Republic of Iraq

Ministry of Higher Education and scientific Research

University of Mosul
College of Petroleum and Mining Engineer
Department of Mining Engineering

The Effect of Different concentration of

Hydrochloric Acid (HCL) on the corrosion
behavior of Several types of metals

SUMPLTTED BY

Hussein Nouri Abdullah Basheer

Ahmed Rasheed Mustafa Faris

Supervised by
Dr.Hudhaifa Raad Hamzah
A.L Mr. Adil Akram Mahmood

submit a graduation project to the college of Petroleum and Mining Engineering /

Mining Department as part of the requirements for Bachelor`s degree in Petroleum
and Mining Engineering
(2022_2023)
 ‫ميحرلا نمحرلا هللا‬ ‫بسم‬

‫ّللاِ َٗ ِث َش ْح ََ ِز ِٔ فَ ِجزَ ِى َل‬

‫}ق ِ ِ ّ‬
‫و‬ ‫ْ‬
‫ض‬ ‫َ‬ ‫ف‬‫ث‬ ‫و‬
‫ْ‬ ‫ُ‬
‫فَ ْي‪ْ َٞ‬ف َش ُح٘اْ}‬

‫ا‪ٟٝ‬خ [‪ّ٘ٝ‬س‪.]85 :‬‬

 ‫االٕـــــــــذاء‬

‫اى‪ ٍِ ٚ‬ميئ هللا ثبىٖ‪ٞ‬جخ ٗاى٘قبس ‪ ..‬إى‪ ٍِ ٚ‬عيَْ‪ ٜ‬اىعطبء ثذُٗ اّزظبس ‪ ..‬إى‪ ٍِ ٚ‬أحَو أسَٔ‬

‫ثنو افزخبس ‪ ..‬أسج٘ ٍِ هللا أُ ‪َٝ‬ذ ف‪ ٜ‬عَشك ىزش‪ ٙ‬ثَبسا ً قذ حبُ قطبفٖب ثعذ ط٘ه اّزظبس‬

‫ٗسزجق‪ ٚ‬ميَبرل ّجً٘ إٔزذ‪ ٛ‬ثٖب اى‪ٗ ً٘ٞ‬ف‪ ٜ‬اىغذ ٗإى‪ ٚ‬األثذ ‪..‬‬

‫(ٗاىذ‪ ٛ‬اىعز‪ٝ‬ز )‪ ….‬إى‪ٍ ٚ‬الم‪ ٜ‬ف‪ ٜ‬اىح‪ٞ‬بح ‪ ..‬إى‪ٍ ٚ‬عْ‪ ٚ‬اىحت ٗإى‪ٍ ٚ‬عْ‪ ٚ‬اىحْبُ ٗاىزفبّ‪.. ٜ‬‬

‫إى‪ ٚ‬ثسَخ اىح‪ٞ‬بح ٗسش اى٘ج٘د‬

‫إى‪ ٍِ ٚ‬مبُ دعبئٖب سش ّجبح‪ٗ ٜ‬حْبّٖب ثيسٌ جشاح‪ ٜ‬إى‪ ٚ‬أغي‪ ٚ‬اىحجب‪ٝ‬ت ( اٍ‪ ٜ‬اىعز‪ٝ‬زح)‬

‫اى‪ ٚ‬اىقذٗح اىحسْخ ٗ اىقبٍخ اىشبٍخخ امزت ٕزٓ اىنيَبد ٍِ ٍْطيق ٍب ىَسزٔ ٍْل خاله‬

‫االع٘اً ا ىسبثقخ فقذ مْذ صذ‪ٝ‬قب ثز٘ج‪ٖٞ‬برل ‪ٍ ,‬ششذا ثْصبئحل ‪ٍ٘,‬جٖب ثعجبسارل ‪ ,‬عط٘فب‬

‫ثنالٍل ٗ اخب حّْ٘ب ىْب (ً‪ ً.‬عبده امشً ٍحَ٘د) ٗدمز٘سّب اىفبضو اىز‪ ٛ‬رىو اىصعبة (د‪.‬‬

‫حز‪ٝ‬فخ سعذ حَزح) ٗ ال ّْس‪ ٚ‬اىز‪ ٛ‬رىو مو اىصعبة فقذ مبُ أثب ٗ صذ‪ٝ‬قب ىجَ‪ٞ‬ع اىطالة سئ‪ٞ‬س‬

‫قسٌ ْٕذسخ اىزعذ‪( ِٝ‬د‪.‬عزاىذ‪ ِٝ‬اىج٘اد‪...)ٛ‬اى‪ ٍِ ٚ‬مبّ٘ا ٍالر‪ٍ ٗ ٛ‬يجئ‪ ٜ‬اى‪ ٍِ ٚ‬رزٗقذ‬

‫ٍعٌٖ اجَو اىيحظبد اى‪ ٚ‬أٗىئل اىز‪ ِٝ‬جَعزْب ٍعٌٖ قبعبد اىَعشفخ اى‪ ٚ‬اىز‪ ِٝ‬سأفزقذٌٕ طالة‬

‫مي‪ٞ‬ز‪ ٜ‬االفبضو ‪ ٗ.‬أخ‪ٞ‬شا اسئو هللا أُ ‪٘ٝ‬فقْب خذٍخ ى٘طْْب اىحج‪ٞ‬ت‪.‬‬

ABSTRACT

The corrosion behavior of metals immersed in hydrochloric acid (HCl)

solution was investigated in this study. The objective was to understand the effects

of HCl acid on different metals and their corrosion behaviors. The metals studied

included CK-45, Brass, Carbon steel, 201-stain, Bronze and Aluminum. The

experimental setup involved immersing metal samples in HCl solutions of varying

concentrations. The range of these concentrations of HCl is 5%, 8% and 10%. The

weight loss method was employed to determine the corrosion rates of the metals

over a four weeks period. The samples were periodically removed from the acid

solution, cleaned, and weighed to measure the extent of weight loss. The results

showed that CK-45, Carbon steel, 201-stain, and Aluminum are the most affected

metals in terms of losing weight after immersion in HCl acid. In contrast, Brass

and Bronze are the least affected metals in terms of losing weight after immersion

in HCl acid. Finally, the weight loss of each metal increases slightly with

increasing HCl concentration.

I
 TABLE OF CONTENTS

Abstract I
Table of Contents II
Lest of Figures V
Lest of Tables VI

Chapter One – Introduction

Subject Page
1.1 Corrosion 1
1.1.1 Causes of Corrosion 2

1.1.2 Types of Corrosion 2

1.1.3 Consequences of Corrosion 4

1.1.4 Corrosion Prevention 5

1.2 Hydrochloric acid (HCL) 6

1.2.1 Uses of Hydrochloric Acid (HCl) 6
1.2.1.1 pH Adjustment 6
1.2.1.2 Regeneration of Ion Exchange Resins 7
1.2.1.3 Domestic Cleaning Products 7

1.2.1.4 Laboratory Applications 7

1.2.2 Effects of Hydrochloric Acid (HCl) 7

1.2.2.1 Effects on Metals 8

1.2.2.2 Effects on Minerals 8

1.2.2.3 Effects on Organic Compounds 8

1.2.3 Safety Precautions 9

1.3 Tested Metals 9

1.3.1 CK-45 9

II
1.3.1.1 Properties of CK-45 9

1.3.1.2 Applications of CK-45 01

1.3.2 Brass 00

1.3.2.1 Properties of Brass 02

1.3.2.2 Applications of Brass 01

1.3.3 Carbon Steel 04

1.3.3.1 Properties of Carbon Steel 14

1.3.3.2 Application of Carbon Steel 16

1.3.4 201-stain 17

1.3.4.1 Properties of 201 Stainless Steel 17

1.3.4.2 Application of 201 Stainless Steel 18

1.3.5 Bronze 19

1.3.5.1 Properties of Bronze 21

1.3.5.2 Application of Bronze 20

1.3.6 Aluminum 22

1.3.6.1 Properties of Aluminum 21

1.3.6.2 Application of Aluminum 24

1.3.7 Reasons For Study Corrosion 26

1.3.8 Project Objective 11

1.3.9 Summary 11

Chapter Two-Literature Review

Literature Review 32

Chapter Three–Experimental Work

3.1 Introduction 44
3.2 The Experimental Plan Work Can Be Summarized Below 44
3.3 Preparation Of Specimens 44
III
3.4 The Preparation of Sulfuric Acid for Corrosion Test 47

Chapter Four- Results and Discussion

4 Introduction 54
4.1 Effect of Hydrochloric Acid (HCL) on CK-45 54
4.2 Effect of Hydrochloric Acid (HCL) on Brass 57
4.3 Effect of Hydrochloric Acid (HCL) on Carbon Steel 58
4.4 Effect of Hydrochloric Acid (HCL) on 201-Stain 59
4.5 Effect of Hydrochloric Acid (HCL) on Bronze 61
4.6 Effect of Hydrochloric Acid (HCL) on Aluminum 62

Chapter Five-Conclusion and Future Works

5.1 Conclusion 65
5.2 Future Works 66

IV
 LIST OF FIGURES

List of Figures
Figures Subject Page
3.1 Shape of Specimen 45
3.2 CNC Machine 46
3.3 Accurate Balance 47
3.4 Shows The Specimens Into 5% Hydrochloric Acid (HCL) 48
3.5 Shows The Specimens Into 8% Hydrochloric Acid (HCL) 49
3.6 Shows The Specimens Into 10% Hydrochloric Acid 51
(HCL)
3.7 Measure The Weight of The Sample After It Has Been 50
Thoroughly
3.8 Shows The Corrosion of The Specimens 52
4.1 Variation in CK-45 Weight Over Time After Immersion 56
in Hydrochloric Acid (HCl) at Different Concentrations.
4.2 Variation in Brass weight over time after immersion in 57
Hydrochloric Acid (HCl) at different concentrations.
4.3 Variation in Carbon steel weight over time after 59
immersion in Hydrochloric Acid (HCl) at different
concentrations.

4.4 Variation in 201-stain alloy weight over time after 61

immersion in Hydrochloric Acid (HCl) at different
concentrations
4.5 Variation in Bronze weight over time after immersion in 60
Hydrochloric Acid (HCl) at different concentrations.

4.6 Variation in Aluminum weight over time after immersion 62

in Hydrochloric Acid (HCl) at different concentrations.

V
 LIST OF TABLES

Table Subject Page

4.1 IMMERSED SAMPLES IN HYDROCHLORIC ACID 61
(HCL) AT (5%).
4.2 IMMERSED SAMPLES IN HYDROCHLORIC ACID 61
(HCL) AT (8%).
4.3 IMMERSED SAMPLES IN HYDROCHLORIC ACID 61
(HCL) AT (8%).

VI
 CHAPTER 1
INTRODUCTION
_____________________________________

VII
 INTRODUCTION

1.1. Corrosion

Corrosion refers to the gradual deterioration or destruction of materials,

usually metals, through chemical or electrochemical reactions with their

environment. It is a natural process that occurs when metals are exposed to

substances such as oxygen, water, acids, or salts. Corrosion can result in the

loss of material integrity, reduced functionality, and potential safety hazards [1].

The corrosion process involves the transfer of electrons from the metal

surface, known as oxidation, and the corresponding reduction of another species

in the environment. This electrochemical reaction occurs at localized areas on

the metal surface, often referred to as corrosion sites or corrosion cells. The

corrosion process can be influenced by various factors, including the type of

metal, the specific corrosive environment, temperature, and the presence of

impurities or surface defects [2].

[1[
 1.1.1. Causes of Corrosion

Corrosion can be attributed to various causes, but the most common factors

include: Electrochemical Reactions: The majority of corrosion processes involve

electrochemical reactions between the metal, an electrolyte (such as water or an

aqueous solution), and oxygen. This leads to the formation of anodes (sites where

metal oxidation occurs) and cathodes (sites where reduction reactions occur).

1. Environmental Factors: Corrosion is influenced by environmental conditions

such as temperature, humidity, presence of corrosive gases (e.g., sulfur

dioxide), and exposure to chemicals or salts. These factors can accelerate or

intensify the corrosion process [3].

1.1.2. Types of Corrosion

Several types of corrosion can occur, depending on the specific conditions and

mechanisms involved. Some common types include

1. Uniform Corrosion: This type of corrosion occurs uniformly across the

exposed surface of the material. It leads to a general loss of material

thickness and can result in the weakening of structures or components.

[2[
 2. Galvanic Corrosion: Galvanic corrosion occurs when two dissimilar metals

are in electrical contact with each other in the presence of an electrolyte. The

more active metal experiences accelerated corrosion, while the less active

metal remains relatively unaffected.

3. Pitting Corrosion: Pitting corrosion involves the localized formation of small

pits or holes on the material surface. It can penetrate deep into the material,

leading to localized structural failures.

4. Crevice Corrosion: Crevice corrosion occurs in confined spaces or crevices,

such as gaps, joints, or under deposits on the material surface. The stagnant

environment within the crevice promotes corrosive reactions.

5. Stress Corrosion Cracking: Stress corrosion cracking occurs when a material

is subjected to both tensile stress and a corrosive environment. It can lead to

the formation and propagation of cracks, compromising the material's

integrity [4].

1.1.3. Consequences of Corrosion

Corrosion has significant consequences across various industries, including

[3[
 1. Safety Hazards: Corrosion can weaken structures, pipelines, and equipment,

posing safety risks. Catastrophic failures, such as bridge collapses or

pipeline ruptures, can occur due to corrosion-induced structural integrity

loss.

2. Economic Impact: Corrosion-related costs are substantial, including repair,

replacement, and maintenance expenses. Industries such as transportation,

infrastructure, and manufacturing bear the brunt of these costs.

3. Environmental Impact: Corrosion processes, especially in industrial settings,

can release pollutants into the environment, impacting ecosystems and

human health.

4. Loss of Functionality: Corrosion can degrade the performance and

functionality of materials and components, affecting their intended use and

lifespan [5].

1.1.4. Corrosion Prevention

Developing effective strategies to prevent and mitigate corrosion is essential. This

involves
[4[
 1. Material Selection: Using corrosion-resistant materials or surface coatings

can provide inherent protection against corrosion.

2. Protective Coatings: Applying protective coatings, such as paints, enamels,

or corrosion-resistant films, can create a barrier between the material and the

corrosive environment.

3. Cathodic Protection: Employing techniques such as sacrificial anode

systems or impressed current systems can protect the metal by making it a

cathode, reducing the corrosion rate.

4. Corrosion Inhibitors: Introducing chemicals that inhibit corrosion can slow

down the electrochemical reactions occurring at the metal surface.

5. Design Considerations: Designing structures and equipment with corrosion

prevention in mind [6].

1.2. Hydrochloric acid (HCl)

Hydrochloric acid (HCl) is a strong, highly corrosive acid with a wide

range of applications in various industries and laboratory settings. It is a

colorless, pungent liquid that is soluble in water. Hydrochloric Acid (HCl) is

[5[
classified as a mineral acid and is known for its strong acidity and ability to

react with many substances.

1.2.1. Uses of Hydrochloric Acid (HCl)

Industrial Applications: Hydrochloric Acid (HCl) is extensively used in

industrial processes, including chemical manufacturing, metal processing, and

oil refining. It is employed in pickling and etching processes to remove oxides,

scale, and contaminants from metal surfaces [7].

1.2.1.1. pH Adjustment

Hydrochloric Acid (HCl) is commonly used to adjust the pH of solutions

in laboratory experiments and industrial processes. It is highly acidic and can

lower the pH of solutions effectively.

1.2.1.2. Regeneration of Ion Exchange Resins

HCl is used to regenerate ion exchange resins, which are widely used in

water treatment and purification systems to remove impurities and ions.

[6[
 1.2.1.3. Domestic Cleaning Products

Hydrochloric Acid (HCl) is a key ingredient in many household cleaning

products, including toilet bowl cleaners and descaling agents. Its strong acidity

aids in removing stubborn stains and mineral deposits.

1. 2.1.4. Laboratory Applications

HCl is a staple chemical in laboratory settings. It is used for chemical

synthesis, pH adjustment, and as a reagent in various analytical procedures.

1.2.2. Effects of Hydrochloric Acid (HCl)

Hydrochloric acid (HCL) is highly corrosive to a wide range of materials,

including metals, minerals, and organic compounds. When in contact with HCl

acid, certain materials can undergo dissolution or chemical reactions, resulting

in changes in their physical and chemical properties [8].

1.2.2.1. Effects on Metals

HCl acid can react with metals, particularly reactive metals like

magnesium, zinc, or iron, resulting in the release of hydrogen gas and the
[7[
 formation of metal chloride salts. The reaction can cause corrosion and

degradation of the metal surface.

1.2.2.2. Effects on Minerals

HCl acid can dissolve certain minerals, especially those composed of

carbonates, such as limestone or marble. The acid reacts with the carbonate

ions, leading to the formation of carbon dioxide gas, water, and soluble

metal chloride salts.

1.2.2.3. Effects on Organic Compounds

HCl acid can react with organic compounds, such as alcohols or

amines, to form organic chloride compounds. These reactions are often

employed in organic synthesis and purification processes.

1.2.3. Safety Precautions

Hydrochloric acid is a highly corrosive and hazardous substance. It can

cause severe burns upon contact with the skin, eyes, or respiratory system.
[8[
 Therefore, appropriate safety precautions should be followed when handling

HCl acid, including wearing protective clothing, gloves, and eye protection.

Adequate ventilation should be ensured when working with HCl acid to avoid

inhalation of fumes. Proper storage and handling procedures should be

implemented to prevent accidental spills or releases.

1.3. Tested Metals

1.3.1. CK-45

CK-45, also known as C45 or 1.1191, is a medium carbon steel alloy. It is

widely used in various industries due to its excellent mechanical properties and

good machinability. CK-45 belongs to the class of steels known as carbon steels,

which contain carbon as the primary alloying element [9].

1.3.1.1. Properties of CK-45:

1. Carbon Content: CK-45 has a carbon content ranging from 0.42% to 0.50%.

The carbon content determines the hardness and strength of the steel.

[9[
 2. Strength and Hardness: CK-45 exhibits high tensile strength and hardness,

making it suitable for applications where strength and durability are

required.

3. Machinability: CK-45 steel has good machinability, allowing for ease of

cutting, shaping, and forming. It can be readily machined using conventional

machining processes.

4. Weldability: CK-45 steel can be welded using various welding techniques

such as arc welding and gas welding. However, preheating and post-weld

heat treatment may be necessary to prevent cracking and improve the weld's

mechanical properties.

5. Wear Resistance: CK-45 offers good wear resistance, making it suitable for

applications where components are subjected to abrasive wear or impact.

6. Heat Treatment: CK-45 steel can be heat treated to enhance its mechanical

properties. Common heat treatment processes include annealing,

normalizing, quenching, and tempering.

1.3.1.2. Applications of CK-45

[10[
 1. Machinery and Equipment: CK-45 is widely used in the manufacturing of

machinery and equipment components, such as shafts, gears, sprockets, and

hydraulic components, due to its excellent strength, hardness, and

machinability.

2. Automotive Industry: CK-45 steel is employed in various automotive

applications, including crankshafts, connecting rods, axles, and gears, where

high strength and wear resistance are required.

3. Tool and Die Making: CK-45 is used for manufacturing tooling components

such as dies, punches, and molds, thanks to its good hardness and wear

resistance properties.

4. Construction: CK-45 steel finds applications in the construction industry,

such as in the production of structural components, shafts, and supports, due

to its high strength and durability.

5. General Engineering: CK-45 is utilized in a wide range of general

engineering applications, including fasteners, bolts, nuts, and general-

purpose machinery parts.

1.3.2. Brass

[11[
 Brass is an alloy composed primarily of copper (Cu) and zinc (Zn), with

varying proportions of each element depending on the desired properties. It is a

versatile material with a wide range of applications due to its desirable

combination of mechanical, electrical, and aesthetic properties [10].

1.3.2.1. Properties of Brass:

1. Copper-Zinc Composition: Brass typically contains copper as the base

metal, ranging from around 55% to 95%, and zinc as the alloying element,

ranging from around 5% to 45%. The proportion of copper and zinc

influences the properties of the brass, such as its strength, ductility, and

corrosion resistance.

2. Strength and Ductility: Brass exhibits good strength and ductility, making it

suitable for applications that require both structural integrity and formability.

The addition of zinc enhances the strength of brass compared to pure copper.

3. Corrosion Resistance: Brass has excellent corrosion resistance, especially in

atmospheric and freshwater environments. The presence of zinc in the alloy

provides protective properties against corrosion.

4. Electrical Conductivity: Brass is an excellent conductor of electricity,

making it suitable for electrical and electronic applications. Its electrical

[12[
 conductivity is lower than that of pure copper but higher than that of many

other metals.

5. Machinability: Brass is known for its excellent machinability, which allows

for ease of cutting, shaping, and forming using various machining processes.

It produces excellent surface finishes and can be readily worked into

complex shapes.

6. Aesthetic Appeal: Brass has an attractive golden appearance, making it a

popular choice for decorative applications, architectural elements, jewelry,

musical instruments, and artistic creations.

1.3.2.2. Applications of Brass

1. Plumbing and Fittings: Brass pipes, valves, connectors, and fittings are

commonly used in plumbing systems due to their corrosion resistance,

durability, and ease of installation.

2. Electrical and Electronics: Brass is used in electrical connectors, terminals,

switches, and various components due to its good electrical conductivity and

resistance to corrosion.

[13[
 3. Automotive Industry: Brass is utilized in automotive applications, including

radiators, connectors, terminals, and electrical components, due to its

excellent combination of strength, corrosion resistance, and formability.

4. Musical Instruments: Brass instruments, such as trumpets, trombones, and

saxophones, are made from brass alloys due to their acoustic properties and

aesthetic appeal.

5. Decorative and Architectural Applications: Brass is widely used in

decorative and architectural applications, including door hardware, furniture

fittings, lighting fixtures, statues, and ornamental elements.

6. Marine Applications: Brass is resistant to corrosion in seawater, making it

suitable for marine applications such as shipbuilding, marine fittings, and

marine hardware.

7. Precision Engineering: Brass is employed in precision engineering

applications, including precision components, instrumentation, and

watchmaking, due to its machinability and dimensional stability.

1.3.3. Carbon steal

Carbon steel is a type of steel that primarily consists of iron and carbon as

the major alloying elements. It is one of the most widely used materials in various

[14[
industries due to its versatility, strength, and affordability. The carbon content in

carbon steel typically ranges from 0.05% to 2.0%, although higher carbon contents

can be present in certain specialized grades [11].

1.3.3.1. Properties of Carbon Steel

1. Strength and Hardness: Carbon steel exhibits high strength and hardness,

making it suitable for structural applications that require durability and load-

bearing capacity. The strength of carbon steel can be further enhanced

through heat treatment processes.

2. Ductility and Toughness: Carbon steel possesses good ductility and

toughness, allowing it to be easily formed and shaped without fracturing. It

can withstand impact and withstand deformation without failure.

3. Machinability: Carbon steel generally has good machinability, allowing it to

be easily machined, drilled, cut, and shaped using conventional machining

processes. The machinability can vary depending on the carbon content and

other alloying elements present.

4. Weldability: Carbon steel is typically weldable and can be joined using

various welding techniques, such as arc welding, gas welding, and resistance

[15[
 welding. However, precautions and proper welding procedures should be

followed to avoid issues such as weld cracking and brittleness.

5. Corrosion Resistance: Carbon steel is susceptible to corrosion, particularly

when exposed to moisture and aggressive environments. However, the

addition of alloying elements, such as chromium or nickel, can enhance its

corrosion resistance in specific applications.

6. Cost-Effectiveness: Carbon steel is relatively inexpensive compared to other

alloyed steels, making it a cost-effective choice for many applications.

1.3.3.2. Applications of Carbon Steel

1. Structural Components: Carbon steel is widely used in the construction

industry for structural components such as beams, columns, and frames due

to its strength and durability.

2. Automotive Industry: Carbon steel is utilized in the manufacturing of

automobile parts, including chassis components, engine components, and

body panels, due to its strength and cost-effectiveness.

3. Pipelines and Plumbing: Carbon steel pipes and fittings are commonly used

in oil and gas pipelines, water supply systems, and plumbing applications

[16[
 due to their strength, corrosion resistance (with proper coating), and ease of

installation.

4. Machinery and Equipment: Carbon steel is used in the production of various

machinery and equipment components, including gears, shafts, bolts, and

fasteners, due to its strength and machinability.

5. Tools and Cutting Equipment: High carbon steel is used for the production

of cutting tools, drills, saw blades, and other tools that require hardness and

wear resistance.

6. Structural Fasteners: Carbon steel bolts, screws, and nuts are widely used in

construction, manufacturing, and infrastructure projects for fastening

purposes.

7. Shipbuilding: Carbon steel is employed in shipbuilding for various structural

components and hull construction due to its strength and weldability.

1.3.4. 201-stain

It seems that you are referring to "201 stainless steel." 201 stainless steel is a

type of austenitic stainless steel that contains about 16-18% chromium, 3.5-5.5%

nickel, and a lower carbon content compared to other stainless steel grades. It is a

[17[
cost-effective alternative to 304 stainless steel and is commonly used in various

applications [12].

1.3.4.1. Properties of 201 Stainless Steel

1. Corrosion Resistance: 201 stainless steel exhibits good resistance to

corrosion in mild atmospheric and oxidizing environments. However, it is

less resistant to corrosion compared to 304 stainless steel, particularly in

chloride-rich environments.

2. Strength and Toughness: 201 stainless steel offers moderate strength and

toughness, making it suitable for structural applications that require strength

and durability.

3. Formability: 201 stainless steel has good formability, allowing it to be easily

shaped and fabricated into different forms, such as sheets, coils, tubes, and

wires.

4. Weldability: 201 stainless steel is generally considered to have good

weldability. It can be welded using various methods, including arc welding,

resistance welding, and spot welding. However, proper welding procedures

should be followed to avoid issues such as sensitization and embrittlement.

[18[
 5. Magnetic Properties: Unlike austenitic stainless steels like 304 and 316, 201

stainless steel is generally magnetic due to its microstructure.

1.3.4.2. Applications of 201 Stainless Steel

1. Decorative Applications: 201 stainless steel is commonly used in decorative

applications, such as interior and exterior architectural elements, kitchen

appliances, decorative trim, and automotive trim.

2. Utensils and Cookware: Due to its corrosion resistance and cost-

effectiveness, 201 stainless steel is used in the manufacturing of utensils,

cookware, and kitchen appliances.

3. Automotive Trim and Exhaust Systems: 201 stainless steel is utilized in the

production of automotive trim, exhaust systems, and components due to its

aesthetic appeal and moderate corrosion resistance.

4. Furniture and Fixtures: 201 stainless steel finds applications in the furniture

industry, including handles, frames, hinges, and decorative accents.

5. Food Processing Equipment: The corrosion resistance and cost-effectiveness

of 201 stainless steel make it suitable for food processing equipment, such as

food storage containers, conveyor systems, and processing machinery.

[19[
 6. Industrial Applications: 201 stainless steel is used in various industrial

applications, including construction, chemical processing, and

transportation, where moderate corrosion resistance and cost-effectiveness

are required.

1.3.5. Bronze

Bronze is a type of alloy that primarily consists of copper (Cu) combined

with other elements, most commonly tin (Sn). It is an ancient material that has

been used for thousands of years due to its desirable properties, such as strength,

durability, and corrosion resistance. Bronze is widely used in various applications,

ranging from sculptures and decorative items to industrial components and

machinery [13].

1.3.5.1. Properties of Bronze

1. Copper-Tin Composition: Bronze typically contains a significant amount of

copper, usually in the range of 80% to 95%. The addition of tin, which

ranges from 5% to 20%, provides the desired characteristics of bronze.

[20[
 However, other elements, such as aluminum, zinc, and nickel, can also be

added to create specific bronze alloys with enhanced properties.

2. Strength and Hardness: Bronze is known for its excellent strength and

hardness compared to pure copper. The addition of tin and other alloying

elements improves the mechanical properties of bronze, making it suitable

for structural applications.

3. Corrosion Resistance: Bronze exhibits good corrosion resistance,

particularly in atmospheric and freshwater environments. It forms a

protective oxide layer on its surface that helps prevent further corrosion.

4. Wear Resistance: Bronze has excellent wear resistance, making it suitable

for applications involving friction and mechanical stress. It is commonly

used in bearings, bushings, gears, and other components that experience

sliding or rotational motion.

5. Machinability: Bronze is relatively easy to machine, allowing for precision

shaping, cutting, and forming. It produces good surface finishes and can be

readily worked into intricate shapes.

6. Thermal Conductivity: Bronze has high thermal conductivity, making it

useful for applications where heat transfer is important. It is commonly used

in heat exchangers and cooling systems.

[21[
1.3.5.2 Applications of Bronze

1. Sculptures and Artworks: Bronze is widely used in the creation of

sculptures, statues, and artistic pieces due to its durability, aesthetic appeal,

and ability to retain intricate details.

2. Bearings and Bushings: Bronze bearings and bushings are used in various

industries, including automotive, industrial machinery, and aerospace, due to

their excellent wear resistance and low friction properties.

3. Electrical Contacts: Bronze alloys with high electrical conductivity are

utilized in electrical connectors, terminals, and switches, where good

electrical performance and corrosion resistance are required.

4. Marine Applications: Bronze is commonly used in marine environments due

to its corrosion resistance and ability to withstand seawater. It is used for

propellers, fittings, ship components, and marine hardware.

5. Musical Instruments: Bronze alloys, such as phosphor bronze, are used in

the manufacturing of musical instruments, including cymbals, bells, and

various brass instruments, due to their unique sound characteristics and

durability.

[22[
 6. Industrial Components: Bronze is employed in various industrial

components, such as gears, valves, fittings, pump parts, and hydraulic

components, due to its strength, wear resistance, and corrosion resistance.

7. Coins and Medals: Bronze is historically used for coinage and the

production of medals and commemorative plaques due to its durability and

aesthetic appeal.

1.3.6. Aluminum

Aluminum is a lightweight and versatile metal known for its excellent

strength-to-weight ratio, corrosion resistance, and thermal conductivity. It is the

third most abundant element in the Earth's crust and has a wide range of

applications across various industries [14].

1.3.6.1. Properties of Aluminum

1. Lightweight: Aluminum is a lightweight metal, with a density about one-

third that of steel. This makes it an ideal choice for applications where

weight reduction is desired, such as in transportation (e.g., automobiles,

aircraft, and trains) and portable structures.

2. Strength: Although aluminum is lightweight, it exhibits good strength. Its

strength can be further enhanced through alloying and heat treatment

[23[
 processes. Aluminum alloys offer a wide range of strength levels, allowing

for the selection of the appropriate grade for specific applications.

3. Corrosion Resistance: Aluminum has excellent corrosion resistance due to

the formation of a thin, protective oxide layer on its surface. This oxide layer

acts as a barrier, preventing further oxidation and corrosion. In highly

corrosive environments, aluminum can be further protected through coatings

or anodizing processes.

4. Electrical Conductivity: Aluminum is an excellent conductor of electricity,

making it suitable for electrical transmission lines, wiring, and various

electrical applications.

5. Thermal Conductivity: Aluminum has good thermal conductivity, allowing

for efficient heat transfer. It is commonly used in heat sinks, heat

exchangers, and other cooling applications.

6. Ductility and Formability: Aluminum is highly ductile and can be easily

formed into different shapes and profiles using various manufacturing

processes, such as extrusion, rolling, and forging. It can be formed into

complex shapes, making it suitable for intricate designs and applications.

[24[
 7. Recyclability: Aluminum is 100% recyclable without any loss of its original

properties. Recycling aluminum requires significantly less energy compared

to primary production, making it an environmentally friendly material.

1.3.6.2 Applications of Aluminum

1. Transportation: Aluminum is extensively used in the transportation industry,

including automobile bodies, aircraft structures, train carriages, bicycles, and

marine vessels. Its lightweight nature helps improve fuel efficiency and

reduce emissions.

2. Construction and Architecture: Aluminum is used in various construction

applications, such as window frames, curtain walls, roofing, siding, and

structural components. Its lightweight nature, corrosion resistance, and

aesthetic appeal make it a popular choice in architectural design.

3. Packaging: Aluminum is widely used for packaging purposes, such as

aluminum cans for beverages, food containers, and foil packaging. Its

lightweight, impermeability to moisture and light, and recyclability make it

suitable for preserving and protecting a wide range of products.

[25[
 4. Electrical and Electronics: Aluminum is used in electrical conductors, power

cables, electrical enclosures, and heat sinks for electronic devices due to its

electrical conductivity and thermal properties.

5. Consumer Goods: Aluminum is found in various consumer goods, including

appliances, cookware, furniture, sports equipment, and handheld devices,

due to its lightweight nature, durability, and aesthetic appeal.

6. Renewable Energy: Aluminum is used in the renewable energy sector,

particularly in the manufacturing of solar panels, wind turbine components,

and heat exchangers for geothermal systems.

7. Industrial Applications: Aluminum finds application in various industrial

sectors, including machinery and equipment, chemical processing, and

aerospace, due to its corrosion resistance, strength, and formability.

1.3.7. Reasons for study corrosion

We study corrosion because of the damage causes which include the

following:

1- Dimensional change and loss of mechanical properties:

[26[
Corrosion leads to a loss of weight due to the dissolution of the metal and

consequently to its dimension change. Therefore, corrosion Allowance is

often given when it is present and at design. These areas are thicker in the

medium in which the wear rates are higher than in those in which the wear

rates are low. Dimensions of the metal part due to corrosion have an impact

on mechanical properties, as they are less tolerant to external loads, i.e.

increasing their plastic deformation and Elastic Deformation. The use of

metal in corrosive media causes low values for many mechanical properties,

especially fatigue strength and cracks that lead to fast fracture.

2- Appearance: The appearance of the metal is highly affected when it

is corroded, as the metal always looks bad. Therefore, corrosion-resistant

metals such as aluminum or stainless steel should be used in place of

carbon steel, as building materials such as windows and materials,

especially in the facades of external buildings, and the good appearance

of these materials is due to their resistance to air corrosion. As for metals

with weak resistance to corrosion, they are coated with different types of

coatings to improve their appearance by reducing their wear.

[27[
3- Economic damages due to preventive measures: The economic

damages resulting from corrosion are numerous and important, as this

failure often causes productive facilities to stop work unprogrammed,

and the corresponding additional unforeseen economic costs. Likewise,

the occurrence of corrosion leads to a high cost of periodic maintenance,

as in many cases it is necessary to replace the damaged metal part with

another new part. There are many examples that indicate that choosing a

relatively high-cost material but with good economic resistance to

corrosion is preferable to using a particular material that is cheaper but is

subject to rapid damage due to corrosion. What requires that it be

changed periodically, and in both cases it is observed that corrosion

causes economic damage due to increased costs. Also, preventive

measures to reduce corrosion are included in the costs of operation and

maintenance. Corrosion sometimes leads to an unexpected failure of

metal parts in production complexes, and here lies mainly the

seriousness of the problem of corrosion. As failure occurred suddenly, it

may lead to significant damage greater than that caused by the expected

erosion. In this regard, we must carefully determine the rates of wear in

the metal parts during the course of the production process, through

[28[
continuous measurements, periodic checks of rates of wear and

continuous examination of metal parts to take preventive measures

before the degree of corrosion reaches the extent that causes production

to stop working or affect the course of the production process.

4- Production pollution: The corrosion products change the chemical

nature of the medium, i.e. its pollution and it is often not desirable as the

commercial requirements are obtaining a pure product with specific

specifications and free from pollution.

5- Safety loss: Corrosion sometimes or often leads to disasters if

preventive measures are not taken to prevent or reduce it, for example

dealing with hazardous materials such as toxic gases such as hydrogen

sulfide gas (H2S) and concentrated acids such as sulfuric and nitric acid,

flammable materials, radioactive materials and chemicals at high

temperatures and when High pressure requires the use of certain mineral

substances that do not corrode significantly under such conditions, For

example, the occurrence of corrosion between gases and acids formed as

a result of interactions with tank surfaces may lead to the collapse of

these tanks and consequently the release of gases as hydrogen sulfide

gas, which leads to economic and human losses, and in many cases the
[29[
 occurrence of corrosion in a small metal part leads to the collapse or fall

of your entire structure, and has caused Corrosion products are

sometimes converted to non-harmful substances into explosives [15].

1.3.8. Project Objective

The main objective of this project is to know the corrosion effect of

Hydrochloric Acid (HCL) on the mechanical properties of minerals, and to
develop effective protection measures for these minerals.

1.3.9. Summary

This chapter covers the definition and causes of corrosion on metals by

Hydrochloric Acid (HCL). It lays down the classification of corrosion, the

damage it causes, the reasons for its study, and the main objective of this

project.

[30[
 CHAPTER 2
LITERATURE REVIEW
__________________________________

[31[
 LITERATURE REVIEW

This chapter outlined the existing literature which is directly relevant to the topic of this

research .

TFH Mohamed , Abed El Rahim and MAM Ibrahim: Studied the Improving the

Corrosion Behavior of Ductile Cast Iron in Sulphuric Acid (Heat Treatment), the

investigation studied appears the effect of heat treatment on the corrosion behavior of

ductile cast iron (DCI) in H2SO4 environment through the tempered specimens at different

tempering times show better corrosion resistance in H2SO4 solution than that without heat

treatment. In the additions the mechanical properties such as tensile strength also appears

positives results. [16]

Zainab Azeez Betti Corrosion-fatigue occurs by the combined actions of cyclic loading and

corrosive environment. The effect of shot peening on cumulative corrosion-fatigue life of

1100-H12 Al alloy was investigated. Before fatigue testing, specimens were submerged in

3.5%NaCl solution for 71 days. Constant fatigue tests were performed with and without

corrosive environment. Cumulative corrosion-fatigue tests were also carried out in order to

determine the fatigue life before and after shot peening. The constant fatigue life was
[32[
significantly reduced due to corrosive environment and the endurance fatigue limit was

reduced by 13% compared with dry fatigue. In case of shot peening the cumulative,

corrosion -fatigue life was increased by a factor of about (2) compared with cumulative

corrosion-fatigue life without shot peening. It was found that the CFLIF% (Cumulative

Fatigue Life Improvement Factor) was about (2-6) due to shot peening surface treatment [17].

Branch, M., & Mahshahr, I. (2012) Corrosion is one of the major problems in the

oil and gas industry is one that automatically allocates huge sums annually. Polyurethane is

a thermoses polymer with various applications. Using form this polymer has spread for

military applications by Otto Bayer in 1930. In one general look polyurethane is product of

Iso Syanate and ploy with each other, So that: Iso + ploy = polyurethane. Spend large cost

for application and launching oil and gas transitions, has cleared the necessity protection

from them agonist corrosion. In this direction protection coating with specific properties

such as high electricity resistance presented to market by various companies that each of

them has special advantage and disadvantages.

In this research has tried while analysis coatings specifications of gas and oil transitional

pipelines, has compared properties and common qualities of them with each other .[18]

[33[
 Lilly, M. T., Ihekwoaba, S. C., Ogaji, S. O. T., & Probert, S. D. (2007)

the corrosion of the external surfaces of such pipelines is a major problem ,which are not

usually adequately safeguarded during construction. A cathodic- protection (CP) system

should be applied to the pipeline before this period.[19]

Wang, X., Qi, X., Lin, Z., & Battocchi, D. (2018) Corrosion and corrosion-induced

damage have resulted mostly in malfunctions and sometimes even in failures of metallic

structures, including oil and gas pipelines. In this study, new high-performance composite

coatings were developed by incorporating nanoparticles in the polymer resins with

applications to oil and gas pipelines. The graphene nanoplatelets under different

concentrations were used to prepare the epoxy-based nanocomposites and were then

evaluated through mechanical and electrical tests. The integration of high-speed disk and

ultrasonication were adopted as the dispersion technique to overcome nanoparticle

agglomeration. Electron microscopy techniques were used to investigate the agglomeration.

The new composites were qualitatively and quantitatively evaluated in terms of contact

angle, surface roughness, adhesion to the substrate, corrosion resistance, and abrasion

resistance. The results suggested that the composite with 0.5~1.0 wt.% of the graphene

nanofillers led to the largest improvement in both mechanical and electrochemical

[34[
properties. Distribution of nanoparticles in the matrix was observed using scanning electron

microscopy and surface roughness using atomic force microscopy. Large agglomeration that

was observed at the higher concentrations mainly resulted in the reduction of corrosion

resistance and abrasion resistance.[20]

Wang, X., Tang, F., Qi, X., Lin, Z., Battocchi, D., & Chen, X. (2019) Corrosion

accounts for huge maintenance cost in the pipeline community. Promotion of protective

coatings used for oil/gas pipeline corrosion control, in terms of high corrosion resistance as

well as high damage tolerance, are still in high demand. This study was to explore the

inclusion of nanoparticle fullerene-C60 in protective coatings for oil/gas pipeline corrosion

control and mitigation.

Fullerene-C60/epoxy nanocomposite coatings were fabricated using a solvent-free

dispersion method through high-speed disk (HSD) and ultrasonication. The morphology of

fullerene-C60 particles was characterized by transmission electron microscopy (TEM), and

dynamic light scattering (DLS). The data analysis indicated that the nanoparticles were

effectively dispersed in the matrix. The performance of the nanocomposites was investigated

through their mechanical and electrochemical properties, including corrosion potential,

tensile strength, strain at failure, adhesion to substrate, and durability performance. Dogbone

shaped samples were fabricated to study the tensile properties of the nanocomposites, and

[35[
improvement of strength, ultimate strain, and Young’s modulus were observed in the

C60/epoxy specimens. The results demonstrated that the C60/epoxy composite coatings also

had improvements in adhesion strength, suggesting that they could provide high damage

tolerance of coatings for engineering applications. Moreover, the electrochemical impedance

spectroscopy (EIS) results generated from the accelerated durability test revealed that the

developed fullerene-C60 loaded composite coatings exhibited significantly improved

corrosion resistance. The nanocomposite with 0.5 and 1.0 wt.% of C60 particles behaved as

an intact layer for corrosion protection, even after 200-h salt spray exposure, as compared to

the control coating without nanofiller in which severedamage by over 50% reduction was

observed.[21]

Ammar, A. U. Shahid& Khan, Z. A. (2018) Coating is one of the most effective

measures to protect metallic materials from corrosion. Various types of coatings such as

metallic, ceramic and polymer coatings have been investigated in a quest to find durable

coatings to resist electrochemical decay of metals in industrial applications.

Many polymeric composite coatings have proved to be resistant against aggressive

environments.

Two major applications of ferrous materials are in marine environments and in the oil and

gas industry. Knowing the corroding behavior of ferrous-based materials during exposure to

[36[
these aggressive applications, an effort has been made to protect the material by using

polymeric and ceramic-based coatings reinforced with nano materials. Uncoated and coated

cast iron pipeline material was investigated during corrosion resistance by employing EIS

(electrochemical impedance spectroscopy) and electrochemical DC corrosion testing using

the “three electrode system”. Cast iron pipeline samples were coated with Polyvinyl

Alcohol/Polyaniline/FLG (Few Layers Graphene) and TiO2/GO (graphene oxide)

nanocomposite by dip-coating. The EIS data indicated better capacitance and higher

impedance values for coated samples compared with the bare metal, depicting enhanced

corrosion resistance against seawater and “produce water” of a crude oil sample from a local

oil rig; Tafel scans confirmed a significant decrease in corrosion rate of coated samples. [22]

Fan, L. (2019) This study is to explore and develop chemically-bonded enamel

coating (200-300 um) on steel pipes, when subjected to soil and thermal environments, in

order to improve the corrosion protection and safety of hazardous liquid and natural gas

pipelines while reducing pressure loss. Out of five types of enamels and their various

mixtures, Tomatec slurry and GP2118 powder were selected for steel pipeline applications.

They were applied at approximately 810 °C to the inside surface of steel pipes in wet and

electrostatic processes, respectively. The thickness and surface roughness of the enamel

coating were measured using a gauge and an optical microscope, respectively. The

[37[
microstructure and porosity of the coating, and coating-steel bond strength were

characterized using scanning electron microscopy and PosiTest, respectively. The corrosion

resistance of enamel-coated pipelines, with and without cathodic protection (CP), is

evaluated using salt spray and electrochemical tests. The stress distribution of enamel-coated

pipes and their susceptibility to stress corrosion cracking (SCC) were studied with finite

element analyses and slow strain rate tests, respectively. The surface roughness of the two

coatings were ~ 1 µm and quite desirable in oil and gas transmission. Small Fe protrusions

grew into each coating to form anchor points with a bond strength of 17 MPa between the

enamel and its steel substrate. The residual thermal stress remained at the coating-steel

interface is 2.5 MPa and thus negligible. Both enamel coatings increased the corrosion

resistance of steel pipes in NaCl solution by three orders of magnitude. CP neither caused

debonding at the coating-steel interface nor accelerated degradation process of the coating.

The more negative the applied CP potential, the more susceptible to SCC the enamel-coated

steel.[23]

Abd El-Lateef H. M. & Ismayilov T. A. (2012) One of the serious problems of oil

extracting industry is the corrosion process. The successful application of carbon steels in oil

and gas pipelines and production tubular in Carbon Dioxide (CO2) containing environments

depends mainly on either the formation of protective corrosion product film or the use of

[38[
corrosion inhibitors. The mechanism of corrosion of carbon steel in media containing CO2

is complex, and in dependence on the prevailing conditions it may lead to general or local

corrosion and corrosion cracking. The inhibition mechanism is attributed to the strong

adsorption ability of the selected inhibitors on steel surface, forming a good protective layer,

which isolates the surface from the aggressive environment.

The current state of research in corrosion protection of steel pipelines against CO2 corrosion

is surveyed. The review covers CO2 corrosion and its inhibition. The influence of inhibitors

molecular structure on corrosion layers in CO2 corrosion is discussed.[24]

Nikitin E., Shumatbaev G., Sinyashin K., & Kazimova, K. (2019) The problem of

corrosion of metal equipment is one of the most actual problems in oil industry. One of the

methods to solve this problem is the development of new low-toxic, accessible and effective

corrosion inhibitors. For this purpose, we carried out the synthesis of the new α-

aminophosphonates based on syntanyl phosphites, formalin and diethanolamine according to

the Kabachnik-Fields reaction. The resulting products are characterized by 1H, 31P, 13C

NMR, IR and mass spectroscopy methods. The obtained compounds contain a long radical

chain of industrial (poly) ethoxylated alcohol residue with different length of the

hydroxyethyl fragment, as well as an active center containing O-P-C-N fragment, which

impart them inhibitory properties toward corrosion processes. The anticorrosive activity of

[39[
the new aminophosphonates was studied by gravimetric analysis method. In the article the

effect of concentration, time and degree of ethoxylation of the hydrocarbon radical in alpha-

aminophosphonates on the protective effect of inhibitors was studies. It was shown that the

obtained aminophosphonates exhibit high values of the protective effect of steel in a highly

mineralized medium containing 250 g/m3 СО2 and 200 g/m3 Н2S. The high value of the

protective effect (82-85%) at inhibitor concentration of 25 mg/l was found. The maximum

protective effect at 50 mg/ml dosage of the inhibitor is 94.3%, while there is a decrease of

the corrosion rate (less than 0.04 mm/year).[25]

Deyab, M. A., Mohamed, N. H., & Moustafa, Y. M. (2017) A wax coating was

prepared using waste materials (isolated microcrystalline waxes) to protect petroleum

pipelines against corrosion in 0.6 M NaCl solution. The corrosion protection performance of

isolated microcrystalline wax coating was detected by electrochemical impedance

spectroscopy (EIS) and open circuit potential (OCP) measurements. EIS spectra confirmed

that the corrosion of carbon steel in 0.6 M NaCl solution significantly inhibited by isolated

microcrystalline wax coating. Positive shift of OCP also indicated that the microcrystalline

wax acts as a protective coating. The effect of temperature on the performance of isolated

microcrystalline wax coating was investigated and discussed.[26]

[40[
 Lervik, J. K., Børnes, A. H., Kulbotten, H., & Nysveen, A. (2004) Application of

AC direct electrical heating (DEH) on subsea pipelines requires a special design of the

corrosion protection system. The first electrically heated pipelines in the North Sea were

supplied with anodes banks at the ends for AC current transfer in addition to single anodes

distributed along the heated pipeline according to CP-design requirements from standards

and class societies. Anodes were also installed at pipejoints where pipes sections with

different magnetic properties are connected, as current transfer between pipe and seawater

will occur at these locations. In case of buried pipelines high temperatures for the anodes

implies reduced cathodic protection. For these installations modified solutions for cathodic

protection are required. Measurements have been made on a scale test installation without

distributed anodes in a project initiated by an oil company. In this case the anode banks at

the ends must be designed both for cathodic protection and AC current transfer to seawater.

For Cr13 (13% Chromium content) pipelines welding of the anode connections should be

avoided related to hydrogen embrittlement. A design with clad steel carbon pipes for the

current transfer zones at the ends where anodes are connected has been chosen to solve this

problem. For economical and practical reasons, the length of the clad steel sections should

be as short as possible. This is especially true for a reeled installation method. It has been

verified by tests that the minimum length of the clad steel section depends on the material

characteristics of both the clad steel carbon pipe and Cr13 pipes. When the magnetic and

[41[
electrical properties of Cr13 pipes are known, carbon steel pipes can be selected to obtain a

minimum current transfer length. These material data are not available from the

manufacturer and must be determined by measurements.[27]

Amir Samimi، Soroush Zarinabadi (2011) proceeds to investigate the reason for

corrosion in steel pipes with three poly ethylene layers, Corrosion in industries is controlled

by one of the following methods.A-Corrosion-resistant alloys, B- Corrosion inhibitors, C-

Stabilization method, D- Corrosion-resistant alloys. First layer Immediately after the pipe

one form of film of liquid or gum of epoxy is created. Minimum dryer thickness must be

between 20-60 micron, Second layer polymer creates adhesiveness between layers 1 and 3

and must be compatible with both layers. Minimum thickness must be between 160-200

micron. Thickness may increase or reduce according to the mutual agreement with customer

but minimum thickness must be investigated safely, Third layerPolyethylene coating must

be formed in this layer. Thickness must be uniform in all through the pipe and minimum

general thickness must be acceptable, they concluded an analysis of reasons for three-

layered poly ethylene coating separation.Good function of coating depends to a high extent

to its adhesiveness rate to metal surface. Initial adhesiveness and its durability in contact

condition are of those factors that result in high efficiency of coating in long term. The

extent of initial adhesiveness has a very high relationship with coating flow and its wetting

when applying coating and also with cleanliness of surface and its readiness. [28]

[42[
[43[
 CHAPTER 3
Experimental Work
________________________________

[44[
 3.1 Introduction
Throughout the present work, the project was conducted on a set of samples (metals) that
were immersed in HCl with different concentrations.

3.2 The Experimental Plan Work Can Be Summarized Below

1. Material selection(metals).

2. preparing selected specimen for experimental work.

3. After diluting the acid, we put each metal separately in the beaker.

4. every Seven days each specimen should be cleaned then compare the original weight

Six types of minerals have been selected (Copper, Brass, Bronze, Ck-45, Stainless
steel, Aluminum), Its mechanical properties such as good mechanical strength,
excellent machinability and high in corrosion strength.

3.3 Preparation of Specimens

The specimens are made according to standard specification 50 mm (length) 10

mm dimeter, Figure (3-1).

[45[
 Fig. (3-1): shape of Specimen

The preparation of specimens is made by (CNC) machine in – northern – technical

university – mechanical workshop.

The figure below explains the machine that used in the preparation of specimens.

[46[
 Fig. (3-2) CNC Machine.

In the next step after the specimens are prepared, the specimens must be purifying
from calculation and impurities by water to get a pure metal (in general the
substances increasing the weight of the specimens).

The measurement of weight of each specimen is fundamental by accurate balance.

[47[
 Fig. (3-3) Accurate Balance.

3.4 The Preparation of for Hydrochloric Acid Corrosion Test

In this step the specimens will be divided into three groups for each metal (copper,
brass, bronze, ck-45, bronze, carbon steel, and aluminum)

[48[
- The first group will be put in the 5% (HCl) as shown in figure below
-

Fig. (3-4) Shows the Specimens into 5% Hydrochloric Acid (HCl).

[49[
- The second group will be put in the dilute solution 8% (HCl) as shown in
figure (3-6)

Fig. (3-5) Shows the Specimens into 8% Hydrochloric Acid (HCl).

[50[
 - The third group will be put in the dilute 10% (HCl) as shown in figure (3-7)

Fig. (3-6) Shows the Specimens into 10% Hydrochloric Acid (HCl).

For period of twenty-eight days, in every Seven days each specimen should be
cleaned then compare the original weight with the current weight to determine the
loses amount of the weight for each specimen as shown in figures below.

[51[
Fig. (3-7) Measure the weight of the sample after it has been thoroughly cleaned

[52[
Fig. (3-8) Shows the Corrosion of The Specimens.

[53[
 ‫‪CHAPTER‬‬ ‫‪4‬‬
‫‪RESULTS AND DISCUSSION‬‬

‫ــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــ‬

‫[‪[54‬‬
4. Introduction
When metals are immersed in hydrochloric acid (HCl), their behavior and

reactions can vary depending on the specific metal and the concentration of the

acid. This study examined the corrosion behavior of 6 different metals when

immersed in HCl acid. These metals are CK-45, Brass, Carbon steel, 201-stain,

Bronze and Aluminum. Moreover, three different concentrations of Hydrochloric

Acid (HCl) were considered for each metal. The weight of each mineral was

measured after one week, then after two weeks, then after three weeks, and finally

after four weeks. Accordingly, each weight was compared to its original weight

before being immersed in Hydrochloric Acid (HCl).

4.1. Effect of Hydrochloric Acid (HCl) on CK-45

Figure 4-1 presents the variation in CK-45 weight over time after immersion

in Hydrochloric Acid (HCl) acid at three different concentrations. This figure

clearly shows that the weight of CK-45 decreases significantly after one week.

This corrosion behavior occurred at all the concentrations tested. In the second,

third and fourth week, the weight of the CK45 steel decreases, but with a slight

ratio. Therefore, it can be stated that the greatest weight loss occurs within the first

week. Moreover, the maximum loss in weight occurs at 10% of Hydrochloric Acid

[55[
(HCl) in comparison with the other concentrations. The weight of metals can

decrease when they are immersed in hydrochloric acid (HCl) due to a process

called corrosion or dissolution. When a metal reacts with Hydrochloric Acid (HCl),

it can undergo a chemical reaction that results in the formation of metal chloride

salts and the release of hydrogen gas (H2).

[56[
Fig. (4-1) Variation in CK-45 weight over time after immersion in Hydrochloric
Acid (HCl) at different concentrations.

[57[
4.2. Effect of Hydrochloric Acid (HCl) on Brass
Figure 4-2 presents the variation in Brass weight over time after

immersion in Hydrochloric Acid (HCl) at three different concentrations. This

figure shows that the weight of the brass decreases slightly after being immersed in

Hydrochloric Acid (HCl) acid. In contract to the CK-45, there is no big change in

Brass weight with time. This behavior occurred for all the testes concentrations .

Fig. (4-2) Variation in Brass weight over time after immersion in Hydrochloric
Acid (HCl) acid at different concentrations.

[58[
4.3. Effect of Hydrochloric Acid (HCl) on Carbon steel
Figure 4-3 presents the variation in Carbon steel weight over time after

immersion in Hydrochloric Acid (HCl) at three different concentrations. This

figure shows that the weight of the carbon steel decreases significantly within the

first and second weeks. Thus, within the third and fourth weeks the weight

decreases slightly. In general, it can be said that this behavior occurs at all the

tested concentrations of HCl acid.

[59[
 Fig. (4-3) Variation in Carbon steel weight over time after immersion in
Hydrochloric Acid (HCl) at different concentrations.
4.4. Effect of Hydrochloric Acid (HCl) on 201-stain
Figure 4-4 presents the variation in 201-stain weight over time after

immersion in Hydrochloric Acid (HCl) at three different concentrations. This

figure clearly shows that the weight of 201-stain decreases significantly after one

week. This corrosion behavior occurred at all the concentrations tested. In the

second, third and fourth week, the weight of the CK45 steel decreases, but with a

slight ratio. This behavior similar to that happened for Ck-45.

[60[
 Fig. (4-4) Variation in 201-stain alloy weight over time after immersion in
Hydrochloric Acid (HCl) at different concentrations
4.5. Effect of Hydrochloric Acid (HCl) on Bronze
Figure 4-5 illustrates the variation in bronze weight over time after

immersion in Hydrochloric Acid (HCl) at three different concentrations. Along the

tested times, this figure shows that the weight of the bronze decreases slightly after

[61[
being immersed in Hydrochloric Acid (HCl). This behavior similar to that

happened for brass.

Fig. (4-5) Variation in Bronze weight over time after immersion in Hydrochloric
Acid (HCl) at different concentrations.

[62[
4.6. Effect of Hydrochloric Acid (HCl) on Aluminum
acid at three different concentrations. This figure shows that the Aluminum weight

decreases Figure 4-6 illustrates the variation in Aluminum weight over time after immersion in

HCl significantly with passing time for all the tested concentrations. Further, the highest lost in

Aluminum weight accrued within the first week.

Fig. (4-6) Variation in Aluminum weight over time after immersion in

Hydrochloric Acid (HCl) at different concentrations.
[63[
 TABLE 4-1 IMMERSED SAMPLES IN HYDROCHLORIC ACID )HCL( AT (5%).

Metal type weight A week Two Three Four weeks

before later weeks weeks later
immersion later later
CK-45 43.99 42.76 42.69 42.66 42.65
Brass 32.14 32.12 32.08 32.07 32.03
Carbon steel 38.30 38.02 37.16 37.14 37.09
201-stain 36.71 35.38 35.34 35.34 35.33
Bronze 51.71 51.71 51.69 51.69 51.67
Aluminum 14.77 14.04 13.85 13.77 13.70

TABLE 4-2 IMMERSED SAMPLES IN HYDROCHLORIC ACID (HCL) AT (8%).

Metal type weight A week Two Three Four weeks

before later weeks weeks later
immersion later later
CK-45 44.53 44.37 44.32 44.30 44.30
Brass 34.48 34.46 34.43 34.43 34.40
Carbon steel 37.72 37.04 36.86 36.78 36.75
201-stain 39.23 37.80 37.78 37.78 37.77
Bronze 52.15 52.14 52.13 52.13 52.12
Aluminum 13.42 12.50 11.70 11.21 10.86

TABLE 4-3 IMMERSED SAMPLES IN HYDROCHLORIC ACID (HCL) AT (8%).

Metal type weight A week Two Three Four weeks

before later weeks weeks later
immersion later later
CK-45 43.37 40.61 40.48 40.46 40.45
Brass 34.69 34.68 34.65 34.64 34.61
Carbon steel 38.31 37.62 35.53 35.49 35.44
201-stain 36.98 33.96 33.88 33.85 33.80
Bronze 51.24 51.24 51.22 51.22 51.21
Aluminum 12.80 11.61 11.45 11.38 11.31
[64[
 ‫‪CHAPTER‬‬ ‫‪5‬‬
‫‪CONCLUSION AND FUTURE WORKS‬‬
‫ــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــ‬

‫[‪[65‬‬
5.1. Conclusion
This study experimentally examined the corrosion behavior of six different

metals after being immersed in Hydrochloric Acid (HCl) for four weeks. These

metals are CK-45, Brass, Carbon steel, 201-stain, Bronze and Aluminum. Further,

three different concentration was taken into our consideration. These concentration

of Hydrochloric Acid (HCl) are 5%, 8% and 10%. The main conclusion of this

study is listed below:

1- The weight of all considered metals decreased in different ratios after

immersion in Hydrochloric Acid (HCl).

2- The weight loss of each metal increases slightly with increasing

Hydrochloric Acid (HCl) concentration.

3- CK-45, Carbon steel, 201-stain, and Aluminum are the most affected

metals in terms of losing weight after immersion in Hydrochloric Acid

(HCl).

4- Brass and Bronze are the least affected metals in terms of losing weight

after immersion in Hydrochloric Acid (HCl).

5- For CK-45, Carbon steel, 201-stain, and Aluminum, the maximum losses

in weight occurred within the first week.

[66[
5.2. Future works

1- Investigate the corrosion behavior of the metals under consideration after

immersion in a different acid.

2- Study the cumulative fatigue damage under corrosion and laser peening.

3- Study the effects of Shot Peening on corrosion in metals.

[67[
References

*1+ Frankel, G. S. (1998). Pitting corrosion of metals: a review of the critical factors.

Journal of the Electrochemical society, 145(6), 2186.

*2+ North, N. A., & MacLeod, I. D. (1987). Corrosion of metals. In Conservation of

marine archaeological objects (pp. 68-98). Butterworth-Heinemann.

*3+ Charng, T., & Lansing, F. (1982). Review of corrosion causes and corrosion

control in a technical facility. TDA progress report, 42(69), 145-156.

*4+ Evans, U. R. (1951). Stress corrosion: its relation to other types of corrosion.

Corrosion, 7(7), 238-244.

*5+ Sastri, V. S. (2015). Challenges in corrosion: costs, causes, consequences, and

control. John Wiley & Sons.

*6+ Ghali, E., Sastri, V. S., & Elboujdaini, M. (2007). Corrosion prevention and

protection: practical solutions. John Wiley & Sons.

*7+ Mishra, A. K., Ebrahimi, N., Shoesmith, D. W., & Manning, P. E. (2016, March).

Materials selection for use in hydrochloric acid. In CORROSION 2016. OnePetro.

[68[
*8+ Del Angel, G., & Benitez, J. L. (2001). Effect of HCl acid on the

hydrodechlorination of chlorobenzene over palladium supported catalysts. Journal

of Molecular Catalysis A: Chemical, 165(1-2), 9-13.

*9+ Çelik, S., & Ersozlu, I. (2014). Investigation of microstructure and mechanical

properties of friction welded aisi 316 and ck 45 steels. High Temperature Materials

and Processes, 33(2), 161-170.‫‏‬

[10] Heidarzadeh, A., Saeid, T., & Klemm, V. (2016). Microstructure, texture, and

mechanical properties of friction stir welded commercial brass alloy. Materials

Characterization, 119, 84-91.

*11+ Dwivedi, D., Lepková, K., & Becker, T. (2017). Carbon steel corrosion: a review

of key surface properties and characterization methods. RSC advances, 7(8), 4580-

4610.

*12+ Riley, W. D., Dunning, B. W., & Soboroff, D. M. (1985). Spectral characteristics

of grinding sparks used for identification of scrap metals (Vol. 8932). US

Department of the Interior, Bureau of Mines.

[69[
*13+ Jia, J. H., Chen, J. M., Wang, J. B., & Zhou, H. (2004). Friction and wear

properties of bronze–graphite composite under water lubrication. Tribology

International, 37(5), 423-429.

*14+ Ehrenreich, H., Philipp, H. R., & Segall, B. (1963). Optical properties of

aluminum. Physical Review, 132(5), 1918.

[15] https://petro.yoo7.com/t7090-topic

[16]- TFH Mohamed, SS Abdi El Rahim and MAM Ibrahim,Improving the Corrosion
Behavior of Ductile Cast Iron in Sulphuric Acid by Heat Treatment Chemistry
Department, Faculty of Science, Ain Shams University, Abbassia, Cairo, Egypt.

[17]- Zainab Azeez Betti 2014, Interaction of Corrosion-Cumulative Fatigue and

Shot Peening of 1100-H12 Aluminum Alloy University of Technology.
[18]- Branch, M., & Mahshahr, I. "Use of polyurethane coating to prevent corrosion
in oil and gas pipelines transfer". International Journal of Innovation and Applied
Studies, 1(2), 186-193,(2012)..

[19]- Lilly, M. T., Ihekwoaba, S. C., Ogaji, S. O. T., & Probert, S. DProlonging the lives
of buried crude-oil and natural-gas pipelines by cathodic protection. Applied
energy, 84(9), 958-970,(2007).
.
[20]- Wang, X., Qi, X., Lin, Z., & Battocchi, D"Graphene Reinforced Composites as
Protective Coatings for Oil and Gas Pipelines. Nanomaterials" (Basel,
Switzerland), 8(12), (2018).

[21]- Wang, X., Tang, F., Qi, X., Lin, Z., Battocchi, D., & Chen, X. Enhanced Protective
Coatings Based on Nanoparticle fullerene C60 for Oil & Gas Pipeline Corrosion
[70[
Mitigation. Nanomaterials (Basel, Switzerland), 9(10), (2019).

‫‏‬
[22]- Ammar, A. U., Shahid, M., Ahmed, M. K., Khan, M., Khalid, A., & Khan, Z. A.
"Electrochemical Study of Polymer and Ceramic-Based Nanocomposite Coatings for
Corrosion Protection of Cast Iron Pipeline Materials" (Basel, Switzerland), 11(3),
(2018).

[23]- Fan, L. "Chemically-bonded enamel-coated steel pipelines for corrosion

protection and flow efficiency", (2019).

.[24]- Abd El-Lateef, H. M., Abbasov, V. M., Aliyeva, L. I., & Ismayilov, T. A.
"Corrosion protection of steel pipelines against CO2 corrosion-a review",Chemistry
Journal, 2(2), 52-63,(2012).

[25]- ‫‏‬Nikitin, E., Shumatbaev, G., Terenzhev, D., Sinyashin, K., & Kazimova, K. "New
α-aminophosphonates as corrosion inhibitors for oil and gas pipelines
protection". Civil Engineering Journal, 5(4), 963-970,(2019).

[26]- Deyab, M. A., Mohamed, N. H., & Moustafa, Y. M. "Corrosion protection of

petroleum pipelines in NaCl solution by microcrystalline waxes from waste
materials Electrochemical studies. Corrosion Science", 122, 74-79,(2017).

[‫ ‏‬27]- Lervik, J. K., Børnes, A. H., Kulbotten, H., & Nysveen, A. "Design of anode
corrosion protection system on electrically heated pipelines". In The Fourteenth
International Offshore and Polar Engineering Conference. OnePetro,(2004, May)..‫‏‬

[28]- Amir Samimi ، Soroush Zarinabadi,"An Analysis of Polyethylene Coating

Corrosion in Oil and Gas Pipelines" .Journal of American Science; 7(1):1032-1036,
ISSN: (1545-1003) ،) 2011).

‫‏‬

[71[