ViewCorrosion.aspx Corrosion Source Predict http://www.corrosionsource.com/software/predict.htm Corrosion Source Online Corrosion Problem Solver http://www.corrosionsource.com/handbook/CPS/#type enpICDA Internal Pipeline Corrosion Predictor http://www.enpicda.com/demo/index.php?page=main IMOA - http://www.imoa3.webinfoserver.com/flash.html NORSOK Standard http://www.standard.no/pronorm-3/data/f/0/10/40/5_10704_0/M-506.pdf The Nickel Institute Crevice corrosion guide for stainless steels http://www.nickelinstitute.org/index.cfm/ci_id/10646.htm Argentum Solutions ThermExpert http://www.argentumsolutions.com/thermexpert_intro.html MESA Products Inc CP Design Centre http://www.cpdesigncenter.com/private/private_index.html - Stainless Steels - Material Properties Online http://www.sci.fi/~benefon/Metallurgy.php Ashcroft Corrosion Guide - InterCorr Socrates http://intercorr.com/software/socrates/soc.html Honeywell Strategy http://hpsweb.honeywell.com/Cultures/enUS/Products/AssetApplications/corrosion/StrategySoftware/default.htm CC Technologies CorLAS http://www.cctechnologies.com/products/software/corlas/index.htm Acet Asset Condition Evaluation Tool http://www.acet.co.uk/ Elsyca Cat Pro http://www.elsyca.com/CorrosionProtectionACMitigation/Technology/Ca tPro/tabid/3763/Default.aspx Technical Toolboxes RSTRENG http://www.ttoolboxes.com/products/rstreng.htm NACE Online NACE corrosion database http://www.knovel.com/web/portal/basic_search/display?_EXT_KNOVE L_DISPLAY_bookid=532 12 Brief reviews of readily accessible software tools for Durability DeZurik Materials Selection Guide Purpose: Dezurik MSG is used in a range of industries to select materials appropriate for a given environment Ease of use Quite easy, although the layout is not perfect, and a large proportion of data is missing Industry coverage: All Environment coverage A wide range of environments Materials: Cast Iron, Ni-Resist, Carbon Steel, 304 SS, 316 SS, 317 SS, Duplex, Alloy 20, Monel, Nickel, Hastelloy B, Hastelloy C, Titanium, Bronze, Acid-Bronze, Aluminium ProFlow Dynamic Corrosion Database Purpose: A free online database for finding a material suitable for use in specified environments Ease of use Excellent Select environment and performance needed, and click submit Very fast Industry coverage: All Environment coverage: Very wide range Materials: Alloy 20, Aluminium, Brass, Buna N, Carbon Steel, Carpenter Custom, Delrin, Ductile Iron, EPDM, Grafoil, Hastelloy C, Hypalon, Monel, Neoprene, Nylon, PTFE, SS316, Viton IMOA Stainless Steel Selector Purpose: Flash program using a scoring system to select stainless steels for use in an open air environment Ease of use: Very easy to use, simply select the conditions relevant to the purpose Industry coverage: Building Environment coverage: Very limited, open air environments only Materials: Stainless Steels Predict 2.0 Purpose: Predict is used to find the corrosion rate of a material in a given environment Ease of use Confusing at first, can be made to work quite well with experience Industry coverage: Intended for any industry using stainless steels Environment coverage: User defined concentrations of common corrosive agents Materials: Unclear, though it seems to be some form of steel (composition not given) Knovel Online Corrosion Database Purpose: Online database containing corrosion compatibility data for a wide range of materials and environments Ease of use Unknown Industry coverage: All Environment coverage: Very wide range Materials: Very wide range Socrates 8.0 Purpose: Socrates screen a material database using the environment, the application and certain required mechanical characteristics Ease of use Simple, but need a good estimation of environment composition Industry coverage: The oil industry, specifically tubing, liners, wellheads, subsurface equipment, flow lines and specialty equipment Environment coverage: User defined partial pressures of common corrosive agents Materials: Wide range of stainless steels and Ni-based alloys; Alpha, Beta and Alpha-Beta Titanium; Cobaltbased alloys; Zirconium 13 Appendix B Examples of the content of CES EduPack dealing with Durability Table B1 Commonly encountered liquid environments* Environment Where encountered Water and aqueous solutions Water (fresh) Fresh water is ubiquitous: any object: exposure to high humidity, rain or washing acquires a film of water containing (unless distilled) dissolved oxygen and, usually, other impurities Water (salt) Materials in marine environments are exposed to salt water and wind-carried spray Seawater varies in composition depending on the location It is typically 3.5% Soils differ greatly in composition, moisture content and pH The single most important property of a soil that determines its corrosive behaviour is its electrical resistivity – a low resistivity means that the water in the soil has high concentration of dissolved ions A resistivity below 109 µohm.cm is very corrosive; one with a resistivity above x 1010 µohm.cm is only slightly corrosive The choice of material for use in soil depends on this and on the pH Acidic (peaty) soils have a low pH, alkali soils (those containing clay or chalk) have a high one Body fluids include blood, urine, saliva sweat and gastric fluids All are water-based with high ion-content, some acidic, stimulating electro-chemical and acid attack Soils Body fluids Acids and alkalis Acetic acid, CH3COOH Hydrochloric acid, HCl Hydrofluoric acid, HF Nitric acid HNO3 Sulphuric acid, H2SO4 Sodium hydroxide, NaOH Acetic acid is an organic acid made by the oxidation of ethanol It is used in the production of plastics, dyes, insecticides and other chemicals Dilute acetic acid (vinegar) is used in cooking Hydrochloric acid is used as a chemical intermediate, for ore reduction, for pickling steel, in acidizing oil wells and in other industrial processes In dilute form it is a component of household cleaners Hydrofluoric acid is used for the etching of glass, synthesis of fluorocarbon polymers, aluminum refining, as an etchant for silicon-based semi-conductors and to make UF6 for uranium isotope separation Nitric acid is used in the production of fertilizers, dyes, drugs and explosives Sulfuric acid, of central importance in chemical engineering, is used in making fertilizers, chemicals, paints and in petrol refining It is a component of acid rain Sodium hydroxide of this concentration is found in some household cleaners, the making of soap and in the cleaning in food processing Fuels, oils and solvents Benzene, C6H6 Carbon tetrachloride, CCl4 Crude oil Diesel oil Kerosene (paraffin oil) Lubricating oil Petroleum (gasoline) Silicone fluid, ((CH3)2SiO)n Benzene is used as an industrial solvent, as well as in the synthesis of plastics, rubbers, dyes and certain drugs It is also found in tobacco smoke Carbon tetrachloride is used principally to manufacture refrigerants, as a drycleaning solvent and as a pesticide (now banned in the US) Refined petroleum is not corrosive to metals, but crude oil usually contains saline water, sulfur compounds and other impurities, some acidic Diesel oil is a specific fractional distillate of crude oil It is the primary fuel for truck, shipping and non-electric and diesel-electric rail transport Its use for car propulsion is increasing Diesel oil acts both as fuel and as lubricant in the engine Paraffin is used as aviation fuel, as well as being commonly used for heating and lighting on a domestic level It is used to store highly reactive metals to isolate them from oxygen Oil is used as a lubricant in most metal systems with moving parts Typically, these are mineral oils, and frequently contain sulfur Low sulfur synthetic oils can also be produced Lubricating oil is less corrosive than petroleum and diesel oil because it is base on hydrocarbons with higher molecular weight Petroleum is a volatile distillate of crude oil It is used mainly to power engines, for cars, light aircraft and agricultural equipment It often contains additives such as lead, ethanol or dyes Silicone oils are synthetic silicon-based polymers They are exceptionally stable and inert They are used as brake and hydraulic fluids, vacuum pump oils, and as lubricants for metals and for textile threads during sewing and weaving of fabrics 14 Vegetable oil Vegetable oils are derived from olive, peanut, maize, sunflower, rape and other seed and nut crops They are widely used in the preparation of foods They are the basis of bio-fuels Alcohols, aldehydes, ketones Acetone, CH3COCH3 Acetone is the simplest of keytones It is widely used as a degreasing agent and a solvent, and as a thinning agent for polyester resins and other synthetic paints (commonly nail varnish), a cleaning agent and as an additive in automobile fuels It is used in the manufacture of plastics, drugs, fibers and other chemicals Ethyl alcohol, C2H5OH Ethanol is made by fermentation, and thus in alcoholic beverages It is used medically as a solvent for disinfectants and for cleaning wounds before dressing them It is used industrially as a solvent, a dehydrating agent and as a “green” fuel for cars Methyl alcohol, CH3OH Methanol is used in glass cleaners, stains, dyes, inks, antifreeze, solvents, fuel additives and as an extractant for oil It is also used as a high-energy fuel for cars, aircraft and rockets, and is a possible fuel for fuel cells Formaldehyde, CH2O Formaldehyde is used as a disinfectant in medical applications It is used industrially to make many resins (including melamine resin and phenol formaldehyde resin) and glues, including those used in plywood It is found in car exhausts and tobacco smoke It is the basis of embalming fluids 15 Table B2 Corrosion inhibitors and the materials for which they work Environment Inhibitors (materials) Water and aqueous solutions Water (fresh) Calcium bicarbonate (Steel, Cast Iron), polyphosphate (Cu, Zn, Al, Fe), calcium hydroxide (Cu, Zn, Fe), sodium silicate (Cu, Zn, Fe), sodium chromate (Cu, Zn, Pb, Fe), potassium dichromate (Mg), sodium nitrite (Monel), benzoic acid (Fe), calcium and zinc metaphosphates (Zn) Water (salt) Sodium nitrite (Fe), sodium silicate (Zn), calcium bicarbonate (all metals), amyl stearate (Al), methyl-substituted dithiocarbamates (Fe) Soils Calcium nitrate is added to concrete to inhibit corrosion of steel reinforcement in soils Acids and alkalis Acetic acid, CH3COOH (10%) Thiourea, arsenic oxide, sodium arsenate (all for Fe) Hydrochloric acid, HCl (10%) Ethylaniline, mercaptobenzotriazole, pyridine and phenylhydrazine, ethylene oxide (all used for Fe), phenylacridine (Al), napthoquinone (Al), thiourea (Al), chromic acid (Ti), copper sulphate (Ti) Hydrofluoric acid, HF (40%) Thiourea, arsenic oxide, sodium arsenate (all for Fe) Nitric acid HNO3 (10%) Thiourea, arsenic oxide, sodium arsenate (all for Fe), hexamethylene tetramine (Al), alkali chromate (Al) Sulphuric acid, H2SO4 (10%) Phenylacridine (Fe), sodium chromate (Al), benzyl thiocyanate (Cu and Brass), hydrated calcium sulphate (Fe), aromatic amines (Fe), chromic acid (Ti), copper sulphate (Ti) Sodium hydroxide, NaOH (10%) Alkali silicates, potassium permanganate, glucose (all for Al) Fuels, oils and solvents Benzene, C6H6 Anthraquinone (Cu and Brass) Carbon tetrachloride, CCl4 Formamide (Al), aniline (Fe, Sn, Brass, Monel and Pb), mesityl oxide (Sn) Diesel oil PTFE suspension (all metals), chlorinated hydrocarbons (all metals), polyhydroxybenzophenone (Cu) Kerosene (paraffin oil) PTFE suspension (all metals), chlorinated hydrocarbons (all metals), polyhydroxybenzophenone (Cu) Lubricating oil PTFE suspension (all metals), chlorinated hydrocarbons organozinc compound selected such as zinc dithiophosphate and zinc dithiocarbamate.(all metals), poly-hydroxybenzophenone (Cu) Petroleum (gasoline) PTFE suspension (all metals), chlorinated hydrocarbons (all metals) Vegetable oil Anthraquinone (Cu and Brass) Alcohols, aldehydes, ketones Ethyl alcohol, C2H5OH Potassium dichromate, alkali carbonates or lactates (Al), benzoic acid (Cu and Brass), alkaline metal sulphides (Mg), ethylamine (Fe), ammonium carbonate with ammonium hydroxide (Fe) Methyl alcohol, CH3OH Sodium chlorate with sodium nitrate (Al), alkaline metal sulphides (Mg), neutralised stearic acid (Mg), Polyvinylimidazole (Cu) 16 Acetic Acid (10%) Soils, alkaline (clay) Soils, acidic (peat) Water (salt) Water (fresh) Composites Hydrochloric Acid (10%) Technical Hydrofluoric Acid (40%) Porous Nitric Acid (10%) Glasses Sulfuric Acid (10%) Ceramics and glasses Sodium Hydroxide (10%) A B B B B A D A B B B A C A A A A A A A A A A A A A A A D C C B B B B B A D A D B B A C B A A B A A A A A A A A A A A D A A Sodium Hydroxide (60%) B D D D D B D C B D B B C A A A A A B C A A A A A A A A D A A 17 A A A A A B A A A A A A A A A A A A A A A A A A A A A A A B B Benzene D D D D D A C B B D B A D A A A A A B C A A A A A A A A C C C A A A A A A A A A A A A A A A A A A A A A A A A A A A A A A A Carbon Tetrachloride D D D D D C D D D D D A D D D D D D D D D D D D D D D D D D D A A A A A A A A A A A A A A A A A A A A A A A A A A A A A A A Diesel Oil D D D D D A C C C D B A D A A A A A B C A A A A A A A A B A A A A A A A A A A A A A A A A A A A A A A A A A A A A A A A A A Lubricating Oil C C C C C A C C B C A A C A A A A A B C A A A A A A A A C C C A A A A A A A A A A A A A A A A A A A A A A A A A A A A A A A Paraffin Oil (Kerosene) B B B B B A A A A C A A A A A A A A A A A A A A A A A A A C C A A A A A A A A A A A A A A A A A A A A A A A A A A A A A A A Petroleum (gasoline) B B B B B A D A A C A A B A A A A A A A A A A A A A A A D C C A A A A A B A A A A A A A A A A A A A A A A A A A A A A A A A Silicone Fluids C C C C C A B A A C A A B A A A A A A A A A A A A A A A B A A A A A A A A A A A A A A A A A A A A A A A A A A A A A A A A A Vegetable Oils B B B B B A A A A A A A A A A A A A A A A A A A A A A A A A A Fuels, oils and solvents Alcohols and aldehydes A A A A A A A A A A A A A A A A A A A A A A A A A A A A A D D Acetone Non-ferrous Cast iron High carbon steel Medium carbon steel Low carbon steel Low alloy steel Stainless Steel Aluminum alloys Copper alloys Lead alloys Magnesium alloys Nickel alloys Titanium alloys Zinc alloys Borosilicate glass Glass ceramic Silica glass Soda-lime glass Brick Concrete Stone Alumina Aluminum nitride Boron carbide Silicon Silicon carbide Silicon nitride Tungsten carbides Zirconia Al / SiC composite CFRP GFRP Acids and alkalis B B B B B A A A A A A A A A A A A A A A A A A A A A A A A C C Ethyl Alcohol (ethanol) Ferrous Aqueous environments A A A A A A A A A A A A A A A A A A A A A A A A A A A A A A A Formaldehyde (40%) Metals Material Environment Table B3 Corrosion-resistance ranking of materials in common environments B B B B B A C A A A A A A A A A A A A A A A A A A A A A A D D Methyl Alcohol (methanol) Hydrofluoric Acid (40%) Hydrochloric Acid (10%) Acetic Acid (10%) Soils, alkaline (clay) Soils, acidic (peat) Water (salt) Water (fresh) Thermosets Nitric Acid (10%) Thermoplastics Sulfuric Acid (10%) Elastomers Sodium Hydroxide (10%) D D D D D C A A A A C A A D A C A A A C A A A A A A A C D D D D D D D C C A C A D A A D A C C A A D A A A A A D A A D D Sodium Hydroxide (60%) B B C D B B D A A A C C A D A D A A A A D D A A A B A A A A 18 B B C B B D D D D D D D D A C A D A B A D A C D A D C B A D Benzene B B C D B C D A C C C C A D A D A A A A A C A B A D D C A A B B C B B D D D D D D D D A D A A A B A C A C A A D A A A A Carbon Tetrachloride D D D D D C D A C A D D C D A D A D A C D D A D A D B D D D B B C B B D B D D C C D A A A B C A A A A A A C A C B A A A Diesel Oil B B C D B C D A C A C C A A A D A A A A A C A A A C A A A A B B C B B D A D D A C D A A C B A A A A A A A C A C A A A A Lubricating Oil B B C D B B D A A A D A A D A B A A A B A A A A A C A C A C B B C B B D B D D B A D A A B A A A A A B A A A A B A A A A Paraffin Oil (Kerosene) C C D D C C A A A A C A A D A C A A A C A A A A A A A C D D B B B B B C C D D D B D A A B A A A A A A A A C A B A A A A Petroleum (gasoline) B C D D B B D A A A D A A D A B A A A B A A A A A C A C A C B B B B B B A A A A A C A A B B A A B B C C A A A C B A B A Silicone Fluids B B C D B B B A A A A A A A A B A A A A A A A A A B A A A A B B B B B D D C D A A C A B B B A A A A A A B C A A B A A B Vegetable Oils B A B D B B B A A A A A A A A B A A A A A A A A A A A A A A Fuels, oils and solvents Alcohols and aldehydes B B C B B B D A A A D C D D A A D A B C D C A D A D C D A D Acetone Polymers Bamboo Cork Leather Paper and cardboard Wood Butyl Rubber EVA Isoprene Rubber (IR) Natural Rubber (NR) Neoprene, CR Polyurethane (elPU) Silicone elastomers (SI) ABS Cellulose polymers (CA) Ionomer (I) Nylons (PA) Polycarbonate (PC) Polyetheretherketone (PEEK) Polyethylene (PE) PET Acrylic (PMMA) Acetal (POM) Polypropylene (PP) Polystyrene (PS) Teflon ( PTFE) Polyurethane (tpPUR) Polyvinylchloride (tpPVC) Epoxies Phenolics Polyester Acids and alkalis B B B B B B D A A A D A D C C A A A A A C A A A A D A C A D Ethyl Alcohol (ethanol) Woods and paper Aqueous environments B B B B B C B A A C D C A D C A A A A A A A A C A D A A A A Formaldehyde (40%) Natural materials Material Environment Table B3 (continued) Corrosion-resistance ranking of materials in common environments B B B B B B D A A A D A D D C A A A A A D A A B A D A D A A Methyl Alcohol (methanol) Sodium hydroxide, NaOH (10%) Sulphuric acid, H2SO4 (10%) Nitric acid HNO3 (10%) Hydrofluoric acid, HF (40%) Hydrochloric acid, HCl (10%) Acetic acid, CH3COOH (10%) Acids and alkalis Glass Graphite Glass, Graphite Glass, Graphite Glass, Graphite HDPE, PP, GFRP, Rubber PTFE, Fluorocarbon polymers, Rubber PTFE, PVC, Phenolics, PE-CTFE PET, PTFE, PE-CTFE, Phenolics PVC, LDPE, HDPE, PTFE, PE-CTFE 19 Glass, Porcelain, Graphite Hydroxyapatite, Alumina bio-ceramic, Bioglass ceramic, Calcium phosphate bioceramic, Glass-ionomer, Vitreous carbon, Zirconia bio-ceramic Brick, Pottery, Glass, Concrete Glass, Concrete, Brick Glass, Concrete, Brick, Porcelain Ceramics and glasses HDPE, PTFE HDPE, PP, PVC, Most polymers (except PHB, PLA and those that are bio-degradable) corrode only slowly in soil Acrylic, Silicone, Ultra high mol wt polyethylene (UHMWPE) Steel, bare in high-resistivity soil, coated or with galvanic protection in those with low resistivity Cobalt-chromium alloys, Nickel-titanium alloys (Nitinols), Nickel-chromium alloys, Precious metals implants, Silver amalgam, Stainless steel, Titanium, Gold, Platinum Soils Aluminum, Stainless steel, Nickel and nickel alloys, Titanium, Monel Copper, Nickel and nickel alloys, Titanium, Monel, Molybdenum, Tantalum, Zirconium, (Platinum, Gold, Silver) Lead, Copper, Stainless Steel Carbon Steels, Monel, Hastelloy C, (Platinum, Gold, Silver) Stainless steel, Titanium, 14.5% Silicon cast iron, Alloy 20 (40Fe, 35Ni, 20Cr, 4Cu)) Stainless steel, Copper, Nickel based alloys, Lead, Tungsten, 14.5% Silicon cast iron, Zirconium, Tantalum, Alloy 20 (40Fe, 35Ni, 20Cr, 4Cu), (Platinum, Gold, Silver) Nickel and its alloys, Stainless steels, Magnesium PET, HDPE, GFRP All polymers are corrosion free in salt water, though some absorb up to 5%, causing swelling Copper, Bronze, Stainless steels, Galvanised steels, Lead, (Platinum, Gold, Silver) Water (salt) Body fluids PET, HDPE, GFRP All polymers are corrosion free in fresh water, though some absorb up to 5%, causing swelling Polymers and composites Aluminum alloys, Stainless steels, Galvanized steel, Copper alloys Metals Water (fresh) Water and aqueous solutions Environment Table B4 Preferred materials and coatings for given environments Glass Glass HDPE, PTFE, Epoxies, Polyimides HDPE, PP, PTFE, Buna (nitrile) rubber, Viton, GFRP HDPE, PP, PTFE, GFRP HDPE, PP, PTFE, Rubber PTFE, HDPE, PP, Buna (nitrile) rubber, Viton,GFRP HDPE, PP, PET HDPE, PP, PET Carbon steel, Aluminum, Stainless steels Carbon steel, Stainless steel, Brass, Copper, Aluminum, Monel Carbon steel, Stainless steel, Aluminum, Monel Stainless steel, Carbon steel, Aluminum Carbon steel, Stainless steel, Brass, Aluminum, Hastelloy C, Alloy 20 (40Fe, 35Ni, 20Cr, 4Cu)) Carbon steel, Aluminum Aluminum, Carbon steel, Stainless steel Crude oil Diesel oil Kerosene (paraffin oil) Lubricating oil Petroleum (gasoline) Silicone fluid, ((CH3)2SiO)n Vegetable oil PTFE, HDPE, PP, GFRP PTFE , HDPE, PP PTFE, HDPE, PET, POM, Nitrile or butyl rubber Steel, Stainless steel, Copper Steel, Stainless steel, Lead, Monel Stainless steel, Monel, Hastelloy C Ethyl alcohol, C2H5OH Methyl alcohol, CH3OH Formaldehyde, CH2O 20 PTFE, HDPE, PP copolymer (PPCO) Aluminum, Carbon steel, Stainless steel Acetone, CH3COCH3 Glass, GFRP Glass Glass Glass, Graphite Glass Glass Glass Glass Glass, Porcelain, Enamelled metal Glass, Graphite POM, PTFE, Rubber Carbon steel, Stainless steel, Aluminum, Hastelloy C, Monel, (Platinum, Gold, Silver) Carbon tetrachloride, CCl4 Alcohols, aldehydes, ketones Ceramics and glasses Glass, Graphite PTFE Polymers and composites Carbon steel, Stainless steel, Aluminum, Brass Metals Benzene, C6H6 Fuels, oils and solvents Environment Table B4 (continued) Preferred materials and coatings for given environments ... A A A A A A A A A A A A A A A A A A A A A A A A A A A A A Diesel Oil D D D D D A C C C D B A D A A A A A B C A A A A A A A A B A A A A A A A A A A A A A A A A A A A A A A A A A A A A A A A A A. .. A A A A A A A A A A A A A A A A A A A A A A A Silicone Fluids C C C C C A B A A C A A B A A A A A A A A A A A A A A A B A A A A A A A A A A A A A A A A A A A A A A A A A A A A A A A A A Vegetable... A A A A A A A A A A A A A C C A A A A A A A A A A A A A A A A A A A A A A A A A A A A A A A Petroleum (gasoline) B B B B B A D A A C A A B A A A A A A A A A A A A A A A D C C A A A A A B A A A