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William HawkesGraduate Diploma: Spring Term: 2013-2014.
Conservation Of MetalworkWord Count: 2912
Describe the principle mechanisms of the oxidization andcorrosion of ferrous and copper alloy objects, and explain how
storage and display environments affect this. Identify anddiscuss two case studies demonstrating the good and badeffects of long-term storage and /or display of ferrous or
copper alloy objects.
William HawkesGraduate Diploma Spring Term 2013-2014.Conservation Of MetalworkWord Count:
Corrosion is the deterioration of any metal as a
result of chemical reactions between it, and the
surrounding environment. This subject cannot
possibly covered in any detail due to the
restrains of this paper, but this is a brief
overview of the principles involved
This paper will discuss what corrosion is, how it
occurs and its varying types. Finally this paper
will look at the ways in which the environment
can affect metals and how we can control
corrosion.
Corrosion and the environment:
Some metals occur naturally in the metallic state
and are stable under normal conditions (room
temperature and in fresh air), while others will
rapidly tarnish and corrode on exposure to air.
The ease, with which metals will react and form
compounds, by giving up some of their electrons,
is often expressed by their electrode potential
(E°). Metals with a high positive value are
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William HawkesGraduate Diploma Spring Term 2013-2014.Conservation Of MetalworkWord Count:
stable and it may even be difficult to form
compounds with these metals, while those with a
high negative value will react spontaneously
(Dungworth, 2012).
Table 3: Electrode Potentials of Common Metals:Name (symbol) (E° (v))
Gold (Au) +1.50
Mercury (Hg) +0.85
Silver (Ag) +0.80
Copper (Cu) +0.34
Antimony (Sb) +0.10
Lead (Pb) - 0.13
Tin (Sn) - 0.14
Iron (Fe) -0.44
Arsenic (As) - 0.68
Zinc (Zn) - 0.76
As can be seen in the fabrication of iron
objects, the flash corrosion of the surface is a
result of the iron having a relatively high
negative electrode potential. In an indoors
environment, this oxide layer on the surface of
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William HawkesGraduate Diploma Spring Term 2013-2014.Conservation Of MetalworkWord Count:
the metal is what stops further corrosion. This
layer is usually stable at room temperature and
at a Relative Humidity (RH) of 65% or less.
However when the RH goes above the 65% mark, a
layer of active corrosion, which is bright
orange, friable and considered active, quickly
forms. This corrosion product is usually
lepdiocrosite (Selwyn, 2004).
Galvanic Cell Reactions:
When we consider the corrosion of copper or iron,
the reactions we see the results of, in the form
of corrosion products, are galvanic cell or
electrochemical reaction. As in all chemical
reactions, corrosion reactions occur through an
exchange of electrons.
In electrochemical reactions, the electrons are
produced by a chemical reaction in one area, the
anode area. The electrons travel through a
metallic path, usually the parent metal, and are
consumed through a different chemical reaction in
another area, the cathodic area.
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William HawkesGraduate Diploma Spring Term 2013-2014.Conservation Of MetalworkWord Count:
Anodic Reactions.
The generic chemical reaction for this metal loss
at anodic sites is:
M- M+ + e-
Where M is an uncharged metal atom at the metal
surface, M+ is a positively charged metal ion in
the electrolyte and e- is an electron that
remains in the metal.
This type of chemical reaction is called metal
oxidation, even though it does not directly
involve oxygen, but only results in an increase
in positive charge on the atom undergoing
oxidation or loss of electrons. This resultant
ion is dissolved into the water.
More than one electron can be lost in the
reaction, as in the case of iron where the most
common anodic reaction is:
Fe- → Fe2+ + 2e-
Where Fe is metallic iron. Fe2+ is a ferrous ion
that carries a double positive charge.
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William HawkesGraduate Diploma Spring Term 2013-2014.Conservation Of MetalworkWord Count:
Cathodic Reactions.
The electrons that are produced at anodic sites
are consumed at cathodic sites. The type of
chemical reactions that consume electrons are
called reduction:
One of the most common cathodic reactions is the
reduction of oxygen:
O2 + 4e- + 4H2O- → 4OH-
Further to this, the four OH- ions are free in
the water to combine with the Fe2+ ions to form
Fe(OH)2 following the equation:
Fe2+ + OH- →Fe(OH)
This whole process can be seen in the following
diagram (diagram 1) where the end product is iron
hydroxide, or what we commonly call “rust”.
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William HawkesGraduate Diploma Spring Term 2013-2014.Conservation Of MetalworkWord Count:
Diagram 1: Galvanic reaction with water as the
solvent. (1)
Types of corrosion:Corrosion comes in many different forms and can
be classified by the cause of the chemical
deterioration of a metal:
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William HawkesGraduate Diploma Spring Term 2013-2014.Conservation Of MetalworkWord Count:
1. General Attack Corrosion
“General attack” corrosion on a capstan. (1)
This is the most common type of corrosion and
is caused by a chemical or electrochemical
reaction that results in the deterioration of
the entire exposed surface of a metal.
Ultimately, the metal deteriorates to failure.
General attack corrosion accounts for the
greatest amount of metal destruction by
corrosion, but is considered a “safe” form of
corrosion, due to the fact that it is
predictable, manageable and often preventable.
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William HawkesGraduate Diploma Spring Term 2013-2014.Conservation Of MetalworkWord Count:
2. Localised Corrosion:
Crevice corrosion in steel (2)
Localised corrosion specifically targets one
area of the metal structure. Localised
corrosion is classified as three types:
Pitting: Pitting results when a small cavity,
forms in the metal, usually as a result of
“de-passivation” of a small area. This area
becomes anodic, while part of the remaining
metal becomes cathodic, producing a localised
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William HawkesGraduate Diploma Spring Term 2013-2014.Conservation Of MetalworkWord Count:
galvanic reaction. The deterioration of this
small area penetrates the metal leading to
failure. This form of corrosion is often
difficult to detect due to the fact that it is
usually relatively small and may be covered,
hidden by corrosion products
Crevice corrosion: Crevice corrosion also
occurs at a specific location. This type of
corrosion is often associated with a stagnant
microenvironment, like those found in the low
points of sculptures. Acidic conditions, or a
depletion of oxygen in a crevice can lead to
crevice corrosion.
Repousse low points can form a microenvironment in which
crevice corrosion occurs (3).
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William HawkesGraduate Diploma Spring Term 2013-2014.Conservation Of MetalworkWord Count:
Filiform corrosion: Occurring under painted
or plated surfaces when water breaches the
coating, filiform corrosion begins at small
defects in the coating and spreads to cause
structural weakness.
3. Galvanic Corrosion:
Galvanic corrosion occurs when two different
metals are located together in a corrosive
electrolyte. A “galvanic couple” forms between
the two metals, where one metal becomes the
anode and the other the cathode. The anode, or
sacrificial metal, corrodes and deteriorates
faster than it would alone. The cathode
deteriorates more slowly than it would
otherwise.
Three conditions must exist for galvanic
corrosion to occur:
Electrochemically dissimilar metals must be
present such as copper together with iron
The metals must be in electrical contact, and
The metals must be exposed to an electrolyte
like water.
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William HawkesGraduate Diploma Spring Term 2013-2014.Conservation Of MetalworkWord Count:
Galvanic corrosion is discussed under “Galvanic
cell reactions” see above.
4. Environmental Cracking:
Environmental cracking in steel sheet (4)
Environmental cracking is a process that
results from environmental conditions
affecting the metal. Chemical, temperature and
stress-related conditions can result in the
following types of environmental corrosion:
Stress Corrosion Cracking
Corrosion fatigue
Hydrogen-induced cracking
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William HawkesGraduate Diploma Spring Term 2013-2014.Conservation Of MetalworkWord Count:
Liquid metal embrittlement
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William HawkesGraduate Diploma Spring Term 2013-2014.Conservation Of MetalworkWord Count:
5. Flow-Assisted Corrosion:
Flow assisted corrosion in a textured sheet of steel (5)
Flow-assisted corrosion, or flow-accelerated
corrosion, results when a protective layer of
oxide on a metal surface is dissolved or
removed by wind or water, allowing the metal to
further corrode and deteriorate. Also known as:
Erosion-assisted corrosion
Impingement
Cavitation
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William HawkesGraduate Diploma Spring Term 2013-2014.Conservation Of MetalworkWord Count:
6.Inter-granular corrosion:
A microscopic image of inter-granular corrosion (6)
Inter-granular corrosion is an electrochemical
attack on the grain boundaries in metal. This
often occurs due to impurities in the metal,
which tend to be present more often near grain
boundaries. These boundaries are more
vulnerable to corrosion than the actual crystal
of the metal.
9.De-Alloying:
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William HawkesGraduate Diploma Spring Term 2013-2014.Conservation Of MetalworkWord Count:
De-alloying, or selective leaching, is the
selective corrosion of a specific element in an
alloy. The most common de-alloying is “de-
zincing” of brass. The result of this is a
deteriorated and porous copper.
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William HawkesGraduate Diploma Spring Term 2013-2014.Conservation Of MetalworkWord Count:
9. Fretting corrosion:
Fretting corrosion in metal links (7)
Fretting corrosion occurs as a result of
repeated wearing, weight and/or vibration on an
uneven, rough surface. Corrosion, resulting in
pits and grooves, occurs on the surface.
Fretting corrosion is often found on surfaces
exposed to vibration during transportation.
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William HawkesGraduate Diploma Spring Term 2013-2014.Conservation Of MetalworkWord Count:
Iron Oxides, Chlorides, Hydroxides, Sulphides and
Sulphates:
Iron forms a large variety of compounds as
corrosion products, and exactly which compounds
are formed are dependent on which elements are
present at the time. The following table (Table
1) shows the most commonly encountered iron
corrosion products and their chemical
composition.
Table 1: Corrosion Products of Iron
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William HawkesGraduate Diploma Spring Term 2013-2014.Conservation Of MetalworkWord Count:
(Selwyn, 2004)
Iron (II)
oxide:
Wustite FeO Grey
blackIron (II,
III) oxide
Magnetite (Fe3O4). Black
Iron (II,
III) oxide
(Fe4O5)
Iron (III)
oxide
Haematite α(Fe2O3) Red,
BlackIron (III)
oxide
Maghemite γ(Fe2O3) Red-Brown
Iron (II)
Chloride
FeCl2 White
Iron (III)
Chloride
FeCl3 Green
Iron (III)
Hydroxide.
Goethite α-Fe(OH) Yellow-
BrownIron (III)
Hydroxide.
Akaganeite β-FeO(OH) Yellow-
BrownIron
(III) ,Hydr
oxide.
Lepidocroc
ite
γ-FeO(OH) Orange
Iron (II)
Sulphide
Pyrrhotite
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William HawkesGraduate Diploma Spring Term 2013-2014.Conservation Of MetalworkWord Count:
Copper Oxides:
There are two stable copper oxides, copper (I)
oxide (Cu2O) and copper (II) oxide (CuO). These
are stable due to the electron configuration
shown by each of the molecules. Copper by itself
can lose either one or two electrons making it
either a Cu1+ ion or a Cu2+ ion.
With Copper (i) oxide, the oxygen, which has two
spare electrons in its outer valence or electron
shell, and is therefore O2-, is balanced
electrically by the two copper ions each of which
is Cu1+:
2Cu+ + 02- = Cu2O
(Both sides of the equation balance the numbers
of ions and charges). This reaction is called the
oxidation of copper.
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William HawkesGraduate Diploma Spring Term 2013-2014.Conservation Of MetalworkWord Count:
Copper (I) oxide, also known as cuprous oxide or
cuprite, is insoluble in water and organic
solvents.
When exposed to oxygen, copper naturally oxidises
to copper (I) oxide, but this takes considerable
time. Artificial formation is usually
accomplished at high temperature or high oxygen
pressure. With further heating, copper (I) oxide
will form copper (II) oxide:
2Cu2O +O2 → 4CuO
Copper (ii) oxide, a black solid, melts above
1200 °C with some loss of oxygen. Heating copper
in air can form copper (ii) oxide:
2Cu + O2 → 2CuO
Copper (i) oxide forms on silver-plated copper
items exposed to moisture when the silver layer
is porous or damaged; this kind of corrosion is
known as “red plague”. This is seen on silver
plated objects and electroplated nickel-silver
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William HawkesGraduate Diploma Spring Term 2013-2014.Conservation Of MetalworkWord Count:
pieces, which are of a copper-based alloy
construction
Copper (II) oxide, or cupric oxide (CuO), is the
higher oxide of copper, known as Tenorite.
Table 2: Oxides of Copper.Copper (I) Oxide: (Cuprous Oxide).
Also known as “Cuprite”
Dark red to orangein colour.
Copper (II) Oxide: (Cupric Oxide). Also known as “Tenorite”.
Dull-black colour.
(Scott, 1997).
Copper Chlorides, Hydroxides, Sulphides and
Sulphates:
Again, copper forms a large number of corrosion
products, each dependant on the elements present
at the time of the reaction.
Typically, copper (ii) oxide dissolves in mineral
acids such as hydrochloric acid, sulphuric acid
or nitric acid to give the corresponding copper
(II) corrosion products or salts, represented in
the following equations:
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William HawkesGraduate Diploma Spring Term 2013-2014.Conservation Of MetalworkWord Count:
CuO + 2HNO3 → Cu(NO3)2 + H2O
(Copper nitrate and water)
CuO + 2HCl → CuCl2 + H2O
(Copper chloride and water)
CuO + H2SO4 → CuSO4 + H2O
(Copper sulphate and water)
Passivation layers and relative humidity (RH):
Corrosion relies on the metal being exposed to
the various ions of corrosion, often in gaseous
form, and in an electrolyte. As a result, if a
barrier forms which is impermeable to moisture,
the electrolyte is unable to make contact with
the metal surface. The same can be said for the
ions, if the gaseous ions cannot make contact
with the metal then they cannot react with it.
Therefore the passivation layer is an oxide layer
that can greatly reduce, if not prevent, the
contact of corrosive ions with the underlying
metal’s surface. Freshly exposed metallic
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William HawkesGraduate Diploma Spring Term 2013-2014.Conservation Of MetalworkWord Count:
surfaces will adsorb and react with oxygen
present in the atmosphere almost instantaneously.
E.G:
4Fe + 3O2 → 2Fe2O3.
This reaction occurs spontaneously in air at room
temperature, however, as there is no abundance of
moisture or water to form an electrolyte the
corrosion stops and is deemed passive.
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William HawkesGraduate Diploma Spring Term 2013-2014.Conservation Of MetalworkWord Count:
Case Studies:
The Statue of Liberty, on Bedloe’s Island, New York (8).
1. The statue of Liberty: in the most hostile
environment imaginable for metals.
Standing tall in New York harbour since 1886, the
Statue of Liberty is the tallest statue ever made
entirely of metal. Its arms are 42 feet long and
its torch is 21 feet in height. Its index fingers
are eight feet long and nose is 4-foot 6-inches
long.
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William HawkesGraduate Diploma Spring Term 2013-2014.Conservation Of MetalworkWord Count:
The Statue of Liberty is made entirely of copper
and iron and as such, especially given the fact
that it stands beside a marine environment
comprising salt water on one side and one of the
busiest cities in the world on the other, is
destined to corrode, most prolifically through
“galvanic cell corrosion”.
Lady Liberty is comprised of a copper shroud
consisting of plates of copper, which makes up
the detail of the design. These copper plates are
supported internally by an armature structure of
iron. The copper plates are attached to the
armature by copper straps riveted in place.
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William HawkesGraduate Diploma Spring Term 2013-2014.Conservation Of MetalworkWord Count:
Plans of the iron skeleton of armatures created by Gustave Eiffel in
1885 (9).
In 1984 the process of restoration and
conservation started with a thorough examination
of the structure and all of its components. It
was found that the copper plates, and the straps
that held them to the iron, were relatively
intact and that the patina on the surface of the
copper had acted as a passivation layer and
protected the statues detail to a very high
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William HawkesGraduate Diploma Spring Term 2013-2014.Conservation Of MetalworkWord Count:
degree. However, where the passivation layer had
been breached, the copper was shown to be pitted
and porous as a result of reaction with the
atmosphere. Due to a galvanic reaction between
the copper and the iron, the iron had corroded
preferentially to the copper and formed a
sacrificial anode. Because of this reaction the
iron structure, in many places, had lost more
than half of its thickness. As a measure to
isolate the two metals from each other a foam
strapping was used. This, in theory, was to
prevent the preferential corrosion from
occurring. In practice, however, the foam under
the strapping became waterlogged and created an
electrochemical cell where the water in the
sponge was the electrolyte. (Bellante, 1987).
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William HawkesGraduate Diploma Spring Term 2013-2014.Conservation Of MetalworkWord Count:
Diagram 2: Iron armatures holding the copper shroud together with
copper rivets and saddle straps.
Due to the nature of the work to be carried out
the conservation team needed to remove most of
the iron armatures and replace them, while others
could be pacified through cleaning and chemical
treatments. During this process, it was found,
through analysis, that the initial expectation of
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William HawkesGraduate Diploma Spring Term 2013-2014.Conservation Of MetalworkWord Count:
the corrosion products being chlorides, due to
the marine environment in which the statue
stands, was actually wrong. The greatest
quantities of corrosion products were sulphides,
derived from the pollution of New York. Thus the
green colour that we know and relate to the
statue is copper sulphates and sulphides, which
have formed on the surface of the copper shroud.
The fact of the statue being outdoors will always
mean that the moisture in the air will be
variable, however the statue being so close to a
body of water means that it will be biased on the
high side. In order to prevent iron corrosion
entirely the RH should never exceed 11%, a
condition that is entirely impossible in these
circumstances (Rimmer, 2013). The marine
environment also causes the water in the
atmosphere to be salty and therefore an even
better electrolyte in which the corrosion
reactions occur. Because of this, the interior of
the statue was coated in a bituminous layer to
try to exclude the humid atmosphere from
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William HawkesGraduate Diploma Spring Term 2013-2014.Conservation Of MetalworkWord Count:
contacting the metal. This had previously been
done in 1911 but with the use of coal tar instead
of bitumen.
The nature of the statue means that it can never
be protected from the elements and effects of the
environment, however the patina on the copper,
and the bituminous layer inside the statue
provide some protection by reducing the chances
of a galvanic cell being created. The statue is
now under a regimen of monitoring and this is
critical to the early detection of problems and
the ability to be able to prevent more
interventive processes being necessary.2. A bronze statue in a museum environment:
Any bronze in a museum environment must be kept
at a maximum RH of 50%, and that is only where
the object is of mixed media. In fact the RH
should be consistently around the region of 42-
46% for the benefit of the bronze.
As with any museum object there is a need to
inspect the bronze on a regular basis to identify
any corrosion early. The type of corrosion most
31
William HawkesGraduate Diploma Spring Term 2013-2014.Conservation Of MetalworkWord Count:
often seen in the museum environment is “general
attack corrosion”, and this is what we are aiming
to prevent more often than not indoors.
The most common corrosion on bronzes displayed
indoors is copper chloride. The chlorine present
in the atmosphere is in the form of chloride ions
(Cl-) that can easily be dissolved into an
electrolyte.
Another, far more controllable, source of
chloride ions is through contact from hands.
Human hands are virtually never free from oils
and perspiration, which is acidic in nature and
deposits on the surface of the metal, and can
remain mobile across its surface for up to two
weeks (Edgecumbe1 - pers comm.)
The further reaction between water, copper
chloride and sulphur dioxide results in the
formation of copper chloride, hydrochloric acid
and sulphuric acid.
2 CuCl2 + SO2 + 2 H2O → 2 CuCl + 2 HCl + H2SO4
1Richard Edgecumbe: Victoria and Albert Museum 2014.
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William HawkesGraduate Diploma Spring Term 2013-2014.Conservation Of MetalworkWord Count:
As a result the surface of the bronze is attacked
and etched by both of the acids and the end
result is “bronze disease”. In this situation it
is necessary to place the objects in to a dry
environment with the RH as low as possible but
certainly below 40%, in order to stop the
activity of the cupric chloride.
(Williamstown, 2009)
So what do we do?Given the number of corrosion products that can, and do
occur on both iron and copper, given that the air we
breathe is comprised of the very reactants that are
responsible for these corrosion products, and finally,
given that the earth is so laden with water, we as
conservators must accept that our endeavor is not to stop
objects from corroding, that they will eventually corrode
away is inevitable, but what we do is manage that
degradation and corrosion so that we can have the maximum
benefit and enjoyment form the object possible.
The principle of this management is to control the
elements responsible for the corrosion. The ways in which
33
William HawkesGraduate Diploma Spring Term 2013-2014.Conservation Of MetalworkWord Count:
this can be achieved are to remove reactants, to remove
moisture and to be vigilant in our regimen of
observation.
Passivation layers in the forms of oxidation layers,
patinas and other layers, which we deliberately impart
upon the surfaces of the objects, form an impermeable
layer that prevents the reactant ions form forming and
electrical connection with the metal. Ions, such as
nitrates, sulphates and sulphides, chlorides, hydroxides
and carbonates, all need an electrolyte to form the
electrical connection with the metal. As such we can
eliminate the electrolyte as another way to prevent
corrosion. This, in practice, means the prevention of
moisture getting in contact with the metal.
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William HawkesGraduate Diploma Spring Term 2013-2014.Conservation Of MetalworkWord Count:
Bibliography:
BELLANTE, E. L. A. C., E.B. 1987. Restoring the Statue of Liberty: Construction or Conservation?, Washington, Internation Council on Monuments and Sites.
DUNGWORTH, D. 2012. Metals and Metalworking: a research framework for archaeometallurgy. Historical Metallurgy Society. November ed.: Historical Metallurgy Society.
RIMMER, M., THICKETT, D., WATKINSON, D. AND GANIARIS, H. 2013. Guidelines for the Storage and Display of Archaeological Metalwork, Swindon, English Heritage.
SCOTT, D. A. 1997. Copper Compounds in Metals and Colorants: Oxides and Hydroxides. IIC. Studies in Conservation, 42, 93-100.
SELWYN, L. 2004. Metals and Corrosion, A Handbook for the Conservation professional, Ottawa,, Canadian Conservation Institute.
WILLIAMSTOWN, A. C. C. 2009. Care and handling of Bronze Objects,WACC.
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William HawkesGraduate Diploma Spring Term 2013-2014.Conservation Of MetalworkWord Count:
Diagrammatic and Picture Credits:
Diagram 1: Galvanic corrosion diagram:
http://www.corrosionist.com/Iron_Corrosion.htm
(Accessed 27/3/2014)
Diagram 2: Armature structure and attachments:
http://corrosion-doctors.org/Landmarks/statue-
saddle.htm
(Accessed on 27/3/2014
Title page. A bronze sculpture of a Greek God:
http://newsolio.com/bronze-metal-working-how-is-a-
bronze-sculpture-made,17
(Accessed 27/3/2014)
1. General attach corrosion on a capstan:
www.corrosionanalysisnetwork.org
(Accessed 30/3/2014)
2. Crevice corrosion:
davidnfrench.com
(Accessed 30/3/2014
3. Repousse bronze box:
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William HawkesGraduate Diploma Spring Term 2013-2014.Conservation Of MetalworkWord Count:
http://www.rubylane.com/item/419645-2009-1020A/
Large-Art-Nouveau-French-Bronze.
(Accessed 28/3/2014)
4. Environmental Cracking:
www.integratedglobal.com
(Accessed 30/3/2014)
5. Flow assisted corrosion:
www.cospp.com
(Accessed 30/3/2014)
6.Inter-granular corrosion:
www.cospp.com
(Accessed 30/3/2014)
7.Fretting Corrosion:
corrosion.ksc.nasa.gov
(Accessed 30/3/2014)
8. The statue of Liberty on Bedloe’s Island:
http://en.wikipedia.org/wiki/
File:0328Jersey_City_Statue_of_Liberty.JPG
(Accessed on 27/3/2014)
9. The armature structure design of the statue of
liberty:
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William HawkesGraduate Diploma Spring Term 2013-2014.Conservation Of MetalworkWord Count:
http://www.cr.nps.gov/history/online_books/hh/11/
hh11e.htm
(Accessed 27/3/2014)
38