Steel Corrosion and Metallurgical Factors E-Book

Chao Liu

• Herausgeber: Wiley-VCH
• Kategorie: Fachliteratur
• Sprache: Englisch

Seitenzahl: 923

Veröffentlichungsjahr: 2025

Beschreibung

Exploration into the latest research and developments in material corrosion resistance and related technologies

Steel Corrosion and Metallurgical Factors: Laws and Mechanisms offers an in-depth exploration of the latest research on modulating metallurgical factors in various types of steel materials to enhance their corrosion resistance. The book covers a diverse range of materials, including low-alloy steels, stainless steels, ductile iron, rebar, and pipeline steel, and outlines the application of corrosion big data technology and artificial intelligence in the revealing of material corrosion mechanisms.

The book discusses how typical metallurgical factors such as inclusion control, alloying control, and heat treatment control influence the corrosion resistance of stainless or low alloy steels and provides theoretical guidance for corrosion-resistant steel smelting technologies (e.g., inclusions regulation, alloy modulation, and rolling processes) by investigating the laws and mechanisms underlying the influence of various metallurgical factors on the corrosion resistance of steel.

Steel Corrosion and Metallurgical Factors includes information on:

• Micro- chemical-electrochemical theory of corrosion initiation induced by various typical types of inclusions in stainless and low alloy steels
• Influence of elements such as Ca, Sb, Cu, and Cr on the resistance of low-alloy steels to microbial and marine atmospheric corrosion
• Coupled mechanism of microstructure and inclusions in corrosion initiation in steel
• Behavior and mechanism of stress corrosion and hydrogen-induced stress corrosion of pipeline steel induced by environmental and metallurgical factors
• Effects of rare earth and chromium elements on the corrosion resistance of HRB400 rebar in concrete environments
• Metallurgical defects on ductile iron corrosion mechanisms and corrosion big data-artificial intelligence techniques in revealing factors influencing material corrosion

Steel Corrosion and Metallurgical Factors strongly supports metallurgical and materials researchers and engineers in developing new corrosion-resistant steels.

Leseprobe

Steel Corrosion and Metallurgical Factors

Laws and Mechanisms

Chao Liu and Xiaogang Li

Authors

Prof. Chao LiuUniversity of Science and Technology BeijingNo.30 Xueyuan RoadHaidian DistrictBeijing, 100083China

Prof. Xiaogang LiUniversity of Science and Technology BeijingNo.30 Xueyuan RoadHaidian DistrictBeijing, 100083China

Cover Image: © Bloomberg Creative/Getty Images; © LIU KAIYOU/Getty Images

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Print ISBN: 978‐3‐527‐35543‐3ePDF ISBN: 978‐3‐527‐85309‐0ePub ISBN: 978‐3‐527‐85308‐3oBook ISBN: 978‐3‐527‐85310‐6

Preface

Corrosion is a complex degradation process in which a chemical or electrochemical reaction occurs between a metallic material and its environment, leading to the deterioration of the material's structural integrity. It is one of the primary challenges threatening the safe and reliable operation of various engineering systems and materials. The corrosion behavior of iron and steel is influenced not only by environmental factors but also by numerous metallurgical characteristics inherent to the materials themselves. A comprehensive understanding of the corrosion mechanisms of steel, along with the key factors influencing these processes, is essential for enhancing the corrosion resistance of steel and developing more durable materials for industrial applications.

As human activities extend into increasingly harsh environmental conditions, the demand for corrosion‐resistant steel materials in critical infrastructure – such as offshore platforms, bridges, buildings, docks, and ships – has grown significantly. The smelting and casting processes of iron and steel introduce a range of metallurgical factors, including alloying element composition, elemental segregation, inclusions, precipitated phases, dislocations, microstructural variations, and shrinkage defects. These factors, which arise from differences in alloying elements and manufacturing processes, are closely tied to the corrosion behavior of steel materials. Understanding the corrosion mechanisms induced by these factors and evaluating their impact on corrosion resistance is critical for advancing the development of high‐performance, corrosion‐resistant steel alloys.

In recent decades, substantial advancements in production technologies have resulted in significant improvements in the properties of iron and steel materials, particularly low‐alloy steels. However, earlier research and development efforts predominantly focused on mechanical properties as the primary performance metrics, often at the expense of corrosion resistance. This oversight has contributed to several catastrophic incidents, such as the 2018 collapse of the Italian sea‐crossing bridge, the 2020 collapse of the Miami condominium, and the gas pipeline explosion in Hubei, China, all of which were attributed to the failure of steel materials due to corrosion.

This book offers an in‐depth exploration of the latest research on modulating metallurgical factors in various types of steel materials to enhance their corrosion resistance. It covers a diverse range of materials, including low‐alloy steels, stainless steels, ductile iron, rebar, and titanium‐steel composite plates. Additionally, the book highlights cutting‐edge research on the development of corrosion‐resistant steels, leveraging advanced corrosion big data technologies. The objective of this work is to elucidate the mechanisms and modulation techniques for metallurgical factors that influence the corrosion resistance of steel materials, while also identifying emerging trends in the future development of corrosion‐resistant alloys.

Chapter 1 of this book discusses the common types of corrosion in steel materials, providing readers with a foundational understanding of the material degradation process. Chapter 2 primarily introduces the initiation mechanisms of corrosion induced by inclusions in stainless steel, along with studies on the effect of alloying elements on the modification and regulation of inclusions, and how these changes impact the material's pitting corrosion resistance. Chapter 3 focuses on the role of rare earth (RE) elements as alloying elements for controlling inclusions in steel, and their influence on the chemical and electrochemical mechanisms that govern the initiation of localized corrosion induced by inclusions. Chapter 4 discusses the effects of multicomponent inclusion‐controlling elements in 690 MPa‐grade calcium‐treated marine engineering steel on inclusions and their impact on the initiation mechanism of localized corrosion, ultimately proposing three chemical‐electrochemical mechanisms for the initiation of localized corrosion induced by inclusions. Chapter 5 examines the effect of microstructural coarsening on the corrosion resistance of materials. Chapter 6 delves into the coupled mechanisms between microstructural features and inclusions during the initiation and development of corrosion. Chapter 7 analyzes the mechanisms by which alloying elements influence the corrosion resistance of low‐alloy, high‐strength steels, with a focus on the effect of alloying elements on rust layer formation. Chapter 8 investigates the impact and mechanisms of copper (Cu) on the microbiologically influenced corrosion resistance of low‐alloy steels. Chapter 9 introduces the evolution of stress corrosion sensitivity in pipeline steels under soil environments and damaged coatings. Chapter 10 analyzes the influence and mechanisms of inclusions, as typical metallurgical factors, on the hydrogen‐induced stress corrosion cracking resistance of pipeline steel materials. Chapter 11 investigates the effects of RE elements and chromium modulation on the corrosion resistance of HRB400 rebar in concrete environments, discussing the mechanisms of corrosion under different chloride concentrations and pH‐reduced conditions due to concrete carbonation. Chapter 12 discusses the impact and mechanisms of metallurgical defects such as shrinkage and porosity on the corrosion resistance of ductile iron pipes. The combination of these technologies allows for the efficient identification of key microalloying elements and their contributions to improving the corrosion resistance of steel, thus enhancing the efficiency of research and development efforts in corrosion‐resistant steel alloys.

This book aims to provide theoretical guidance for corrosion‐resistant steel smelting technologies (e.g., inclusions regulation, alloy modulation, rolling processes) by investigating the laws and mechanisms underlying the influence of various metallurgical factors on the corrosion resistance of steel. The findings are intended to be applied directly to the steel production process. By utilizing state‐of‐the‐art research methodologies, this book contributes to advancing our understanding of corrosion in stainless steels, low‐alloy steels, ductile iron, and rebar and offers innovative perspectives for the future development of corrosion‐resistant steels.

This work presents the latest advancements in the study of corrosion mechanisms and the modulation of corrosion‐resistant steels, making it an invaluable resource for scientists, researchers, and students across various disciplines. It underscores the critical role of metallurgical factors in influencing the corrosion behavior of steel. The authors encourage readers to consult the references cited throughout the text to gain a deeper understanding of the research discussed in this book.

The authors wish to express their sincere gratitude to the numerous individuals who contributed to the preparation of this manuscript, including those involved in the artwork and typesetting. The authors extend their thanks to the editorial team at Wiley Press for accepting the proposal and providing the opportunity to write this book. Special appreciation is also given to the National Materials Corrosion and Protection Data Center for their technical support.

The authors thank Prof. Herman Terryn and Dr. Reynier I. Revilla from Vrije Universiteit Brussel, Prof. Xuequn Cheng, Prof. Zhiyong Liu, Prof. Cuiwei Du, Prof. Dawei Zhang, Prof. Jingshe Li, Prof. Shufeng Yang, Dr. Tianyi Zhang, Dr. Liwei Wang, Dr. Tianqi Chen, Dr. Zhichao Che, Dr. Da Wei, Dr. Xiaohu Zhang, Dr. Chao Li, Dr. Hui Xue, Zaihao Jiang, Xuan Li, Qinglin Li, Chan Li, Zhiyi Wang, Fansong Wu, Xun Zhou, Liang Sun, Lianjun Hao, and Xiaokun Cai from the University of Science and Technology Beijing for their invaluable assistance throughout the project.

The authors acknowledge the financial support from the National Basic Research Program of China (973 Program, Grant No. 2014CB643300), the National Natural Science Foundation of China (Grants Nos. U22B2065, U21A20113, 51471018, 51401034, 52104319, and 52374323), and the China Scholarship Council. The authors also thank the National Materials Corrosion and Protection Data Center and the State Key Laboratory of Advanced Metallurgy for their support!

Although the cover lists two authors, this book represents the collective achievements of the research team at the National Materials Corrosion and Protection Data Center. at the University of Science and Technology Beijing in the field of corrosion‐resistant steel research. It encapsulates the collective wisdom of dozens of dedicated researchers.

December 2024Beijing, China

Chao Liu

Xiaogang Li

1Corrosive Environments and Types of Steel

1.1 Introduction

Corrosion is defined as the process by which metallic materials when interacting in a specific environment undergo a chemical or electrochemical reaction that degrades their properties. Any material, especially metal material, has its specific use in environment. Use in an unsuitable environment may lead to premature corrosion damage to the material and induce corrosion accidents, which will not only cause economic losses but even cause casualties and environmental pollution [1].

According to statistics, more than half of the steel is in service in the natural environment (atmosphere, soil, and water), another part is used in industrial acids, alkalis, salts, or high‐temperature and high‐pressure environment, and a very small part is used in extreme harsh environments, such as high‐temperature, high‐humidity, and high‐salt spray extreme marine atmospheric environments, deep‐sea environments below 300 m, and dry and hot desert environments. Therefore, the service environment of steel is extremely complex, the study also shows that the type of corrosion of steel in specific environments is also diversified, which leads to the complexity of steel varieties. Correct and comprehensive understanding of the corrosion environment and corrosion type of steel in the development of high‐quality steel is the first major issue.

1.2 Natural Corrosive Environments

1.2.1 Atmospheric Corrosive Environments

Atmospheric corrosion environment accounts for more than half of the total corrosion environment. According to the humidity of the surface, it can be divided into three categories: (i) dry atmospheric corrosion: when there is a discontinuous liquid film layer on the surface, a very thin invisible oxide film is formed on the surface of the metal whose free energy of reaction is negative, for example, the thickness of the oxide film of iron is about 30 Ǻ. (ii) Damp atmospheric corrosion: corrosion that occurs when there is a thin liquid film layer on the surface of the metal that is invisible to the naked eye, such as for example, rusting of iron when there is no rain or snow. (iii) Wet atmosphere corrosion: corrosion that occurs when the humidity of the air is close to 100%, or when moisture in the form of rain, snow, foam, etc., falls on the metal surface, and there is a film layer of condensed water visible to the naked eye on the surface of the metal. According to regional conditions and atmospheric characteristics, this can be divided into rural atmosphere, marine atmosphere, suburban atmosphere, industrial atmosphere, etc.

The main environmental factors that impact atmospheric corrosion are: (i) Humidity: the greater the humidity, the easier the metal surface condensation, the longer the electrolyte film exists, and the more the corrosion rate increases. There exists a critical humidity for metallic materials, and the corrosion rate of the material increases dramatically when the humidity is greater than the critical humidity level. For iron and steel, copper, nickel, zinc, and other metals, the critical humidity is about 50–70% between. (ii) Temperature: in other conditions are the same, areas with high average temperatures have higher atmospheric corrosion rates. (iii) Rainfall: rainwater may damage and wash away the rust layer on the material surface, accelerating corrosion. However, in some cases, rain can slow down corrosion to some extent by washing away dust, salt particles, or water‐soluble corrosion products from the rust layer on the metal surface. (iv) Atmospheric composition: outside the basic composition of the atmosphere, atmospheric pollutants, such as sulfides, nitrides, CO, and CO2, salt particles, and sand, can accelerate atmospheric corrosion to some extent. (v) The impact of abnormal climatic conditions: for example, acid rain can reduce the corrosion resistance of Fe, Zn, Cu, Pb, and other metal greatly. Due to the complexity of atmospheric factors, the corrosion behavior and rate of materials under specific atmospheric conditions can be determined through long‐term field testing. The usual corrosive classification of the atmospheric environment is shown in Table 1.1.

Table 1.1 Classification of environmental corrosivity in terms of corrosion rates of different metals in the first year of exposure.

Corrosion rate of metals

Corrosion type

Unit

Carbon steel

Zn

Cu

Al

C1 (Very low)

g/m

2

/a μm/a

<10 <1.3

<0.7 <0.1

<0.9 <0.2

<0.2

C2 (Low)

g/m

2

/a μm/a

10–200 1.3–25

0.7–5 0.1–0.7

0.9–5 0.1–0.6

C3 (Medium)

g/m

2

/a μm/a

200–400 25–50

5–15 0.7–2.1

5–12 0.6–1.3

0.6–1.3

C4 (High)

g/m

2

/a μm/a

400–650 50–80

15–30 2.1–4.2

12–25 1.3–2.8

C5 (Very high)

g/m

2

/a μm/a

650–1500 80–200

30–60 4.2–8.4

25–50 2.8–5.6

1.2.2 Soil Corrosion Environments

Soil consists of a variety of granular minerals, moisture, gases, microorganisms, and other multiphase compositions, with biological activity, ionic conductivity, and capillary colloidal properties. Soil is a special electrolyte, may induce uneven total corrosion of metals and severe localized corrosion [2]. Stray currents and microorganisms also cause soil corrosion.

Soil corrosion and other media electrochemical corrosion processes are due to the metal and the medium of the formation of electrochemical inhomogeneity of the corrosion of the primary battery. At the same time, as the soil medium has multiphase (phases such as soil, water, and air), inhomogeneity and relative stability, and other characteristics, soil environment caused by metal corrosion has its own unique corrosion mechanism and kinetic development process, such as soil macro‐uniformity caused by corrosive macrocells; often soil corrosion plays a greater role.