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Corrosion: Introducing

The document discusses corrosion, including its definition, types, factors influencing it, and prevention methods. Corrosion is the gradual chemical or electrochemical degradation of metals due to environmental factors like air, water, acids. Common types are uniform, galvanic, pitting, intergranular corrosion. Prevention includes material selection, design modifications, coatings, cathodic protection, and controlling the environment.

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keval patel
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147 views29 pages

Corrosion: Introducing

The document discusses corrosion, including its definition, types, factors influencing it, and prevention methods. Corrosion is the gradual chemical or electrochemical degradation of metals due to environmental factors like air, water, acids. Common types are uniform, galvanic, pitting, intergranular corrosion. Prevention includes material selection, design modifications, coatings, cathodic protection, and controlling the environment.

Uploaded by

keval patel
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PPTX, PDF, TXT or read online on Scribd
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By

Vikas Panchal

introducing

CORROSION
Introduction

• Corrosion is a gradual chemical or electro-


chemical attack on a metal by its surroundings
such that the metal is converted into an oxide,
salt or some other compound.

• Surroundings could be any corrosive media


such as air, industrial atmosphere, soil, acids,
and salt solutions.
Underground corrosion Electronic components

Corrosion influenced by flow Automobile Corrosion


Types of Corrosion

• Sometimes it occur due to the presence of


electrolyte in contact with metal.

• The electrolyte is usually aqueous solution of salt,


acid, or alkali, this type of corrosion can be called
wet corrosion.

• All other corrosion phenomena involving


chemical reaction between metal and gas or a
liquid which is not an electrolyte can be classified
as dry corrosion.
Effect of corrosion

• Extremely expensive financially


• Extremely waste of natural resources
• Inconvenience to human beings and
sometimes loss of life
• Shut down of machinery for replacement
Outline

Factors Types of Prevention of


Influencing
Corrosion corrosion corrosion
Factors Influencing
Corrosion
The corrosion of a metal is dependent on:

• Chemical nature of metal


• Environment
• Internal structure
• Nature of engineering application for which it
is used.
Environmental factors

• Concentration
• Temperature and movement of corrodent
• Presence of electro-chemical couples, surface
films and stresses
General Types of corrosion

1) Chemical or dry corrosion


2) Electro – chemical corrosion
Types of corrosion

• Galvanic corrosion
• Corrosion due to differential aeration
• Pitting corrosion
• Uniform corrosion
• Inter granular corrosion
• Stress corrosion
• Erosion corrosion
• Fretting corrosion
Galvanic Corrosion

• When two dissimilar metals are in electrical contact in


an electrolyte, the less noble metal becomes anode in
the galvanic cell and is attacked to a greater extent
than if it were exposed alone.

• For example, galvanized steel, which is steel coated


with zinc, where zinc is sacrificed to protect steel.

• Galvanic corrosion can also take place between two


different areas of a structure of same metal and
immersed in same electrolyte, if the contact areas are
at different temperature.
Galvanic Cell e flow

Anode Cathode
Zn Cu
(0.76) (+0.34)

Zn  Zn2+ + 2e or
oxidation 2H+ + 2e  H2
Cu2+ + 2e  Cu or
Reduction O + 2H O + 4e   4OH
Zn will corrode at the expense of Cu 2 2
Galvanic series
Pitting Corrosion

• Pitting is a form of localized attack that


produces pits or holes in a metal.
• Sources:
– Surface deposits that set up local concentration
cells
– Mechanical ruptures in protective coatings
– Differences in ion and oxygen concentration cells
Uniform Corrosion

• Simplest form of corrosion


• All the surfaces exposed to a corrosive
medium are uniformly attacked
• For example,
– Metal pickling operation ( Fe and Zn in HCL)
– Rusting of a sheet of steel roof
Intergranular Corrosion

• Localized corrosion which take place at grain


boundaries
• Under certain conditions, the grain boundary
regions can be very reactive, results in
intergranular corrosion which causes loss of
strength
• It depends strongly upon the mechanical and
thermal treatment given to the alloy
Stress Corrosion

• It is result of the combined effects of tensile


stresses and chemical attack.
• Stresses involved can be due to normal service
load or residual stresses resulting from
manufacturing.
• It is found in alloys and not in pure metals
• Sc occurs in a specific environment for a given
alloy
Erosion Corrosion

• It is defined as the acceleration in the rate of


corrosion due to relative motion between a
corrosive fluid and a metal surface.
• Due to mechanical wear and abrasion action,
grooves, valleys, pits and rounded holes
appear on the metal surface.
• Soft metals such as copper and lead, are
sensitive to erosion corrosion
Fretting Corrosion

• It takes place between mating surfaces that


are subjected to sliding and vibrations as in
the case of shaft and bearings
• Damage appears as grooves or pits
• Damage is accelerated as more debris
accumulates and acts as an abrasive between
the two surfaces
• Surfaces subjected to fretting corrosion in air
often show red, oxidized appearance.
Prevention of Corrosion
Material selection
• Some metals give better performance under
certain environmental conditions
• For example,
– For reducing oxidizing conditions Cu- Ni alloys are
often used
– For oxidizing conditions, chromium containing alloys
are used
– For powerful oxidizing conditions, Ti and its alloys are
used
– Aluminium is resistant to atmospheric oxidation
Design
• An additional thickness of metal over the
required one will reduce corrosion in case of
pipes and tanks
• Welding of tanks, structures or containers in
place of riveting reduces corrosion problems
• If rivets are used, rivet material should be
cathodic to the plate being joined
• Sharp bends and corners should be avoided
• Design system for easy removal and replacement
of parts that are expected to fail rapidly
Coatings
• By application of different types of coatings
such as metallic, inorganic and organic on the
metal surfaces, corrosion can be controlled.
• Metallic coatings are applied in thin layers by
electroplating, hot dipping or spraying.
• Inorganic coatings are applied to attain a
smooth durable finish
• Organic coatings such as paints, are applied to
protect them from corrosive environments.
Cathodic protection
• In this method, electrons are supplied to the
metal structure to be protected.
• If electrons are supplied to the steel structure,
metal dissolution will be suppressed and rate
of hydrogen evolution increases.
• The metal to be protected is electrically
connected to another metal which is more
reactive to the environment.
Environment
• Lowering fluid temperature reduces corrosion
by lowering the corrosion reaction rates.
• Decreasing the velocity of a corrosive fluid
reduces erosion corrosion
• Reducing concentration of corrosion ions in a
solution can decrease corrosion rate of a
metal
• Inhibitors are substances which, when added
to environment decreases its corrosiveness.
Corrosion as useful process
• Etching process for microstructural
observation
• Dry cell batteries
• Electroplating
• Electrochemical machining
• Acid pickling or macro etching for surface
crack detection

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