Corrosion Behavior Of Cast Iron Research Articles

Corrosion Behavior of Cast Iron in Engine Coolant

Corrosion Behavior of Cast Iron in Engine Coolant

Corrosion Behaviour of Nodular Cast Iron Used for Rotor Manufacturing in Different Wastewaters

Submersible drainage sump pumps work in a highly corrosive environment, forming films with corrosive reaction products on the surface. Pump rotors are high-demand parts, so they are made of quality materials with good wear and corrosion resistance properties such as nodular graphite cast iron. This paper analyses the corrosion behaviour of cast iron used in the manufacture of rotors in three types of wastewaters, with variable pH. Nodular graphite cast iron samples were immersed in wastewater for 30, 60, and 90 days and tested by linear polarisation and electrochemical impedance spectroscopy (EIS). Also, the layers of reaction products formed on the surface of the material were analysed by SEM and EDS. The results showed that nodular cast-iron immersed in wastewater with acidic pH showed intense corrosion, the oxide layer formed on its surface is unstable. Also, the final structure of the product layer is that of a tri-layer with cations and anions absorbed from the corrosion media: the double-electric layer directly connected to the metal surface, an internal layer consisting of ferrous compounds and ferric compounds that control the diffusion of oxygen, an outer layer, and a compact crust of ferric compounds. The change in the pH of the wastewater has a major influence on the corrosion rate of the cast iron, which increases from 356.4 µm/year in DWW-1 (6.5 pH) to 1440 µm/year in DWW-2 (3 pH) and 1743 µm/year DWWW-3 (11 pH) respectively. As can be seen, the experimental study covers the problem of the corrosion behaviour of the pump rotor in various types of wastewaters this aspect is particularly important for the good use of wastewater pumps and to predict possible deviations for the operation of the equipment within the treatment plants.

Influence of water and sodium chloride content on corrosion behavior of cast iron in silty clay

Corrosion of metals induced by highly salinized soils will reduce service life of pipelines in Qaidam Basin. The corrosion behavior of cast iron in silty clay was investigated using electrochemical measurements, Scanning Electron Microscopy and X-ray Diffraction. The corrosion rate is proportional to water and salt content, with the maximum rate of 5.27% with salt content of 30%. The etch pits enlarge and grow in quantity. The conductivity of pore water dominates with water, and the more susceptibility of penetrating and film breaking appears with chloride concentration. The products hinder the oxygen transportation and corrosion rate reduces exponentially with time.

Factors influencing corrosion of metal pipes in soils

Deterioration of buried metal pipes due to corrosive soil environment is a major issue worlwide. Although failures of buried pipe due to corrosive soil is an old problem, yet such failures are still uncontrollable even with the application of advanced corrosion protection technologies. Therefore, understanding factors causing corrosion of buried pipes is necessary. This article reviews factors causing corrosion of buried pipes in soils. Factors include moisture content, soil resistivity, pH, dissolved oxygen, temperature and microbial activity. Moreover, we discuss the influence of manufacturing method and the comparison of corrosion behaviour of cast iron, ductile and mild steel pipes. We found that corrosion rate of pipes increases with moisture contents up to the critical moisture value. Although pH affects corrosion, there is no relationship between corrosion and pH and the corrosion rates of buried pipes are inversely proportional to soil resistivity. Soils containing more organic matter show high resistivity. Dissolved oxygen in soil develops differential cell which accelerates corrosion of metallic pipe. Different types of bacteria present in soil develop biofilms on metallic pipes, which deteriorates pipes with time.

Corrosion Behavior of Cast Iron in Freely Aerated Stagnant Arabian Gulf Seawater

In this work, the results obtained from studying the corrosion of cast iron in freely aerated stagnant Arabian Gulf seawater (AGS) at room temperature were reported. The study was carried out using weight-loss (WL), cyclic potentiodynamic polarization (CPP), open-circuit potential (OCP), and electrochemical impedance spectroscopy (EIS) measurements and complemented by scanning electron microscopy (SEM) and energy dispersive X-ray (EDX) investigations. WL experiments between two and 10 days’ immersion in the test electrolyte indicated that the weight-loss the cast iron increases with increasing the time of immersion. CPP measurements after 1 h and 24 h exposure period showed that the increase of time decreases the corrosion via decreasing the anodic and cathodic currents, as well as decreasing the corrosion current and corrosion rate and increasing the polarization resistance of the cast iron. EIS data confirmed the ones obtained by WL and CPP that the increase of immersion time decreases the corrosion of cast iron by increasing its polarization resistance.

Electrochemical Corrosion Behavior of Different Graphite Shapes Cast Irons in Acidic Solution

The effect of graphite shapes on the electrochemical corrosion behavior of cast iron was studied by means of weight loss tests, electrochemical measurements and electron microscopy. It was found that the electrochemical corrosion behavior of graphite is significantly different from one other, and the corrosive potential difference between carbide ad the matrix is the main driving force of the different phase corrosions. Among them, the center A type and edge D type graphite exhibited the highest corrosion resistance. The corrosion of white iron is worst, because there are so many type carbides in white iron and so there is an obvious tendency to produce micro-cell in white iron.

Atmospheric Corrosion Behavior of Salvaged Marine Cast Iron Artifacts

The atmospheric corrosion behavior of cast iron after six months immersion was studies by means of optical stereomicroscope and X-ray diffraction techniques. The results showed that active corrosion occurred on the rusted specimen covered with many thin spherical shells of solid material. The XRD analysis indicated the formation of β-FeOOH tends to increase with increasing exposure.

Evaluation of Corrosion Behaviour of Grey Cast Iron and Low Alloy Steel in Cocoa Liquor and Well Water

Corrosion behaviour of cast iron and low alloy steel in cocoa liquor and well water was investigated. The average weight losses of the specimens were measured using digital weighing balance. The results showed that the weight losses of both cast iron and low alloy steel in both media increases with time. Corrosion rate of cast iron in cocoa liquor increases rapidly with time for up to 336 hours (1000 μm/yr), but in well water the rapid rate of corrosion only lasted up to 187 hours (1160 μm/yr) thereafter it continuously dropping until 264 hours (667 μm/yr) after which it remains constant. Low alloy steel corroded faster in cocoa liquor up to 264 hours (200 μm/yr), whereas the initial rapid corrosion rate only lasted up to 168 hours (180 μm/yr) in well water environment. The results revealed that low alloy steel exhibited better corrosion resistance in both media, with cocoa liquor been more aggressive. Thus, low alloy steel will be a better material for piping and pumping system in cocoa processing industries.

Corrosion behaviour of cast iron exposed to Arabian Gulf environment

PurposeThe purpose of this paper is to determine the long‐term corrosion behavior of cast iron coupons in the Jubail Industrial City (JIC), Saudi Arabia.Design/methodology/approachThe samples were exposed under atmospheric, underground, and splash zone conditions, at Khaleej Mardumah Test Station (KMTS) in Jubail. Soil, groundwater, seawater and air particulate samples were collected at the exposure sites and were analyzed. Secondary electron microscopy (SEM), X‐ray diffraction (XRD) and X‐ray fluorescence (XRF) were used to examine the surface morphology of the test coupons and identify the corrosion products developed on the surface of the metals. The corrosion rates of the coupons were determined by weight loss method.FindingsThe results showed that the atmosphere, underground and splash zone conditions all were very corrosive to cast iron, due to temperature and humidity variations as well as the high chloride and sulfate concentrations in the region. The splash zone was the most corrosive regime of the three test zones. The main corrosive ions in the environments were identified as chloride and sulfate. The maximum chloride and sulfate concentrations were measured to be 8.94 and 49.65 μg/m3in atmosphere, 8,040 and 1,410 ppm in soil, and 29,500 and 5,770 mg/l in seawater, respectively. The corrosion rates of cast irons were found to be 343‐536 μm/y in splash zone, 90‐214 μm/y in underground, and 22‐27 μm/y in atmosphere. Compared to other parts of the world, the soil, marine and atmospheric environments at the selected test site are very corrosive.Originality/valueIn this paper, corrosion of cast iron is presented in atmospheric, soil and splash zone conditions along the eastern coast of the Arabian Gulf.

Experimental Investigation on Corrosion of Cast Iron Pipes

It is well known that corrosion is the predominant mechanism for the deterioration of cast iron pipes, leading to the reduction of pipe capacity and ultimate collapse of the pipes. In order to assess the remaining service life of corroded cast iron pipes, it is imperative to understand the mechanisms of corrosion over a long term and to develop models for pipe deterioration. Although many studies have been carried out to determine the corrosion behavior of cast iron, little research has been undertaken to understand how cast iron pipes behave over a longer time scale than hours, days, or weeks. The present paper intends to fill the gap regarding the long-term corrosion behaviour of cast iron pipes in the absence of historical data. In this paper, a comprehensive experimental program is presented in which the corrosion behaviour of three exservice pipes was thoroughly examined in three simulated service environments. It has been found in the paper that localised corrosion is the primary form of corrosion of cast iron water pipes. It has also been found that the microstructure of cast irons is a key factor that affects the corrosion behaviour of cast iron pipes. The paper concludes that long-term tests on corrosion behaviour of cast iron pipes can help develop models for corrosion-induced deterioration of the pipes for use in predicting the remaining service life of the pipes.

Thermal influence on cast iron corrosion in aqueous salt solutions and composite water

The corrosion behavior of cast iron in aqueous salt solutions and in composite water at various thermal conditions has been studied by weight-loss, open-circuit potential and potentiostatic methods. The corrosion rate of cast iron increases and the open-circuit potential shifts towards less noble direction with increase of temperature. Cast iron corrosion is higher in aqueous solution of NaCI and KCI salt than other salts. The cathodic and anodic polarization curves exhibit that the reaction is controlled cathodically.

Improvement of Corrosion Behavior of Cast Iron for Sulfuric Acid Concentration Plants by Modification of Composition and Structure

Improvement of Corrosion Behavior of Cast Iron for Sulfuric Acid Concentration Plants by Modification of Composition and Structure

Corrosion of some Aluminium Casting Alloys and Cast Iron in Uninhibited Alcohol/Water Coolants

Measurements were made of the corrosion behaviour of cast iron and five aluminium alloys at 70°c in a range of uninhibited alcohol/water mixtures of practical application as cooling liquids. Corrosion was assessed by weight changes and, with the aluminium alloys where the amount of corrosion was small, by visual observation and comparison. In most solutions appreciable corrosion and graphitisation of cast iron occurred. Absolute values of corrosion rates were much lower for the aluminium alloys with alloy LM 8 giving the best performance. Ethanediol/water mixtures were the least aggressive of the coolants tested. Data are provided for the pH stability of the coolants in the test conditions used.