Volume 13 - Corrosion Part 10 ppt

Schutz, Effects of Iron on the Corrosion Resistance of Titanium, in Industrial Applications of Titanium and Zirconium, STP 728, American Society for Testing and Materials, 1981, p 163-1

Grade 7 45 Boiling nil

Grade 12 45, 50 Boiling nil

Grade 12 0.5 Boiling nil

Hydrochloric acid + 4% FeCl 3 + 4% MgCl 2 , chlorine saturated Grade 7 19 82 0.46

Hydrochloric acid

+5 g/L FeCl 3 Grade 7 10 Boiling 0.279

Hydrogen peroxide

Sodium fluoride

Grade 12 10 Boiling 11.6

Sulfamic acid

Grade 7 40 25 0.23

Ti-3-8-6-4-4 1 Boiling nil

Sulfuric acid, naturally aerated

Ti-3-8-6-4-4 5 Boiling 1.85

Sulfuric acid, aerated

Source: Ref 13, 26, 68, 80, 109, 133, 138

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Corrosion of Zirconium and Hafnium

T.L Yau and R.T Webster, Teledyne Wah Chang Albany

Introduction

ZIRCONIUM was first identified by Klaproth in 1789 In 1824, Berzelius made the first impure metal by reducing potassium fluorozirconate with potassium In 1925, van Arkel and de Boer prepared the first high-purity zirconium by using an iodide decomposition process The commercial Kroll process was developed in 1946 at the Bureau of Mines in Albany, OR

Although zirconium is sometimes described as an exotic or rare element, it is in fact plentiful It is ranked 19th in abundance of the chemical elements occurring in the earth's crust, and it is more abundant than many common metals, such as nickel, chromium, and cobalt The most important source for zirconium is zircon (ZrSiO4), which occurs in several regions throughout the world in the form of beach sand

In 1940, Gillett discovered the excellent corrosion resistance of zirconium in a large number of acids and alkalies This property was confirmed by Kroll in 1946 when ductile zirconium became available Kroll predicted that zirconium would find uses in hydrochloric acid (HCl) applications Hydrochloric acid is regarded as the most corrosive of the common acids Indeed, one of the earliest applications for zirconium was in the handling of HCl

About the time of Kroll's work, Kaufman and Utermeyer found that the early measurements of the thermal neutron cross section of zirconium were incorrect, because the metal that was tested contained hafnium Hafnium occurs naturally with zirconium in ores (the corrosion of hafnium is discussed in section "Corrosion Resistance of Hafnium" in this article) When the hafnium was removed, zirconium was found to have a very low thermal neutron cross section This high transparency to thermal neutrons, coupled with excellent corrosion resistance and good mechanical properties, makes zirconium very useful in nuclear power applications, especially as cladding for uranium fuel and for other reactor internals

Nuclear applications account for a large portion of all the zirconium consumed The excellent corrosion resistance of zirconium to strong acids and alkalies, salts, seawater, and other agents has attracted increasing attention for applications

in chemical-processing equipment Zirconium is used as a getter in vacuum tubes, as an alloying element, and in the manufacture of such diverse items as surgical appliances, photoflash bulbs, and explosive primers Along with niobium, zirconium is superconductive at low temperatures and is used to make superconductive magnets

Physical and Mechanical Properties of Zirconium

Typical physical and mechanical properties of zirconium are given in Table 1 for comparison with the properties of other structural metals First, the density of zirconium is lower than that of iron or nickel Second, zirconium has a low coefficient of thermal expansion The coefficient of thermal expansion of zirconium is about two-thirds that of titanium, about one-third that of AISI type 316 stainless steel, and about one-half that of Monel Third, zirconium has high thermal conductivity about 18% better than that of type 316 stainless steel

Table 1 Typical physical and mechanical properties of zirconium

3600 °C (651 °F) 900.0

Electrical resistivity, ·cm at 20 °C (70 °F) 39.7

Temperature coefficient of resistivity per °C 20 °C (70 °F)

Zirconium forms intermetallic compounds with most metallic elements, and only a limited number of alloys have been developed For nuclear service, it is desirable to have zirconium alloys with improved strength and corrosion resistance in high-temperature water or steam The most common alloys Zircaloy-2 and Zircaloy-4 contain the strong stabilizers tin and oxygen, as well as the stabilizers iron, chromium, and nickel The other alloys of commercial importance are Zr-2.5Nb and Zr-1Nb In zirconium, niobium is a mild stabilizer

Zirconium ores generally contain a few percent of its sister element, hafnium Hafnium has chemical and metallurgical properties similar to those or zirconium, although its nuclear properties are markedly different Hafnium is a neutron absorber, but zirconium is not As a result, there are nuclear and non-nuclear grades of zirconium and zirconium alloys The nuclear grades are essentially hafnium free, and the non-nuclear grades may contain up to 4.5% Hf Properly speaking, the alloy names Zircaloy, Zr-2.5Nb, and Zr-1Nb apply to nuclear grade materials American Society for Testing and Materials (ASTM) specifications for non-nuclear grades list UNS R60704 as the alloy corresponding closely to Zircaloy-4 and UNS R60705 and R60706 as the alloys corresponding closely to Zr-2.5Nb Properties and design specifications for zirconium alloys are given in Tables 2, 3, 4, and 5

Table 2 Chemical compositions of zirconium alloys

Zr706 6.64 0.24

Table 5 ASME mechanical requirements for Zr702 and Zr705 used for unfired pressure vessels

Maximum allowable stress in tension for metal temperature not exceeding °C (°F)

Tensile

strength

Minimum yield

Corrosion Resistance of Zirconium

Zirconium is a reactive metal, as evidenced by its redox potential of -1.53 V versus the normal hydrogen electrode at 25

°C (75 °F) It has a high affinity for oxygen When zirconium is exposed to an oxygen-containing environment, an adherent, protective oxide film forms on its surface This film is formed spontaneously in air or water at ambient temperature and below Moreover, this film is self-healing and protects the base metal from chemical and mechanical attack at temperatures to 300 °C (570 °F) As a result, zirconium is very resistant to corrosive attack in most mineral and organic acids, strong alkalies, saline solutions, and some molten salts Zirconium is not attacked by oxidizing media unless halides are present

There are a few media that will attack zirconium Among them are hydrofluoric acid (HF), ferric chloride (FeCl3), cupric chloride (CuCl2), aqua regia, concentrated sulfuric acid (H2SO4), and wet chlorine gas Table 6 lists media for which corrosion test data have been reported for zirconium and its alloys The data in Table 6 should be viewed as a guide to

application of zirconium in chemical process media Corrosion resistance should be determined in situ if possible because

the process medium may differ greatly from the reported media

Table 6 Corrosion resistance of zirconium alloys in various media

Corrosion rate Temperature

Aqua regia 3:1 Room >1.3 >50 3 parts HCl/1

Saturated 28 80 nil pH 5

Calcium fluoride

Saturated 90 195 nil pH 5

Calcium hypochlorite 2, 6, 20 100 212 <0.13 <5

Carbonic acid Saturated 100 212 <0.13 <5

Carbon tetrachloride 0-100 Room

Chlorine gas (more

than 0.13% H 2 O)

100 94 200 >1.3 >50

Chlorine gas (dry) 100 Room <0.13 <5

Chlorinated water 100 212 <0.05 <2

Chloroacetic acid 100 Boiling <0.025 <1

Chromic acid 10-50 Boiling <0.025 <1

Cupric cyanide Saturated Room >1.3 >50

(239 °F)

Dichloroacetic acid 100 Boiling <0.5 <20

Ethylene dichloride 100 Boiling <0.13 <5

0-70 Room

to 100

212 <0.05 <2

Fluoboric acid 5-20 Elevated >1.3 >50

Hydrazine

Mixture 130 265 nil 2% hydrazine

+ saturated NaCl + 6% NaOH

48 Boiling <0.13 <5 <0.13 <5 B.P = 125 °C

(257 °F); shallow pits

Hydrobromic acid

Mixture Boiling <0.025 <1 <0.025 <1 24% HBr +

50% acetic acid (glacial)

Sodium bisulfate 40 Boiling <0.025 <1 <0.025 <1 B.P = 107 °C