1、MIL-HDBK-735 9999970 0374472 024 m NOT MEASUREMENT SENSITIVE MI L-HDBK-735 (M R) 15 JANUARY 1993 MILITARY HANDBOOK MATERIAL DETERIORATION PREVENTION AND CONTROL GUIDE FOR ARMY MATERIEL, PART ONE, METALS ,- IO AMSC NIA DISTRIBUTION STATEMENT A. Approved for public release; distribution is unlimited.
2、AREA MFFP Provided by IHS Not for Resale No reproduction or networking permitted without license from IHS -,-,- MIL-HDBK-735 W 9999970 0374473 TbO FOREWORD 1. This military handbook is approved for use by all Activities and Agencies of the Department of the Army and is available for use by all Depar
3、tments and Agencies of the Department of Defense. 2. Beneficial comments (recommendations, additions, deletions) and any pertinent data that may be of use in improving this document should be addressed to: Director, US Army Research Laboratory, Materials Directorate, Materials Standardization Office
4、, ATTN: AMSRL-MA-S, Watertown, MA, 02172-0001, by using the self-addressed Standardization Document Improvement Proposal (DD Form 1426) appearing at the end of this document or by letter. 3. This handbook was developed under the auspices of the US Army Materiel Commands Engineering Design Handbook P
5、rogram, which is under the direction of the US Army Industrial Engineering Activity. Research Triangle Institute was the prime contractor for the preparation of this handbook, which was prepared under Contract No. DAAG34-73-C-005 1. 4 11 Provided by IHS Not for Resale No reproduction or networking p
6、ermitted without license from IHS -,-,-MIL-HDBK-735 9999970 0174474 9T7 MI L-H DBK-735( MR) CONTENTS FOREWORD ii LIST OF ILLUSTRATIONS xv LIST OF TABLES xx LIST OF ABBREVIATIONS AND ACRONYMS . xxv CHAPTER 1 INTRODUCTION O a 1-1 PURPOSE 1-1 1-2 SCOPE 1-1 1-3 FOCUS . 1-2 1-4 ARMY ENVIRONMENTS 1-2 1-5
7、OVERVIEW OF PART 1-3 REFERENCES . 1-3 CHAPTER 2 CORROSION PROCESSES 2-1 CHEMISTRY OF CORROSION . 2-1 2-1.1 OXIDATION-REDUCTION REACTIONS . 2-1 2-1.2 ELECTROMOTIVE FORCE SERIES . 2-2 2-1.3 GALVANIC SERIES 2-2 2-1.4 POLARIZATION AND MIXED POTENTIAL THEORY . 2-4 TYPES OF CORROSION 2-6 2-2.1 UNIFORM COR
8、ROSION 2-6 2-2 2-2.1.1 Manifestation and Quantification 2-6 2-2.1.2 Conducive Conditions . 2-6 2-2.1.3 Mechanisms . 2-6 2-2.1.4 Application Constraints and Protection Approaches . 2-7 2-2.1.5 Example 2-10 2-2.2.1 Manifestation and Quantification 2-10 2-2.2.2 Conducive Conditions . 2-11 2-2.2.3 Mecha
9、nisms . 2-11 2-2.2.4 Application Constraints and Protection Approaches . 2-11 2-2.2.5 Examples . 2-13 2-2.3.1 Manifestation and Quantification 2-13 2-2.3.2 Conducive Conditions . 2-14 2-2.3.3 Mechanism 2-14 2-2.3.4 Application Constraints and Protection Approaches . 2-15 2-2.4.1 Manifestation and Qu
10、antification 2-17 2-2.4.2 Conducive Conditions . 2-18 2-2.4.3 Mechanism 2-18 2-2.4.4 Application Constraints and Protection Approaches . 2-19 2-2.4.5 Example 2-19 2-2.4.6 Filiform Corrosion 2-19 2-2.4.6.1 Manifestation and Quantification . 2-19 2-2.4.6.2 Conducive Conditions . 2-20 2-2.4.6.3 Mechani
11、sms 2-20 2-2.2 GALVANIC CORROSION 2-10 2-2.3 PITTING CORROSION . 2-13 2-2.4 CREVICE CORROSION . 2-17 . 111 Provided by IHS Not for Resale No reproduction or networking permitted without license from IHS -,-,-MIL-HDBK-735 = 9999770 0374475 833 MIL-HDBK-735( MR) 2-2.5 INTERGRANULAR 2-21 2-2.5.1 Manife
12、station and Quantification 2-21 2-2.5.2 Conducive Conditions . 2-22 2-2.5.3 Mechanisms 2-23 2-2.5.4 Application Constraints and Protection Approaches . 2-25 2-2.5.5 Examples 2-25 2-2.6 SELECTIVE LEACHING 2-25 2-2.6.1 Manifestation and Quantification 2-25 2-2.6.2 Conducive Conditions 2-26 2-2.6.3 Mec
13、hanism 2-26 2-2.6.4 Application Constraints and Protection Approaches . 2-26 2-2.6.5 Examples 2-26 2-2.7 EROSION-CORROSION . 2-26 2-2.7.1 Manifestation and Quantification 2-27 2-2.7.2 Conducive Conditions . 2-27 2-2.7.3 Mechanism 2-32 2-2.7.4 Application Constraints and Protection Approaches . 2-33
14、2-2.7.5 Examples . 2-33 2-2.8 FRETTING CORROSION . 2-33 Manifestation and Quantification 2-33 2-2.8.2 Conducive Conditions . 2-34 Application Constraints and Protection Approaches . 2-35 2-2.8.5 Examples . 2-35 2-2.9 STRESS-CORROSION CRACKING 2-35 Manifestation and Quanitification . 2-35 2-2.9.2 Con
15、ducive Conditions . 2-37 2-2.9.3 Mechanisms . 2-41 2-2.9.5 Examples . 242 Manifestation and Quantification 2-42 2-2.10.5 Example 2-45 Conducive Conditions . 2-46 2-2.1 1.3 Mechanism 2-46 2-2.1 1.5 Examples . 2-49 2-2.12.3 Mechanism 2-52 . . . 2-2.8.1 2-2.8.3 Mechanism 2-34 2-2.8.4 2-2.9.1 2-2.9.4 Ap
16、plication Constraints and Protection Approaches . 2-41 2-2.10 HYDROGEN STRESS . 2-42 2-2.10.1 2-2.10.2 Conducive Conditions . 2-42 2-2.10.3 Mechanisms . 2-43 2-2.10.4 Application Constraints and Protection Approaches . 2-44 Manifestation and Quantification 2-45 2-2.1 1 CORROSION FATIGUE . 2-45 2-2.1
17、1.1 2-2.1 1.2 2-2.1 1.4 Application Constraints and Protection Approaches . 2-48 LIQUID METAL CORROSION 2-49 2-2.12.1 Manifestation and Quantification 2-49 2-2.12.2 Conducive Conditions . 2-50 2-2.12.4 Application Constraints and Protection Approaches . 2-53 2-2.12.5 Examples . 2-54 2-2.13.1 Manifes
18、tation and Quantification 2-54 2-2.12 2-2.13 HIGH-TEMPERATURE OXIDATION AND/ OR EROSION . 2-54 2-2.13.2 Conducive Conditions . 2-55 2-2.13.3 Mechanism 2-57 2-2.13.4 Application Constraints and Protection Approaches . 2-57 2-2.14.1 Manifestation and Quantification 2-61 2-2.14.2 Conducive Conditions .
19、 2-62 2-2.14.4 Application Constraints and Protection Approaches . 2-63 2-2.14 HIGH-TEMPERATURE SULFIDATION AND/ OR EROSION . 2-61 2-2.14.3 Mechanism 2-63 2-2.14.5 Example 2-63 2-2.15 BIOLOGICAL CORROSION . 2-64 O O iv Provided by IHS Not for Resale No reproduction or networking permitted without li
20、cense from IHS -,-,-MIL-HDBK-735 W 9999970 0374476 77T M IL-HDBK-735( MR) 2-2.15.1 Manifestation and Quantification 2-64 2-2.15.2 Conducive Conditions . 2.64 2-2.15.3 Mechanisms . 2-65 2-2.15.4 Application Constraints and Protection Approaches . 2-65 2-2.15.5 Examples . 2-66 2-3.1.1 Production 2-66
21、2-3.1.2 Field 2-69 2-3.2.1 Production 2.70 2-3.2.2 Field 2.78 2-3 ENVI RON MENTS . 2.66 2-3.1 NATURAL ENVIRONMENT 2-66 2-3.2 INDUCED ENVIRONMENT 2-69 2-4 INTERFACES 2-82 METAL TO METAL 2-82 METAL TO NONMETAL . 2-83 REFERENCES . 2.84 2-4.1 2-4.2 CHAPTER 3 CORROSION PREVENTION 3-1 INTRODUCTION 3. 1 3-
22、2 DESIGN CONSIDERATIONS AND PRACTICES 3-1 3-2.1 MATERIAL COMPATIBILITY CONSIDERATIONS . 3-2 3-2.2 GEOMETRY CONSIDERATIONS . 3-5 3-2.3 MECHANICAL DESIGN CONSIDERATIONS . 3-7 3-2.4 ANODIC AND CATHODIC PROTECTION 3-8 3-2.5 OPERATIONAL PARAMETERS . 3-9 SELECTION OF MATERIALS . 3-10 PROCESS AND FABRICATI
23、ON CONSIDERATIONS 3-10 3-4.1 COLD WORKING . 3-11 3-4.2 THERMAL EFFECTS . 3-11 3-5 INHIBITORS . 3-13 3-5.1 PASSIVATING INHIBITORS . 3-13 3-5.2 CATHODIC INHIBITORS 3-14 3-5.3 ORGANIC INHIBITORS . 3-14 3-5.4 PRECIPITATION-INDUCING INHIBITORS 3-15 3-5.5 VAPOR-PHASE INHIBITORS . 3-15 3-5.6 INHIBITED ANIT
24、FREEZE . 3-15 3-6 SURFACE TREATMENTS . 3-16 CHEMICAL CONVERSION COATINGS 3-16 3-3 3-4 3-6.1 3-6.1.1 3-6.1.3 Ferrous Alloys . 3-18 3-6.1.5 Zinc and Zinc Alloys, and Cadmium . 3-21 Aluminum and Aluminum Alloys 3-16 3-6.1.2 Copper Alloys . 3-17 3-6.1.4 Magnesium Alloys . 3-19 3-6.2 ION IMPLANTATION 3-2
25、2 3-6.3 DRY FILM LUBRICANTS . 3-23 3-6.4 SHOT PEENING 3-23 3-7 COATINGS . 3-23 3-7.1 METALLIC COATINGS . 3-23 3-7.1.1 Aluminum Coatings 3-29 3-7.1.2 Cadmium Coatings 3-30 3-7.1.3 Chromium Coatings 3-30 3-7.1.4 Copper Coatings 3-30 3-7.1.5 Lead Coatings 3-30 3-7.1.6 Nickel Coatings . 3-31 3-7.1.7 Tin
26、 Coatings 3-32 V Provided by IHS Not for Resale No reproduction or networking permitted without license from IHS -,-,-MIL-HDBK-735 9999970 0174477 bob M IL-HDBK-735( 1111 R) 3-7.1.8 Zinc Coatings 3-32 Noble Metal Coatings 3-33 Portland Cement Coatings 3-36 3-7.3.3 Rust-Preventive Compounds . 3-41 3-
27、7.3.4.2 Aluminum Cleaning 3-43 3-7.3.4.3 Magnesium Cleaning . 3-44 3-7.3.5 painting Systems . 3-44 VOLATILE CORROSION INHIBITORS . 3-50 3-7.1.9 3-7.2 INORGANIC COATINGS . 3-34 3-72 1 Glassy Coatings . 3-34 3-7.2.2 Metallic-Ceramic Coatings 3-34 3-7.2.3 3-7.3 ORGANIC COATINGS . 3-37 3-7.3.1 Paint, En
28、amel, Varnish, and Lacquer 3-37 3-7.3.2 Adhesives, Sealants, Encapsulants, and Bonding and Potting Compounds . 3-39 3-7.3.4 Metal Cleaning Processes 3-42 Ferrous Metal Cleaning 3-43 3-7.3.4.1 3-8 PACKAGING . 3-47 3-8.1 PACKAGING LEVELS 3-48 3-8.2 3-8.3 DESICCANTS 3-50 REFERENCES 3-50 . CHAPTER 4 MET
29、AL CORROSION AND PREVENTION 4-1 INTRODUCTION 4-1 ALUMINUM AND ALUMINUM ALLOYS . 4-2 WROUGHT ALUMINUM ALLOYS . 4-8 Types of Corrosion 4-13 4-2.1.1.1 Uniform Corrosion . 4-20 Pitting Corrosion . 1 4-20 4-2.1.1.3 Atmospheric Corrosion . 4-20 4-2.1.1.4 Crevice Corrosion . 4-21 4-2.1.1.5 Filiform Corrosi
30、on 4-22 4-2.1.1.6 Intergranular Corrosion 4-22 4-2.1.1.8 Stress-Corrosion Cracking 4-23 4-2.1.1.9 Corrosion Fatigue . 4-23 4-2.1.1.10 Galvanic Corrosion . 4-25 Cavitation and Erosion Corrosion . 4-28 4-2.1.1.12 Fretting Corrosion 4-28 4-2.1.2 Interface Problems 4-28 Methods for Prevention of Corrosi
31、on 4-29 Selection of Materials . 4-29 4-2.1.3.2 Surface Treatments . 4-30 4-2.1.3.4 Design Considerations 4-33 4-2 4-2.1 4-2.1.1 4-2.1.1.2 4-2.1.1.7 Exfoliation 4-23 4-2.1.1.11 4-2.1.3 4-2.1.3.1 4-2.1.3.3 Coatings 4-32 4-2.2 CAST ALUMINUM ALLOYS . 4-33 4-2.2.1 Types of Corrosion 4-35 4-2.2.1.1 Unifo
32、rm and Pitting Corrosion . 4-35 4-2.2.1.2 Stress-Corrosion Cracking 4-35 4-2.2.2 Interface Problems 4-35 Methods for Prevention of Corrosion . 4-35 Types of Alloys 4-35 Types of Corrosion 4-36 4-2.2.3 4-2.3.1 4-2.3.2 4-2.3.3 Interface Problems 4-36 4-2.3 POWDER METALLURGY ALLOYS . 4-35 vi Provided b
33、y IHS Not for Resale No reproduction or networking permitted without license from IHS -,-,-6 . MIL-HDBK-735 9999970 0274478 542 = M IL-HD BK-735( MR) 4-2.3.4 Methods for Prevention of Corrosion 4-38 4-2.4.1 Stress-Corrosion Cracking . 4-38 4-2.4.2 Exfoliation 4-38 4-2.4.3 Biological Corrosion 4-38 4
34、-2.4 EXAMPLES OF CORROSION . 4-38 4-3 BERYLLIUM . 4-39 TYPES OF CORROSION 4-39 4-3.1 4-3.1.1 Uniform Corrosion 4-39 4-3.1.2 High-Temperature Oxidation 4-39 4-3.1.3 Pitting . 4-39 4-3.1.4 Stress-Corrosion Cracking . 4-40 4-3.1.5 Liquid Metal Corrosion . 4-40 4-3.1.6 Galvanic Corrosion . 4-40 4-3.2 ME
35、THODS FOR PREVENTION OF CORROSION 4-40 4-4 CARBON 4-40 4-4.1 TYPES OF CORROSION 4-41 4-4.1.1 Gaseous Oxidation 4-41 4-4.1.2 Interstitial Formation 4-41 4-4.1.3 Oxidation in Solution 4-41 4-4.1.4 Carbide Formation 4-42 4-4.1.5 Galvanic Effects . 4-42 4-4.2 INTERFACE PROBLEMS 4-43 4-4.3 METHODS FOR PR
36、EVENTION OF CORROSION 4-43 4-4.4 EXAMPLES OF CORROSION PROBLEMS . 4-44 4-5 COBALT AND COBALT ALLOYS 4-44 4-5.1 TYPES OF CORROSION 4-44 4-5.1.1 General Corrosion (Uniform and Pitting Corrosion) . 4-44 4-5.1.2 High-Temperature Corrosion 4-46 4-5.1.2.1 Oxidation 4-46 4-5.1.2.2 Hot Corrosion . 4-49 4-5.
37、1.2.3 Liquid Metal Corrosion 4-49 4-5.1.2.4 Molten Sait Corrosion 4-49 4;5.1.3 Erosion-Corrosion . 4-49 4-5.2 4-5.3 METHODS FOR PREVENTION OF CORROSION 4-50 EXAMPLES OF CORROSION PROBLEMS . 4-50 4-6 COLUMBIUM AND COLUMBIUM ALLOYS 4-51 4-6.1 ALLOYS OF COLUMBIUM . 4-51 4-6.2 TYPES OF CORROSION 4-51 4-
38、6.2.1 General Corrosion . 4-51 4-6.2.1.1 Uniform and Pitting Corrosion . 4.5 1 4-6.2.1.2 Caustic Embrittlement 4-53 4-6.2.2 High-Temperature Corrosion 4-53 4-6.2.2.1 Oxidation 4-53 4-6.2.2.2 Liquid Metals 4-54 4-6.2.2.3 Other High-Temperature Media 4-54 4-6.3 METHODS FOR PREVENTION OF CORROSION 4-54
39、 4-6.4 EXAMPLES OF CORROSION PROBLEMS . 4-55 COPPER AND COPPER ALLOYS 4-55 4-7.1 TYPES OF ALLOYS 4.55 4-7 4-7.1.1 Copper and High-Copper Alloys . 4-56 4-7.1.2 Copper-Zinc Alloys . 4-56 4-7.1.3 Copper-Tin Alloys . 4-56 4-7.1.4 Copper-Aluminum Alloys . 4-56 4-7.1.5 Copper-Nickel Alloys 4-56 4-7.2 TYPE
40、S OF CORROSION OF COPPER AND HIGH-COPPER ALLOYS 4-59 vii Provided by IHS Not for Resale No reproduction or networking permitted without license from IHS -,-,-MIL-HDBK-735 = 9999770 0174479 489 = MI L-H DBK-735( MR) O 4-7.2.1 Uniform Corrosion 4-59 Corrosion in Natural Waters . 4-59 Corrosion in Neut
41、ral Solutions . 4-59 Corrosion in Acid Solutions 4-59 Corrosion in Alkaline Solutions 4-60 Pitting and Crevice Corrosion . 4-60 4-7.2.1.1 4-7.2.1.2 4-7.2. i . 3 4-7.2.1.4 4-7.2.1.5 4-7.2.1.6 Weathering Corrosion . . 4-59 Corrosion in Organic Chemicals . 4-60 4-7.2.3 Stress-Corrosion Cracking . 4-60
42、4-7.2.4 High-Temperature Corrosion 4-60 4-7.2.5 Galvanic Corrosion . 4-60 4-7.3 TYPES OF CORROSION OF COPPER ALLOYS . 4-60 4-7.3. I Dealloying . 4-60 4-7.3.1.1 Copper-Zinc Alloys 4-60 I 4-7.3.1.2 Copper-Tin Alloys 4-61 4-7.3.1.3 Copper-Aluminum Alloys . 4-61 4-7.3.1.4 Copper-Nickel Alloys 4-61 4-7.3
43、.2 Uniform Corrosion 4-61 4-7.2.2 . 1 4-7.3.2.1 Weathering Corrosion . 4-61 4-7.3.2.2 Corrosion in Natural Waters . 4-62 4-7.3.2.3 Corrosion in Salt Solutions . 4-65 4-7.3.2.4 Corrosion in Acid Solutions 4-65 4-7.3.2.5 Corrosion in Alkaline solutions . 4-66 4-7.3.3 Pitting and Crevice Corrosion . 4-
44、66 4-7.3.4 Stress-Corrosion Cracking . 4-68 4-7.3.4.2 Copper-Tin Alloys 4-69 4-7.3.4.3 Copper-Aluminum Alloys 4-70 4-7.3.4.4 Copper-Nickel Alloys 4-70 4-7.3.5 High-Temperature Corrosion 4-70 4-7.3.6 Galvanic Corrosion . 4-70 4-7.3.4.1 Copper-Zinc Alloys . 4-69 0 . 4-7.4 INTERFACE PROBLEMS 4-71 4-7.5
45、 4-7.6 METHODS FOR PREVENTION OF CORROSION 4-73 EXAMPLES OF CORROSION PROBLEMS . 4-75 4-7.6.1 Missile Flare Motor . 4-75 4-7.6.2 Automotive Radiators . 4-75 4-8 IRON AND IRON ALLOYS 4-76 4-8.1 TYPES OF ALLOYS 4-76 4-8.2 CAST IRONS 4-76 Types of Corrosion 4-76 4-8.2.1.1 Uniform Corrosion . 4-76 4-8.2
46、.1 4-8.2.1.1. I Weathering Corrosion 4-76 4-8.2.1.1.2 Corrosion in Natural Waters 4-78 4-8.2.1.1.3 Corrosion in Acid Solutions . 4-78 4-8.2.1.1.4 Corrosion in Alkaline Solutions . 4-79 4-8.2.1.2 Galvanic Corrosion . 4-79 4-8.2.1.3 Selective Leaching . 4-79 4-8.2.1.4 Erosion-Corrosion 4-79 4-8.2.J .
47、5 Cavitation . 4-79 4-8.2.1.6 Fretting . 4-79 4-8.2.2 Methods for Prevention of Corrosion 4-79 4-8.2.3 Examples of Corrosion Problems 4-81 4-8.3.1 . 0 4-8.3 CARBON AND LOW-ALLOY STEELS 4-81 Types of Corrosion 4-82 4-8.3.1.1 Uniform Corrosion . 4-82 . v111 Provided by IHS Not for Resale No reproducti
48、on or networking permitted without license from IHS -,-,-MIL-HDBK-735 9999970 0374480 3TO MI L-H DBK-735(MR) 4-8.3.1.1.1 Weathering Corrosion . 4-82 4-8.3.1.1.1.1 Wrought Steels . 4-82 4-8.3.1.1.1.2 Cast Steels 4-84 4-8.3.1.1.2 Corrosion in Natural Waters . 4-84 4-8.3.1.1.3 Corrosion in Acid Solutio
49、ns . 4-84 4-8.3.1.1.4 Corrosion in Alkaline Solutions 4-85 4-8.3.1. I . 5 Corrosion in Salt Solutions . 4-85 4-8.3.1.2 Galvanic Corrosion . 4-85 4-8.3. I . 3 Stress-Corrosion Cracking 4-85 4-8.3.1.4 Corrosion Fatigue . 4-87 4-8.3.1.5 High-Temperature Corrosion 4-87 4-8.3.1.5.1 Oxidation 4-87 4-8.3.1 S.2 Liquid Metal Corrosion 4-87 4-8.3. I . 6 Biological Corrosion . 4-87 4-8.3.2 Interface Problems . 4.87 4-8.3.3 Methods for
