§1. Military design liability and the V-22 Osprey [00:01]
Going to Congress — actually not the Congress, the Supreme Court — decided that military technology is cutting edge, and so there's always a hazard and you cannot sue the manufacturer for a design defect, because the military is considered to be the designer of every piece of military hardware. I can't remember what they call this principle. But in 1992 the Supreme Court ruled that you can't sue Pratt and Whitney for an engine design defect. You can sue them for a manufacturing defect, but you can't sue them for a design defect, because NAVAIR or the Air Force had huge design teams of all these PhD scientists who worked for the government, and Pratt and Whitney would come in and give a presentation — or Boeing if it's an aircraft airframe — and the government would approve it. So therefore the government approved the design, and you can't sue the government. When you signed up, you sign up for hazardous duty, right?
That's not to say you can't get something. I worked on the V-22 Osprey that crashed at Quantico, Virginia. Ship four. There were four military on there and a bunch of civilians. If I remember, Boeing and Bell settled with the military people right away. But the civilians all filed suit anyway. It's a mess, but it finally went to trial, and we can talk about that some other time. It doesn't have to do with corrosion. Just make sure you understand that as military officers, your lives are worthless, okay, at least from a business point of view. But you can eject, and if you survive the ejection you're fine.
Student: Like you said, planes are expensive, so I'm just surprised that they would even consider a single engine.
Well, the engines are — depending on the aircraft — in a military jet the engines are probably more than fifty percent of the cost of the plane. In a commercial jet it's probably twenty, twenty-five percent of the overall acquisition. It depends on the aircraft too, but the engine is going to go for five or ten million on a 747 now. And the nacelle that holds the engine on goes for five million. So if you got four engines, there's sixty million dollars on a 747 which cost about two hundred million — you're talking a third of the cost roughly. On a military jet the engines actually go for even more.
§2. Why military and commercial jet engines diverged [03:10]
One of the problems — and this is really getting into a digression from corrosion — is about twenty or thirty years ago, development of military jet engines and development of commercial engines diverged. Anybody know why? Because they were looking for fuel efficiency in the commercial area. A fifty degree Fahrenheit increase in the operating temperature of a commercial jet engine will save just U.S. airlines fifty billion dollars a year in fuel. That's a lot of money. That's why they're always talking about fuel economy, and they retire engines and look for the latest engines which are more fuel efficient.
In order to get high fuel efficiency, they decided to go to what's called the high bypass jet engine. So there's two equations: one-half mv squared, and the momentum equation, mv. The old jet engines, which are still the military engines, were just a long tube — whatever came in with a certain amount of mass went out the back with the same mass, only it had a much bigger velocity. So a lot more energy, and the energy came from burning the fuel. But the actual thrust-to-weight ratio is momentum. The problem with momentum is you didn't have a lot of mass going through this little tube. So they came up with a high bypass and put these big fans around it. You see this on a commercial jet — engines that are ten feet in diameter. The basic core engine is still in there, but the engine is now driving these fans, which are pulling another mass, a bigger mass. So you get lots of high velocity with a little m through the core, but you get lots of mass with a little v by the fans, and now you get tremendous thrust and tremendous efficiency.
The problem is you can't do this with a supersonic engine, and the military engines want to go above the speed of sound. Commercial engines will go above the speed of sound, but the military engines still are basically the core. They're inherently fuel inefficient, because they want to break the sound barrier. What's the solution? It turns out you can't run modern engines without a computer. The computer is changing parameters in that engine a thousand times a second or faster. The airfoils that control a modern military aircraft — when you're going Mach 1 and a half and you want to take a right turn, no human could respond to all the control surfaces, so you have computers running those control surfaces. A lot of the plane designs now are inherently unstable, just like a submarine going through the water. We won't talk about the fact that the deeper you are, the slower you have to go, because if you go unstable and go deeper than you're supposed to go, it's not a good thing in a submarine.
Same thing in a jet engine. If all of a sudden one of the control surfaces sends you in another direction you didn't want to go, it's not a good thing. When you're going Mach 1 and a half and you take a ninety degree turn, the g forces were such that the pilot will pass out. In fact that's one of the problems: the F-22 and the F-35 can do maneuvers that the pilot cannot take above about eight or nine g's. The blood doesn't get to the brain anymore. The heart is not strong enough to pump it. Because of that, the solution is drones — pilotless aircraft — which should be one of the solutions for the Navy to think of: ships without people.
Student: I'm sure they are.
Well, you have underwater autonomous vehicles. But do you realize what it costs to build a submarine or a surface ship that has to accommodate all these people and their dietary needs and their other needs — to take showers and drink water? If you take the people off, and not only that, they won't die. Those people in Tampa that are fighting the war in Afghanistan, they go home regular time, and someone else takes over. These other guys marching through FOBs, that's not fun at all, but in Tampa it's not so bad.
Some of this technology is actually pretty neat. But that's another one of my diversions — the problems with war. The one war that probably wiped out more of the population of the country than virtually any other war was the U.S. Civil War. We were killing each other and we did it very effectively. If you got wounded, you were a dead man. Medicine couldn't save you. You just bleed to death.
Then World War One was the war to end all wars, and World War Two. But as we've gone along, casualties have become less and less acceptable. When I was actually younger than you, it was the Vietnam War, and they would publish the body count every day, every week, on the front page of the paper. It'd be like a hundred soldiers a day dying in Vietnam. By the time of the Gulf War, we got to the point where it's unacceptable to have U.S. casualties. And now we get to Afghanistan and it's unacceptable to have the enemy casualties. Wait a second — what is war about? You know what Clausewitz said, right? War is extension of politics by other means. I did take ROTC, that's what I learned about the philosophy of war. It's best not to fight wars, it's cheaper too.
§3. The cost of corrosion as a fraction of GNP [10:14]
I just happened to get this book — it arrived after class yesterday — on cathodic protection. I'm sure you all are busy purchasing books like this. It says that the first study on the cost of corrosion was done in 1976, and they found it cost the U.S. seventy billion dollars in 1976, somewhere between three and a half and four and a half percent of the country's gross national product. They redid the study in 1982 and it was a hundred twenty-six billion. By 1991 it was two hundred seventy-six billion. If you calculate that, it's higher than the inflation rate. What it is — lies, damn lies, and statistics — they were including other things. For example, they assume that every automobile that's junked is junked because of corrosion. That's not necessarily true. A lot of them are junked because they're totaled in a crash. That's not corrosion.
However, they've done two studies, one by NIST and one by the National Association of Corrosion Engineers, and they both came up with corrosion costs about 4.2 to 4.9 percent, plus or minus thirty percent statistics, of the gross national product. If it is about five percent of the gross national product, what's that today? The gross national product is about fifteen trillion. So five percent of that is seven hundred fifty billion. Now do you believe that's the cost of corrosion? Neither do I. But that's what the National Association of Corrosion Engineers will tell you. They'll do whatever they do to inflate the numbers, because it's in their best interest. But corrosion does cost a lot of money. The main principle: metals don't want to be metals by nature, so they will go back to their original state over time. The way they do it is by corroding. Corrosion, if you look in the dictionary, is the chemical degradation — it's a slow chemical process. For a corrosion engineer, it's the degradation over time of metals.
§4. Three Mile Island: stress corrosion versus stress-assisted cracking [12:43]
Then you get into questions like Three Mile Island — the sister reactor at Three Mile Island, where they wanted to restart that nuclear reactor. They started up the steam generator. There's a type of acid that you can't produce regularly in the laboratory, but under the high pressures and the startup temperatures, with some sulfur contamination, you get polythionic acid. It's a polymerized sulfur compound. This nickel-based superalloy heat exchanger on reactor 2 — not the one that had all the problems, but they were trying to restart it so it could generate electricity a couple years after Three Mile Island — they started it up, and within a half an hour they had stress corrosion cracks, and it cost them thirty million dollars to repair.
The fundamental question for the insurance carriers was: if all the damage was done in a half an hour, was that a slow process? Was that corrosion? The first press releases to come out of Three Mile Island, from GPU Nuclear which was the utility, the first day and a half they called it stress corrosion cracking, SCC. By the time the attorneys had gotten hold of it, they called it stress-assisted cracking, because the attorneys looked at their insurance contract which excluded corrosion — because corrosion is just a slow gradual wearing away. They knew that if they called it stress corrosion cracking, the insurance company was going to deny the thirty million claim. If they could change the name and call it stress-assisted cracking — well, what cracking is not stress-assisted? You start getting into the story about lawyers. You can go back to the Bible and see what the Bible says about lawyers. But in any case, that's what they do.
§5. Black iron pipe and the magnetite protective coating [14:47]
The second point from yesterday: metals may possess immunity, or we called it nobility, or they can have practical nobility, which means they've got a coating of some sort of protective oxide or something else. To give you an example of something that has a protective oxide — anybody know what this is? [Tom holds up a length of pipe.] Some of you must be mechanical engineers. You should call this a pipe nipple. It's threaded on both ends. Bought it at Home Depot, cost me like a buck. Three-quarter inch by six, black nipple. Why is it a black nipple? Because it's got a coating of Fe₃O₄, magnetite, on the surface. When you heat up steel to above about five or six hundred degrees Fahrenheit — and this thing gets to temperatures of eight or nine hundred degrees when they're forming it in the steel mill — it will form, not Fe₂O₃ which you know as rust, but Fe₃O₄ which is called magnetite. It's slightly magnetic. Ever play that little game with the magnets where you put the mustaches and the beards on the little figures? That's magnetite. That's another use for magnetite.
Black iron pipe has its own inherent coating. If you go down to the basement of MIT and look up, you'll see the fire sprinkler system, and it's black iron pipe. You can tell it's a fire sprinkler system because the couplings are either orange or red — you've seen these Victaulic-type couplings that have gaskets. You probably have similar types of things on board ship. It's black iron pipe. They don't do anything other than just take the regular mill finish — although this one someone put varnish on, which doesn't hurt it. And that keeps it from corroding. How come rust is not protective, Fe₂O₃? Because it flakes off. Rust is flaky.
If you can keep a protective coating on something, you can actually get pretty good protection. This comes out of one of these marine books that I showed you yesterday, and it shows what happens to the corrosion rate in millimeters per year versus exposure time in days. A year is right about in here. If you have attached rust, the corrosion rate is on the order of a tenth of a millimeter per year. What's that in inches? You're Canadian, you know the metric system. A millimeter is forty thousandths of an inch, so a tenth of a millimeter is four thousandths of an inch. I did that calculation in my head. That is the typical corrosion rate for steel in the atmosphere, or in lots of other humid or moist environments. This happens to be sea water, and it was probably painted — but where the paint was worn away, it did rust at about four thousandths of an inch per year. That is a good general rule of thumb for the corrosion rate of steel in water.
The numbers I use are typically 0.002 to 0.010 inches per year — two to ten thousandths of an inch per year. Sometimes people come to me and say, oh, we had this piece of black iron pipe which is about an eighth of an inch thick and it corroded through in one year. And I said, no it didn't. It should last ten years even in a very severe ten-thousandths-an-inch environment, and at four thousandths of an inch per year it should last about twenty-five years. Those of you who have been aboard ship and you have carbon steel piping, how long does it last? About twenty-five or thirty years before you really need to get rid of the whole thing. That used to be the limiting lifetime on ships. But then someone at NAVSEA said, oh, we need ships that will last fifty years, because we can't afford to replace them so often.
§6. Material substitutions for shipboard piping [19:20]
I'm not sure if the person understood what happens to carbon steel, but eventually they learned that the carbon steel is worn out after twenty-five or thirty years. So they replaced it with — you've been at the shipyards — what types of metals are they replacing the carbon steel piping with?
Student: They might be on some of the modern ships that are mostly aluminum ships.
Aluminum actually is what we build most sewage treatment plants out of. Aluminum has very good long-term corrosion resistance — not so much in good water — but on nuclear subs, they first went to cupro-nickel, Monel. Now they're into titanium.
Student: Depends on what the piping system is.
You don't think — what?
Student: Well, in my experience in submarines, if the system is built one way it's pretty much going to stay that way. I know some of the seawater systems have gone titanium, in some of the more specialized builds.
They are using a lot more titanium than they were forty years ago, believe me. Forty years ago they just assumed you scrapped the ship after thirty years, and they would go with the lowest cost, which was carbon steel. Even on subs and critical systems like the reactor systems, they would use cupro-nickel or Monel in critical systems — but there's a lot more titanium in piping now than there used to be. There was no titanium twenty years ago in piping on ship in general. The problem is — and you all know this — titanium, as fabricated, you don't have to use something as thick if you don't need the pressure, but the cost is still a factor of ten, twenty, or thirty times carbon steel.
Student: We saw in one of your slides yesterday that sewage systems are very susceptible to corrosion. So how come we don't use plastic piping on ship or something for that?
Well, there's a couple of reasons. Can I hold that just a second until I finish? If you look at the top of this, it's up in the shear strake region — the top part of the ship where it's bowing from bending — and the rust is flaking off. It's the detachment of the partially protected rust.
§7. The history of polyethylene and the hula hoop [22:00]
So why haven't we switched to plastic? We have been switching to plastic. It turns out plastics are sort of a recent development. The history of polyethylene, which is one of our most common plastics and one of our cheapest plastics — polyethylene really didn't exist in World War Two. They knew about it but it wasn't a commercial development.
In the 1950s, one of the big plastics companies tried to build a plant because they could. They decided they were going to be able to produce hundreds of millions of pounds of polyethylene every year. They started producing it, but they didn't really have a market. Their original manufacturing quality was variable. They tried to take it to somebody and say, why don't you use this for plastic pipe. Because it's easy to extrude, you form everything at temperatures you hardly burn yourself in the plant. Well it turns out, all the production trials they were running, they couldn't sell their junk because it had no consistency. They hadn't come down the learning curve of manufacturing to get consistent quality.
Then a magic thing happened. Someone thought of an application for all these fifty million pounds of scrap polyethylene that was sitting there. It was called the hula hoop. It had no real requirements other than that it be a round tube, and it could be made in different colors. In the 1950s the hula hoop became the big craze. Anybody ever used a hula hoop? Well, all of a sudden they were able to sell their fifty million pounds of polyethylene, and start producing more polyethylene, and over time they learned to make it a better quality.
§8. Polybutylene, Delrin, and the exploding toilets [23:50]
The problem with polyethylene is at about a hundred forty or a hundred fifty degrees Fahrenheit it will creep, it will bulge, it will get an aneurysm, and it will explode on you — or you know, it'll burst and you'll have a flood. So people tried better things like polybutylene, a longer chain hydrocarbon. They put that in lots of houses. Anybody ever have a house that had polybutylene fittings? Yeah, what happened?
Student: PEX?
No, PEX is cross-linked polyethylene. I'll talk about that in a second. That was what I was looking for, a piece of PEX. PEX tubing is fine. Some people are blaming the fittings. There's a billion dollars worth of lawsuits out in Las Vegas and the West Coast on PEX brass fittings, but that's another story. It's a corrosion problem called de-alloying. Maybe we'll talk about it when we get to dealloying-type attack. But anyway, they put in polybutylene, and the fittings are susceptible to stress corrosion cracking. So I talked about metals being energetically unfavorable — they want to go back to nature. If I went back thirty, forty years ago, people said, oh, plastics don't corrode. Ceramics don't corrode. Well, that's not true. They corrode by different mechanisms. Metals corrode by going back to their oxide or their sulfide. Plastics can degrade, and this is not necessarily by a chemical process.
Maybe the corrosion engineers were right, as they started getting into the degradation of these other materials. You can have separation, you can have cracking. The polybutylene fittings started cracking. People had mold growing in their walls because they'd start leaking. I had a daughter who about 1998 bought a condo down in Raleigh, North Carolina, and it had polybutylene. She knew about it, and she got in just under the wire of the class action suit, and they paid her twenty-five hundred dollars to have all the fittings replaced. It's not the end of the world, but they don't use polybutylene because it stress corrosion cracks in certain types of water.
One of the best stories about plastics corroding was DuPont came out with something called Delrin, which is polyformaldehyde — it's called acetal, but basically it's polyformaldehyde. Formaldehyde's one of the simplest hydrocarbons. I think it's CH₂O, you can Google it. If you polymerize this, you can make a ten thousand psi plastic which is very strong, easy to injection mold. DuPont came out with a paper in like 1958 that tested polyformaldehyde in two hundred different solvents, and it was resistant to all these chemicals, and this was the plumbing material of the future.
In 1962, some Germans did a study and showed that over the long haul, at the types of stresses you had, you would get a form of stress corrosion cracking in polyformaldehyde with small amounts of chlorine. So about fifteen or twenty years later, Hoechst paid a nine hundred million dollar class action settlement for Delrin failures. They didn't call it Delrin, their trade name was different. DuPont paid an even bigger settlement, well over a billion, but it's confidential how much they paid in their settlement for Delrin.
The problem with Delrin is a little bit of chlorine. How much chlorine? Ten years ago if you went to the DuPont website and looked at the materials it was resistant to — oh, by the way, the 1958 paper, the one solvent they didn't test the material in was water. They actually never tested it in water. They tested all these organics, and they figured the water wouldn't corrode it — this was the plumbing material of the future. Ten years ago you went to the DuPont website, looked at Delrin and said water, and it said corrosion resistant. With an asterisk: less than half part per million.
Now, how much chlorine is in the Cambridge water this morning, if you want to make coffee? It's basically rain water, but it comes out of Fresh Pond up here since the 1640s, and it has five or ten ppm chlorine. Really good water in the Northeast will be five or ten ppm chlorine — and DuPont says it's corrosion resistant to something that is ten times better than some of the better potable water. The EPA says you can have up to a hundred parts per million chlorine and it's still potable water. So if you're in San Antonio or Las Vegas, you could have seventy, eighty, ninety parts per million chlorine. Delrin is not so good.
What do they make out of Delrin? They had the little water closet valves. You flush the toilet and it fills up with the float and then it shuts off. They were making those things out of Delrin. After about two or three years, the chlorine in the water would cause the Delrin to turn into a brittle plastic, full of little cracks. They had what they called the exploding toilets. When this thing would let go, the sixty psi water pressure would hit the little ceramic top of your water closet, and it would blow off. It wasn't really an explosion. It wasn't a release of gas pressure. It was water pressure knocking the top off, and it was ceramic, it fell to the ground. You'd hear the crash of the breaking top, and then you'd have a flood in your home. People would hear this loud noise which they called an explosion. So you had what they called exploding toilets back in the 1980s from Delrin.
§9. PEX and crosslinking [30:43]
Plastics do corrode, many times in very subtle ways. Some plastics will stress corrosion crack in very clean water, nearly pure water. Water can attack plastics. Same thing with ceramics. They often want to use ceramics at very high temperatures, like in some engine part. Well, sulfur compounds just destroy ceramics in general. These other things do corrode. Environmentally they degrade rather than corrode. But why don't they use PEX? PEX is cross-linked polyethylene, and there are two types of PEX. There's PEX-A and PEX-B. PEX-B is electron beam polymerized.
Remember Charles Goodyear and sulfur and putting it in latex and making rubber? That's how he learned how to make rubber in the 1830s, by putting sulfur in with the latex, and the sulfur would create crosslinks between the long polymer chains. I'm not getting a lot of nods here of remembering Charles. Charles Goodyear got a patent on it, but that's because he didn't know that the ancient Mayans actually used a vine that had natural sulfur compounds. They would mix that, and so their rubber ball — they used to play this game over miles and miles with this rubber ball. Mike Tarkanian, who runs the lab over here, for his bachelor's thesis was the one who rediscovered the fact that the Mayans from thousands of years ago used the morning glory vine, a type of morning glory that had natural sulfur compounds. They mix it with the rubber and they get crosslinking.
You've got these polymer chains, which in polyethylene is basically just C with a bunch of H's. So you got a backbone of carbon — it could be ten thousand carbons long — with hydrogen, and at the end you have to have another hydrogen. The formula is Cₙ H₂ₙ₊₂. For every carbon you got two hydrogens, and you have to have a hydrogen on the ends, both ends, so it's 2n plus 2. That's the formula for polyethylene. It has the exact same formula as paraffin wax. One way to tell if something is polyethylene is you take a little piece, you burn it, and see if it smells like a candle. This is actually one of the scientific tests for polyethylene. You need to understand these sophisticated tests we use in the world.
PEX-A, they basically get crosslinking by hitting it with electron beam, which breaks some of these bonds, and you can actually get links — now you have a carbon coming off this way and this way. You can only have two carbons at a time, but you can have crosslinks with carbon, and you get the same type of thing as taking latex and vulcanizing it. They can do it with an electron beam, or they can do it chemically where they add compounds that help break down some of the polymer chains. Here they're just using a lot of energy to break the polymer chain and hope that it reforms, and it does. This is made by a company called Uponor, this is made by almost everybody else. Now you have enough strength in all directions, and these things don't just burst on you.
The best anyone knows on the PEX, which has been in service for about twenty-five years now, it shows no evidence of deterioration. The PEX will probably last about a hundred years or more. That's the best estimate right now. People are complaining about the brass fittings, but we'll talk about that when we get to the alloying. In fact that's why people like it — you don't have to use much copper. I mentioned yesterday some people are tearing the copper out of their homes to sell the copper and putting PEX back in. So they're taking the investment value in their home, the copper pipes, and replacing it with PEX.
The problem is, some attorneys in Las Vegas got about a quarter billion dollar settlement for corrosion of some of the brass fittings, and so now there's a feeding frenzy by attorneys claiming this causes leaks, except no one's ever seen one of the leaks. They do get corrosion in Las Vegas. Water is not the best water in the world. You can drink it, but it's not good for your pipes. That's another story.
§10. Protective scales and the need for oxygen or sulfur [36:22]
So the point here is the scales can be protective. We sometimes put on artificial scales which are called paint, or galvanizing, which will try to protect things from corrosion. That's general corrosion protection. The next thing about corrosion — third point — is you need free oxygen or sulfur to get corrosion. That's the way it's found in nature. If you're going to have a metal corrode you need some free oxygen. What do we do to prevent that? Let me put it this way: if I have black iron pipe, I can make my boiler system, my heating system of my home out of black —