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Corrosion Evaluation and Durability Estimation of Aluminized Steel Drainage Pipes Mersedeh Akhoondan University of South Florida, [email protected]

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Corrosion Evaluation and Durability Estimation of Aluminized Steel Drainage Pipes Mersedeh Akhoondan University of South Florida, Makhoond@Mail.Usf.Edu University of South Florida Scholar Commons Graduate Theses and Dissertations Graduate School January 2012 Corrosion Evaluation and Durability Estimation of Aluminized Steel Drainage Pipes Mersedeh Akhoondan University of South Florida, [email protected] Follow this and additional works at: http://scholarcommons.usf.edu/etd Part of the Civil Engineering Commons, and the Materials Science and Engineering Commons Scholar Commons Citation Akhoondan, Mersedeh, "Corrosion Evaluation and Durability Estimation of Aluminized Steel Drainage Pipes" (2012). Graduate Theses and Dissertations. http://scholarcommons.usf.edu/etd/4273 This Dissertation is brought to you for free and open access by the Graduate School at Scholar Commons. It has been accepted for inclusion in Graduate Theses and Dissertations by an authorized administrator of Scholar Commons. For more information, please contact [email protected]. Corrosion Evaluation and Durability Estimation of Aluminized Steel Drainage Pipes by Mersedeh Akhoondan A dissertation submitted in partial fulfillment of the requirements for the degree of Doctor of Philosophy Department of Civil and Environmental Engineering College of Engineering University of South Florida Major Professor: Alberto A. Sagüés, Ph.D. Delcie Durham, Ph.D. Yusuf Emirov, Ph.D. Xiao Li, Ph.D. Gray Mullins, Ph.D. Rajan Sen, Ph.D. Date of Approval: October 22, 2012 Keywords: Culverts, Service Life, Limestone Backfill, Natural Waters, Coating Copyright © 2012, Mersedeh Akhoondan DEDICATION This work is dedicated to: My best friend and soul mate, Emir Modarres, who has accompanied me through all the ups and downs of my life and without his unconditional love and support this work would not be possible. My dear parents, Ali Akhoondan and Dr. Taraneh Bahary, and my beloved sister, Dr. Mandana Akhoondan, who believed in me, not just as a daughter and a sister, but as someone who can make a difference. My dear professor, Dr. Alberto Sagüés, who, not only introduced me to the exciting world of corrosion science, but also taught me many valuable life lessons along the way. My dear Uncle Majid, the rest of my family, colleagues, and friends for their help and encouragement. ACKNOWLEDGMENTS I would like to sincerely thank Dr. Alberto Sagüés, my mentor and supervisor for his sage advice, insightful criticism, and patient encouragement. Also, I wish to express my appreciation to Dr. Durham, Dr. Emirov, Dr. Li, Dr. Mullins, Dr. Nachabe Dr. Sen and Dr. Volinsky for serving as supervisory committee members and for their crucial remarks. I gratefully acknowledge the support from the Florida Department of Transportation and the Federal Highway Administration in funding this research. Notably, I thank Mr. Mario Paredes, Project Manager, for his assistance and for providing us with the means to accomplish the project goal. The opinions, findings, and conclusions expressed here are those of the author and not necessarily those of the supporting agency. Special thanks to the University of South Florida Nanotechnology Research & Education Center for their help and for allowing me access to state-of-the-art instruments. I also appreciate the help of undergraduate assistants (Andrew Filippi, David Stump, Arish Sajwani, Paul Clark, Patrick Doyle, Randy Guillen, and Cesar Castaneda) for the acquisition of experimental data. TABLE OF CONTENTS LIST OF TABLES ................................................................................................. iii LIST OF FIGURES ............................................................................................... iv ABSTRACT .......................................................................................................... ix 1. BACKGROUND ................................................................................................ 1 1.1 Aluminized Steel Pipe .......................................................................... 2 1.2 Relevant Corrosion Principles .............................................................. 5 1.2.1 Definitions .............................................................................. 5 1.2.2 Polarization Behavior of Electrochemical Systems ................ 7 1.2.3 Electrochemical Measurement Methods .............................. 10 1.2.4 Passivity ............................................................................... 12 1.2.5 Pitting Corrosion ................................................................... 15 1.3 Corrosion Studies of Aluminum and Aluminized Steel ....................... 16 1.3.1 Corrosion of Aluminum ......................................................... 16 1.3.2 Corrosion of Aluminum-Iron Alloys ....................................... 19 1.3.3 Corrosion Performance of Aluminized Steel......................... 21 2. INTRODUCTION ............................................................................................ 28 2.1 Recent Corrosion Failures ................................................................. 28 2.2 Understanding Corrosion Causes and Open Issues .......................... 30 2.3 Objectives and Research Scope ........................................................ 34 3. EXAMINATION OF FIELD EVIDENCE .......................................................... 36 4. MECHANICAL DISTRESS IN SRAP RIBS ..................................................... 43 5. FORMULATION OF TEST SOLUTIONS ........................................................ 49 5.1 Specifications of Environmental Limits ............................................... 49 5.2 Replication of Field Conditions .......................................................... 51 6. MODE A: EFFECT OF MECHANICAL DISTRESS ON CORROSION PERFORMANCE OF ALUMINIZED STEEL ................................................. 54 6.1 Comparative Corrosion Evaluation of Severely Deformed and Flat Aluminized Steel ............................................................................... 54 6.2 Comparative Corrosion Evaluation of Spiral Ribbed and Plain Corrugated Pipes .............................................................................. 60 6.2.1 Preliminary Tests ................................................................. 60 i 6.2.2 SRAP vs PCAP in Non-flowing Waters ................................ 62 6.2.3 SRAP in Flowing Waters ...................................................... 71 6.3 Corrosion and Simulated Severe Manufacturing Distress .................. 73 6.3.1 Laboratory Experiments ....................................................... 73 6.3.2 Corrosion Propagation Mechanism Modeling ....................... 80 7. MODE B: MECHANISM OF CORROSION PERFORMANCE IN WATER CONTACTING SAND AND LIMESTONE ........................................................... 91 7.1 Corrosion in Sandy Soil ..................................................................... 91 7.2 Corrosion in Limestone Backfill .......................................................... 96 7.2.1 Introduction .......................................................................... 96 7.2.2 Experimental Procedure ....................................................... 98 7.2.3 Results and Discussion ...................................................... 103 7.2.3.1 Solution pH ........................................................... 103 7.2.3.2 Corrosion Development - Physical Observations . 104 7.2.3.3 Corrosion Development - Electrochemical Behavior ............................................................... 106 7.2.3.4 Interpreting EIS Data: Control Specimens and Stage I of Flowing Water Condition ...................... 110 7.2.3.5 Interpreting EIS Data: Stage II .............................. 122 7.2.3.6 Comparison of EIS Results and Metallography .... 130 7.3 Summary ......................................................................................... 132 8. GENERAL DISCUSSION ............................................................................. 135 8.1 Mode A Corrosion Issues ................................................................. 135 8.2 Mode B Corrosion Issues ................................................................. 138 9. CONCLUSIONS ........................................................................................... 140 10. FUTURE WORK ......................................................................................... 143 REFERENCES ................................................................................................. 145 APPENDICES .................................................................................................. 151 Appendix 1: Sample Polarization Diagrams of Al and Steel................... 152 Appendix 2: Example of Fit and EIS Raw Data for EIS Interpretation of Stage I, Stage II and Control Specimens. ...................... 155 Appendix 3: Corrosion and Simulated Severe Manufacturing Distress .. 174 Appendix 4: Limestone Composition Analysis by X-ray Fluorescence Spectrometry. .................................................................... 177 Appendix 5: Corrosion of Plain Corrugated Galvanized Steel Pipe Joining SRAP Segments ................................................... 178 ABOUT THE AUTHOR ......................................................................... END PAGE ii LIST OF TABLES Table 1: Possible reactions in the AI-H2O system .............................................. 19 Table 2: Field failures. ........................................................................................ 28 Table 3: System of equations
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