Documenti di Didattica
Documenti di Professioni
Documenti di Cultura
BY
SURENDRA SINGH Corrosion Control Cell
Discussion Points
Corrosion Types Corrosion Control Methods Corrosion Testing Methods
Corrosion C i
Corrosion is defined as the chemical or electrochemical reaction between a metal and its environment resulting in the loss of the mate ial and its p ope ties material properties.
Electrochemical cell
2+ Anode : 2Fe 2Fe2 + 4e Cathode : O2 + 2H2O + 4e- 4OH-
Net Reaction: 2Fe +02 + H2O Fe2O3 + H2 An electrical connection between anode and cathode A electrolyte An l t l t
Corrosion Rate
Corrosion rate is defined in two form
Short Duration Test Mils Mil per year = K x W / A x T x D L Long D ti T t Duration Test mm/yr = Thickness loss / time
Types of corrosion T f i
Uniform Corrosion Galvanic Corrosion Pitting Corrosion Crevice Corrosion Microbiological Corrosion Corrosion Fatigue Stress Corrosion Cracking Erosion Corrosion Hydrogen Induced g Cracking
Uniform Corrosion
Uniform corrosion is a form of corrosion in which a metal is attacked at about the same rate over the entire exposed surface. Uniform thickness loss
Assessment of Rust
Galvanic C G l i Corrosion i
Galvanic corrosion is an electrochemical action of two dissimilar metals in the presence of an electrolyte and an electron conductive path. It occurs when dissimilar metals are in contact with each other.
Galvanic Series
Pitting Corrosion
Pitti corrosion is a localized attack on a Pitting i i l li d tt k material. The passive film may be destroyed mechanically or by aggressive ions in an electrolyte y gg y
Pitting corrosion occur when the amount of corrosion at one or more points on metal is g g much greater then the average amount of corrosion. Susceptibility of metals to pitting corrosion can be detected by ASTM G48 Standard.
Crevice Corrosion
It occurs mainly in the y crevices at the junction of two metals exposed in aggressive environment. environment Accelerated attack occurs because of a differential in oxygen concentration.
Intergranular Corrosion
Alloys such as austenitic stainless steel & some alloys, when inadequately heat treated during heat-treated welding results chromium carbide p precipitation over grain boundaries. p g Chromium concentration variation between grain vicinity & grain boundary, which i i i b d hi h initiate corrosion i process.
ASTM No. 7
100X
Erosion Corrosion E i C i
The combined action involving corrosion and erosion of metals in the presence of a moving corrosive fluid or a material moving through the fluid, leading to accelerated loss of material The most significant effect of erosioncorrosion is the constant removal of protective film from the metal surface
Sharp corners creates turbulence, leading to erosion corrosion This corrosion mainly occurs in bends, elbows, valves, pumps, blowers, impellers, nozzle etc.
Transgranular SCC
Intergranular SCC I t l
Corrosion F ti C i Fatigue
Corrosion fatigue can be defined as a materials failure mechanism which depends on the combined action of repeated cyclic stresses and chemically reactive environment.
Corrosion fatigue is a special case of stress corrosion caused by the combined effects of cyclic stress and corrosion.
Hydrogen Embrittlement
Hydrogen Embrittlement (HE) causes ductility loss and result in brittle fracture of susceptible materials under applied and residual tensile stresses. Tensile stresses, susceptible T il ibl material, and the presence of hydrogen are necessary t h d to cause hydrogen embrittlement.
Energy for the World
HIC Macrostructure
Prevention of HIC Use low hydrogen welding process Bake heat the welding electrode b f B k or h h ldi l d before welding ldi Preheat the metal to remove moisture Reduce stress by heat treatment
Microbiological Corrosion Mi bi l i l C i
Microbial corrosion is caused by the presence and activities of microbes microbes. The microbes can be bacteria & fungi.
Test the material prior to its usage as per ASTM / ASME Section II / NACE Standard
Energy for the World
Good Design
Bad Design
Paint Application
It acts as a barrier between the susceptible corrosive metal and the particular environment such as chemical, moisture, sunlight and rain. y y Not so costly method and easily applied on the substrate. Better Aesthetics. High degree of adhesion with the substrate. Sufficient thickness can be applied (greater the thickness better the corrosion resistance).
Energy for the World
Paint System
Selection of paint to be applied Surface Preparation Mixing and thinning of paint Application technique Primer layer Intermediate layer Top layer Thickness to be achieved
Type of coating
Lacquers are solutions of natural or synthetic resins (Vinyl chloride, rubber and acrylic) W t emulsion (l t ) C ti Water l i (latex) Coating Oil based Coatings Epoxy Coatings Coal tar Epoxy Coatings Polyurethanes (isocynate and polyol) O Organic Zn rich coating i Z i h ti
Paint/Coating Test
Sl No. 1 2 3 Abrasion/Erosion UV-Resistant Paint Properties Adhesion Paint Test Cross Cut or Cross Hetch Pull-Off Adhesion Taber Test UV-A (340nm) and UV B UV-B (313nm) Conical Bend Test 4 Flexibility Cylindrical Bend Test y Impact Test 5 Paint continuity Pinhole/Holiday Test Standard
ISO 2409 D 4541 D 4060 D 4587 ASTM D 522 ASTM D 522 D2794 ISO 5162
Transformer
Powder coating
Powder coating is a finishing g g technology where a decorative and highly p g y protective coating g can be applied to a wide range of products. p The process involves spraying finely ground electro-statically ground, electro statically charged particles of pigment and resin onto a surface to be coated.
Thermoplastic Powder melts and flows to form a film. Continues to have the same chemical composition when it solidifies Will re-melt when heated. Thick coating surface E Examples l
:
Powder Types
Powder melt flow and cross-link chemically to form film. Cured coatings have different chemical composition than the basic resins. i Will not re-melt when reheated Can produce thin paint like coating of 0.001 0.003 inch thick. Examples
Epoxy Acrylic Urethane
Galvanizing (HDG) G l i i
Iron metallurgically reacts with molten zinc and form a tightly bonded inorganic coating. Zinc coating forms an even and uniform thickness applied to edges and flat surfaces. C Corrosion protection mechanism i t ti h i Zn layer acts as barrier coating Zn is more active than steel and corrode first to protect the cathodic area of the p structure.
HDG Process
Coutesy by AGA(USA)
Cathodic Protection
A technique to control the corrosion of metal surface by making that surface cathode of an electrochemical cell cell. Corrosion Control can be achieved in two ways: 1) Sacrificial Anode 2) Impressed current Cathodic protection is commonly applied on pipelines, pipelines underground storage tanks ships and oil tanks, platforms.
Energy for the World
Sacrificial Anode
Type of sacrificial anodes Zinc, Al, Mg. Used on small structures Anodes welded or bolted to fixtures Need regular checks for wastage
Impressed Current
Involves the use of an external power source metal to be protected is made cathodic to its surroundings Very costly to run mainly used in marine applications oil rigs large anodes placed approximately 100m away.
Step Structure
Dual Structure
Thanks