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Image Analysis of Corrosion Pit Initiation on Astm Type A240 Stainless Steel and Astm Type a 1008 Carbon Steel

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Image Analysis of Corrosion Pit Initiation on Astm Type A240 Stainless Steel and Astm Type a 1008 Carbon Steel IMAGE ANALYSIS OF CORROSION PIT INITIATION ON ASTM TYPE A240 STAINLESS STEEL AND ASTM TYPE A 1008 CARBON STEEL A THESIS SUBMITTED TO THE FACULTY OF THE UNIVERSITY OF MINNESOTA BY H M ZULKER NINE IN PARTIAL FULFILLMENT OF THE REQUIREMENTS FOR THE DEGREE OF MASTER OF SCIENCE ADVISOR: DR. BRIAN HINDERLITER, P.E, CHP February 2016 © H M Zulker Nine 2016 ACKNOWLEDGEMENT I want to express my deepest gratitude to my supervisor, Dr. Brian Hinderliter, a respectable scholar; whose encouragement, guidance, and support from the beginning to the end enabled me to develop an understanding of the subject and also for giving me the privilege of working under his supervision. The knowledge and skills that I have learned from him especially those wonderful conversations about research, coursework and overall life, will be motivating me continuously in my future endeavors. Also thankful to Dr. Hongyi Chen for her encouraging advice and organized class lectures, which helped me a lot to channel my thoughts into different projects. Finally special thanks to Dr. Elizabeth Hill, for agreeing to serve on the thesis committee. H M Zulker Nine i ABSTRACT The adversity of metallic corrosion is of growing concern to industrial engineers and scientists. Corrosion attacks metal surface and causes structural as well as direct and indirect economic losses. Multiple corrosion monitoring tools are available although those are time-consuming and costly. Due to the availability of image capturing devices in today’s world, image based corrosion control technique is a unique innovation. By setting up stainless steel SS 304 and low carbon steel QD 1008 panels in distilled water, half- saturated sodium chloride and saturated sodium chloride solutions and subsequent RGB image analysis in Matlab, in this research, a simple and cost-effective corrosion measurement tool has identified and investigated. Additionally, the open circuit potential and electrochemical impedance spectroscopy results have been compared with RGB analysis to gratify the corrosion. Additionally, to understand the importance of ambiguity in crisis communication, the communication process between Union Carbide and Indian Government regarding the Bhopal incident in 1984 was analyzed. ii Table of Contents ACKNOWLEDGEMENT ................................................................................................................ i ABSTRACT ..................................................................................................................................... ii List of Figures ................................................................................................................................ vii List of Tables ................................................................................................................................... x Chapter 1: Introduction .................................................................................................................... 1 1.1. Corrosion in general ......................................................................................................... 1 1.2. Thesis objective ................................................................................................................ 1 1.3. What is corrosion? ........................................................................................................... 2 1.4. Corrosion on metallic surface .......................................................................................... 2 1.5. Cost of corrosion .............................................................................................................. 4 1.5.1. Economic ...................................................................................................................... 4 1.5.1.1. Plant downtime ........................................................................................................ 5 1.5.1.2. Loss of product ......................................................................................................... 5 1.5.1.3. Loss of efficiency ...................................................................................................... 6 1.5.1.4. Contamination ......................................................................................................... 6 1.5.1.5. Overdesign ............................................................................................................... 6 1.5.2. Human life and safety .................................................................................................. 6 1.5.2.1. Chemical plant explosion in Bhopal, India 1984 ...................................................... 7 1.5.2.2. Sinking of the Tongan inter-island ferry, 2009......................................................... 8 1.5.2.3. Berlin Hall collapse, 1980 ......................................................................................... 8 1.5.2.4. Failure of Aloha airline flight, 1988 .......................................................................... 9 1.6. Corrosion measurement .................................................................................................. 9 1.6.1. Corrosion measuring standards ................................................................................... 9 1.6.1.1. ASTM corrosion standard ...................................................................................... 10 1.6.1.2. NACE corrosion standard ....................................................................................... 11 iii 1.6.2. Corrosion measurement techniques- a literature review ......................................... 12 1.6.2.1. Visual inspection .................................................................................................... 12 1.6.2.2. Spectroscopic measurements ................................................................................ 13 1.6.2.3. Electrochemical measurements ............................................................................. 15 1.6.3. Image analysis as a corrosion measurement tool ...................................................... 16 Chapter 2: Types of corrosion ........................................................................................................ 18 2.1. Passivity ............................................................................................................................... 18 2.2. Classification of corrosion .............................................................................................. 19 2.2.1. Pitting corrosion ......................................................................................................... 20 2.2.2. Mechanism of pitting corrosion ................................................................................. 22 Chapter 3: Corrosion experiment ................................................................................................... 24 3.1. List of Materials: ................................................................................................................. 24 3.2. Preparation ......................................................................................................................... 26 3.2.1. Panel preparation ............................................................................................................ 26 3.2.2. Solution preparation .................................................................................................. 26 3.2.3. Electrochemical cell preparation ..................................................................................... 26 3.3. Experiment procedure ........................................................................................................ 26 Chapter 4: Image analysis algorithm ............................................................................................. 28 4.1. Flowchart of the algorithm ................................................................................................. 28 4.2. Details of the algorithm ...................................................................................................... 29 Chapter 5: Results and discussion .................................................................................................. 35 5.1. Experimental panels............................................................................................................ 35 5.2. Results ................................................................................................................................. 35 5.2.1. Stainless steel in distilled water experiment ................................................................... 35 5.2.2. Stainless steel in half-saturated sodium chloride (NaCl) solution experiment................ 38 5.2.3. Stainless steel in saturated sodium chloride (NaCl) solution experiment ....................... 41 iv 5.2.4. A comparison of images of SS 304 experiments .............................................................. 43 5.2.4.1. Open circuit potential of SS 304 ................................................................................... 45 5.2.4.2 Electrochemical impedance spectroscopy (EIS) of SS 304 ............................................. 46 5.2.5. Carbon steel in distilled water experiment...................................................................... 48 5.2.6. Carbon steel in half-saturated sodium chloride (NaCl) solution experiment .................. 51 5.2.7. Carbon steel in saturated sodium chloride (NaCl) solution experiment ........................
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