Handbook of environmental degradation of materials

604 Pages·2005·19.85 MB·English

by  Myer Kutz

Handbook of Environmental
Degradation of Materials
Edited by
Myer Kutz
Myer Kutz Associates, Inc.
Delmar, New York
Copyright ©2005 by William Andrew,Inc.
No part of this book may be reproduced or utilized in any form or by any means,electronic or
mechanical,including photocopying,recording,or by any information storage and retrieval
system,without permission in writing from the Publisher.
Cover art ©2005 by Brent Beckley / William Andrew,Inc.
ISBN:0-8155-1500-6 (William Andrew,Inc.)
Library or Congress Catalog Card Number: 2005005496
Library of Congress Cataloging-in-Publication Data
Handbook of environmental degradation of materials / edited by Myer Kutz.
p. cm.
Includes bibliographical references and index.
ISBN 0-8155-1500-6 (0-8155)
1. Materials—Effect of environment on—Handbooks,manuals,etc. I. Kutz,
Myer.
TA418.7.H354 2005
620.1(cid:1)122—dc22
2005005496
Printed in the United States of America
This book is printed on acid-free paper.
10 9 8 7 6 5 4 3 2 1
Published by:
William Andrew Publishing
13 Eaton Avenue
Norwich,NY 13815
1-800-932-7045
www.williamandrew.com
NOTICE
To the best of our knowledge the information in this publication is accurate; however the Publisher does not
assume any responsibility or liability for the accuracy or completeness of,or consequences arising from,such
information. This book is intended for informational purposes only. Mention of trade names or commercial
products does not constitute endorsement or recommendation for their use by the Publisher. Final determina-
tion of the suitability of any information or product for any use, and the manner of that use, is the sole re-
sponsibility of the user. Anyone intending to rely upon any recommendation of materials or procedures men-
tioned in this publication should be independently satisfied as to such suitability,and must meet all applicable
safety and health standards.
For my lifelong friendships, none the worse for wear
PREFACE
The idea for the Handbook of Environmental Degra- How can I protect the surface of a product from de-
dation of Materials originated several years ago grading in the environment in which consumers
when Bill Woishnis,the founder of William Andrew will use the product?
Publishing,and I met at my upstate New York office What protective measures can I apply to structural
to discuss materials information needs at the practi- materials if they are subjected to a potentially cat-
tioner level,an area that Bill and I had been involved astrophic attack by intense heat?
in for some time. Several handbooks that I had
The handbook has a practical, not a theoretical,
already published or was then working on dealt en-
orientation. A substantial portion includes chapters
tirely with materials or had substantial numbers of
on preventive and remedial aspects of industrial
chapters devoted to materials. Bill and his partner,
and commercial applications where EDM can have
Chris Forbes, were embarking on a new electronic
major and, in some cases, even catastrophic conse-
publishing venture,Knovel Corporation,that would
quences. I want this handbook to serve as a source of
deliver technical information, much of it on materi-
practical advice to the reader. I would like the hand-
als, to engineers’desktops. We thought that a hand-
book to be the first information resource a practicing
book that dealt with the harm that environmental fac-
engineer reaches for when faced with a new problem
tors could cause to a wide range of engineering
or opportunity—a place to turn to even before turn-
materials would be useful to practitioners, and that
ing to other print sources, including officially sanc-
my expertise at developing handbooks could be com-
tioned ones, or to Internet search engines. So the
bined successfully with his companies’capabilities
handbook is more than a voluminous reference or
for delivering information in print and electronically.
collection of background readings. In each chapter,
The aim of this handbook is to present practical
the reader should feel that he or she is in the hands
aspects of environmental degradation of materials
of an experienced consultant who is providing sen-
(which I shall call “EDM”here):what causes EDM;
sible engineering-design-oriented advice that can
how to detect and measure it; how to control it—
lead to beneficial action and results.
what remediation strategies might be employed to
But why develop such a handbook? The data
retard damage caused by EDM; and how to possibly
in a single handbook of the scope outlined above can
even prevent it. Because an engineer, no matter the
be indicative only, not comprehensive. After all,
industry he or she is employed in,may have to work
this handbook cannot purport to cover any of the
with multiple materials, including metals, plastics,
subjects it addresses in anywhere near the detail that
composites (such as reinforced concrete), even tex-
an information resource devoted to a single subject
tiles and wood, it is useful to know how many dif-
can. Moreover,no information resource—I mean no
ferent kinds of industrial materials degrade environ-
handbook, no shelf of books, not even a web site
mentally,what the principal environmental agents of
or an Internet portal or search engine (not yet, at
degradation are for each class of materials, and the
least!)—can offer an engineer,designer,or materials
degradation control and prevention strategies and
scientist complete assurance that he or she will, by
techniques that are most successful for each class of
consulting such a resource, gain from it all the
materials. The handbook deals with a broad range of
knowledge necessary to incorporate into the design
degradation media and environmental conditions,
of a part, component, product, machine, assembly,
including water and chemicals, weather, sunlight
or structure measures that will prevent its constituent
and other types of radiation, and extreme heat gen-
materials from degrading to the point of failure or
erated by explosion and fire.
collapse when confronted by adverse environmental
The handbook has a design orientation. I want the
conditions,whether anticipated,such as weathering,
handbook to be useful to people with questions such
or unexpectedly severe, such as the heat generated
as these:
by a fire resulting from an explosion.
I’m designing a structure,which will have to operate Nevertheless, when a practitioner is considering
under adverse environmental conditions. What how to deal with any aspect of EDM,whether in the
materials should I specify? design, control, prevention, inspection, or remedia-
vii
viii PREFACE
tion phase, he or she has to start somewhere. The So here is the situation with regard to EDM
classic first step,which I have confirmed in surveys knowledge and information that practitioners find
and focus groups of engineering professionals,was, themselves in:they must have access to information
in the pre-Internet era,either to ask a colleague (usu- that covers numerous materials,as well as numerous
ally,the first choice),open a filing cabinet to look for degradation media and environments, but it has not
reports or articles that might have been clipped and been easy to find information of such broad scope
saved, scan the titles on one’s own bookshelves or, in a single, easily accessible resource. What I have
when all else had failed,go to an engineering library, sought to do with this handbook is to deal with the
where one would hope to find more information EDM knowledge and information situation by in-
sources than in one’s own office,sometimes with the cluding enough information about a broad range of
help of a good reference librarian. subjects that deal with multiple aspects of EDM so
To be sure, there are numerous references that that the handbook will be positioned at the hub of an
deal with separate aspects of EDM. Corrosion, for information wheel, if you will, with the rim of the
example,is a topic that has been covered in great de- wheel divided into segments,each of which includes
tail in voluminous references, from the points of the wealth of information that exists for each of the
view of materials themselves, of corroding media, topics within the subject of materials’environmental
and of testing and evaluation in various industries. degradation. Each individual chapter in the hand-
Professional societies—NACE,ASM International, book is intended to point readers to a web of infor-
and ASTM—have devoted great energy to develop- mation sources dealing with the subjects that the
ing and disseminating information about corrosion. chapter addresses. Furthermore,each chapter,where
The topic of environmental degradation of plastics, appropriate,is intended to provide enough analytical
to take another example, has been covered in other techniques and data so that the reader can employ a
reference books,albeit to a lesser extent. So there are preliminary approach to solving problems. The idea,
many print references where a practitioner can begin then, is for the handbook to be the place for practi-
the study of many individual topics within the sub- tioners,as well as advanced students,to turn to when
ject of EDM. beginning to look for answers to questions in a way
Of course, this is the Internet era. Many, if not that may enable them to select a material,substitute
most, practitioners now begin the search for EDM one material or another,or employ a protection tech-
information by typing words or phrases into a search nique or mechanism that will save money,energy,or
engine. Such activity, if the search has been done time.
properly (a big if, just ask any reference librarian) I have asked contributors to write, to the extent
will yield whatever the search engines have indexed, their backgrounds and capabilities make possible,in
which, of course, may or may not be information a style that will reflect practical discussion informed
useful to the particular situation. And a search en- by real-world experience. I would like readers to feel
gine will not connect practitioners and students to that they are in the presence of experienced teachers
the content of valuable engineering references, un- and consultants who know about the multiplicity of
less one has access to web sites where such refer- technical and societal issues that impinge on any
ences are offered in full text. topic within the subject of environmental degrada-
Moreover,engineers,designers,and materials sci- tion of materials. At the same time,the level is such
entists also practice in an era of innovative materials that students and recent graduates can find the hand-
selection and substitution that enable them to develop book as accessible as experienced engineers.
new versions of products, machines, or assemblies I have gathered together contributors from a wide
that are cheaper and more efficient than older ver- range of locations and organizations. While most of
sions made with more expensive,harder to form,and the contributors are from North America, there are
heavier materials. There can be competition for the two from India, one from Hong Kong, two from
attention of practitioners. For example, while steel Russia (who collaborated on a chapter), and one
may still account for slightly more than half of the from Sweden. Personnel from the Royal Thai Navy
material in an automobile, the rest is made from a contributed to the chapter on oil tankers. Sixteen
wide variety of metallic and non-metallic materials, chapters are by academic authors; 11 are by authors
and the competition among suppliers of these non- who work in industry,are at research organizations,
ferrous materials for inclusion by automobile manu- or are consultants.
facturers is,to judge by the wars of words waged by The handbook is divided into six parts. Part I,
materials trade associations,intense. which deals with an assessment of the economic cost
PREFACE ix
of environmental degradation of materials, has just writes about anti-corrosion paints, and Mark
one chapter, a recapitulation of the work done by a Nichols, at Ford Motor Company in Dearborn,
team including Mike Brongers and Gerhardus Koch, Michigan,writes about paint weathering tests,a topic
both at CC Technologies,a corrosion consultancy in of great interest to auto makers. Mitch Dorfman,who
Dublin,Ohio. Part II contains three chapters on fail- works at Sulzer Metco in Westbury, Long Island,
ure analysis and measurement, by K.E. Perumal, a covers thermal spray coatings. Professor “Vipu”Vip-
consultant in Mumbai, India, Sean Brossia, who ulanandan,with his colleague,J. Liu,deals with con-
works on corrosion at the Southwest Research Insti- crete surface coatings issues. Ray Taylor of the Uni-
tute in Can Antonio,Texas, and Jim Harvey, a plas- versity of Virginia closes Part V with a discussion of
tics consultant in Corvalis,Oregon. coatings defects.
Part III deals with several different types of degra- The handbook concludes with five chapters that
dation. Professors Raymond Buchanan and E.E. cover industrial applications with, collectively, a
Stansbury of the University of Tennessee and A.S. wide variety of materials. The chapters are meant to
Khanna of the Indian Institute of Technology in illustrate in a hands-on way points made more gen-
Bombay cover metallic corrosion. Jim Harvey,in his erally elsewhere in the handbook. The first of these
second chapter in the handbook, treats polymer chapters, on degradation of spacecraft materials,
aging. Neal Berke,who works at WR Grace in Cam- comes from a Goddard Research Center group, in-
bridge,Massachusetts,writes about the environmen- cluding Bruce Banks, Joyce Dever, Kim de Groh,
tal degradation of reinforced concrete. Professor J.D. and Sharon Miller. Branko Popov of the University
Gu of the University of Hong Kong deals with bio- of South Caroline in Columbia wrote the next chap-
degration. Part III concludes with a chapter on mate- ter,which deals with metals,and is on cathodic pro-
rial flammability by Marc Janssens, also at South- tection for pipelines. The next chapter is also on
west Research Institute. metals. David Olson, a professor at the Colorado
In Part IV, the handbook moves on to protective School of Mines in Golden headed a team,including
measures,starting with a chapter on cathodic protec- George Wang of Mines,John Spencer of the Ameri-
tion by Prof Richard Evitts of the University of Sas- can Bureau of Shipping, and Sittha Saidararamoot
katchewan in Saskatoon,Canada. In addition to met- and Brajendra Mishra of the Royal Thai Navy, that
als,Part IV deals with polymers,textiles,and wood. provides practical insight into the real-world prob-
Professors Gennadi Zaikov and S.M. Lomakin of the lem of tanker corrosion. Mikael Hedenqvist of Insti-
Institute of Biochemical Physics in Moscow cover tutionen för Polymerteknologi, Kungliga Tekniska
polymeric flame retardants. Hechmi Hamouda, at Högskolan in Stockholm deals with polymers in his
North Carolina State University in Raleigh, North chapter on barrier packaging materials used in con-
Carolina, writes about thermal protective clothing. sumer products. Steve Tait,an independent consult-
The contributors of the two chapters on wood and ant in Madison, Wisconsin, closes the handbook
measures that can be taken to protect it are from the with a chapter on preventing and controlling corro-
Pacific Northwest—Phil Evans and his colleagues, sion in chemical processing equipment.
Brian Matthews and Jahangir Chowdhury,are at the My undying thanks to all of the contributors:
University of British Columbia in Vancouver and Jeff I salute their professionalism and perseverance. I
Morrell is at Oregon State in Corvalis. know how difficult it is to fit a writing project into a
Protection issues are also the subjects of Part V, busy schedule. Chapters like those in this handbook
which is called Surface Engineering and deals with do not get written in an evening or in a few hours
coatings. Gary Halada and Clive Clayton,professors snatched from a weekend afternoon. Thanks also to
at SUNY in Stony Brook, set the stage for this sec- Millicent Treloar, the acquisitions editor at William
tion of the handbook with a chapter on the intersec- Andrew Publishing. And,of course,many thanks to
tion of design,manufacturing,and surface engineer- my wife Arlene, who successfully cushions each
ing. Professor Tom Schuman at the University of day,no matter how frustrating it’s been.
Missouri—Rolla,continues with a discussion of pro-
tective coatings for aluminum alloys. Professor Rudy Myer Kutz
Buchheit,at the Ohio State University in Columbus, Delmar,New York
CONTRIBUTORS
Stephen Ayer Richard W. Evitts
Forintek Canada Corporation University of Saskatchewan
Vancouver,Canada Saskatoon,Canada
Bruce Banks Kim de Groh
NASA Glenn Research Center NASA Glenn Research Center
Cleveland,Ohio Cleveland,Ohio
Neal Berke J. D. Gu
WR Grace Construction Products The University of Hong Kong
Cambridge,Massachusetts Hong Kong,China
Michiel Brongers Gary Halada
CC Technologies State University of New York
Dublin,Ohio Stony Brook,New York
Sean Brossia Hechmi Hamouda
Southwest Research Institute North Carolina State University
San Antonio,Texas Raleigh,North Carolina
Raymond A. Buchanan James A. Harvey
University of Tennessee Under the Bridge Consulting
Knoxville,Tennessee Corvallis,Oregon
Rudolph G. Buchheit Mikael S. Hedenqvist
The Ohio State University Royal Institute of Technology
Columbus,Ohio Stockholm,Sweden
Jahangir Chowdhury Marc Janssens
University of British Columbia Southwest Research Institute
Vancouver,BC,Canada San Antonio,Texas
Clive Clayton Yutaka Kataoka
State University of New York Tsukuba Norin
Stony Brook,New York Ibaraki,Japan
Joyce Dever Anand Sawroop Khanna
NASA Glenn Research Center Indian Institute of Technology
Cleveland,Ohio Bombay,India
Mitchell R. Dorfman Makoto Kiguchi
Sulzer Metco,Inc. Tsukuba Norin
Westbury,New York Ibaraki,Japan
Philip D. Evans Gerhardus Koch
University of British Columbia CC Technologies
Vancouver,BC,Canada Dublin,Ohio
xi
xii CONTRIBUTORS
Swaminatha P. Kumaraguru Karl Schmalzl
University of South Carolina University of British Columbia
Columbia,South Carolina Vancouver,Canada
J. Liu Thomas Schuman
University of Houston University of Missouri—Rolla
Houston,Texas Rolla,Missouri
S. M. Lomakin John S. Spencer
Institute of Biochemical Physics American Bureau of Shipping
Moscow,Russia Houston,Texas
Brian Matthews E. E. Stansbury
University of British Columbia University of Tennessee
Vancouver,BC,Canada Knoxville,Tennessee
Sharon Miller William Stephen Tait
NASA Glenn Research Center Pair O Docs Professionals L.L.C.
Cleveland,Ohio Madison,Wisconsin
Brajendra Mishra S. Ray Taylor
Colorado School of Mines University of Mississippi Medical Center
Golden,Colorado Jackson,Mississippi
Jeff Morrell Neil Thompson
Oregon State University CC Technologies
Corvallis,Oregon Dublin,Ohio
Mark Nichols Swieng Thuanboon
Ford Motor Company Royal Thai Navy
Dearborn,Michigan
Cumaraswamy Vipulanandan
David L. Olson University of Houston
Colorado School of Mines Houston,Texas
Golden,Colorado
Paul Virmani
Joseph Payer Turner-Fairbank Highway Research Center
Case Western Reserve University McLean,Virginia
Cleveland,Ohio
Ge Wang
K. E. Perumal American Bureau of Shipping
Corrosion and Metallurgical Consultancy Centre Houston,Texas
Mumbai,India
Gennadii E. Zaikov
Branko Popov Institute of Biochemical Physics
University of South Carolina Moscow,Russia
Columbia,South Carolina
Sittha Saidarasamoot
Royal Thai Navy