PEMELIHARAAN

MESIN INDUSTRI

JURUSAN TEKNIK MESIN

UNIVERSITAS PANCASILA
2015

CORROSION

Introduction

Corrosion is the degeneration of

material by reaction of materials with
their environment.
It is not restricted to metals.
Rusting of iron and steel, pitting of
turbine blades, chalking of paint are all
examples of corrosion.
Rusting is the corrosion related to iron
and iron-based alloys. Non-ferrous
metals corrode but do not rust

All materials used for building and

construction (metals; inorganics like
glass, ceramics, or concrete; organics
like rubber, paints, and plastics)
corrode, and even biological systems
like the human body

Corrosion control includes :

1. Monitoring corrosion
2.
3.
4.
5.

Selecting proper materials of

construction
Designing to minimize corrosion
Controlling corrosion by regular
maintenance practices
Taking specific countermeasures, for
example cathodic protection,
protective coatings, use of inhibitors

The maintenance engineer has to

deal with:
1. Monitoring corrosion progress
2. Recognizing corrosion defects,
damages, and failures
3. Maintenance which will prevent
corrosion
4. Application and also selection of
process chemicals and materials which
will not induce corrosion damage

Major factors determining type and

extent of corrosion include:

Temperature
Medium which is in contact with the
corroding material, for example air,
gasoline, oil, water, engine coolant
Mechanical stresses
Flow rates
Electrical potential differences

CORROSION DAMAGE
Disfiguration or loss of appearance
Loss of material
Maintenance cost
Extractive metallurgy in reverse- Loss of
precious minerals, power, water and manpower
Loss in reliability & safety
Plant shutdown, contamination of product
etc

WHY DO METALS CORRODE?

Any spontaneous reaction in the universe is
associated with a lowering in the free energy of
the system. i.e. a negative free energy change
All metals except the noble metals have free
energies greater than their compounds. So they
tend to become their compounds through the
process of corrosion

ELECTROCHEMICAL NATURE
All metallic corrosion are electrochemical
reactions i.e. metal is converted to its compound
with a transfer of electrons
The overall reaction may be split into oxidation
(anodic) and reduction (cathodic) partial
reactions
Next slide shows the electrochemical reactions
in the corrosion of Zn in hydrochloric acid

DISSOLUTION OF ZN METAL IN HYDROCHLORIC ACID ,

Zn 2 HCl ZnCl

-------------------- -(1)

Written in ionic form as,

Zn 2 H 2Cl Zn 2 2Cl H 2

----------------------(2)

The net reaction being,

Zn 2 H Zn 2 H 2

------------------------- (3)

Equation (3) is the summation of two partial reactions,

Zn Zn 2* 2e -----------------------------------------(4) and
2 H 2e H 2 ------------------------------------------(5)
Equation (4) is the oxidation / anodic reaction and
Equation (5) is the reduction / cathodic reaction

FORMS OF CORROSION
Corrosion may be
classified in
different ways
Wet / Aqueous
corrosion & Dry
Corrosion
Room Temperature/
High Temperature
Corrosion

CORROSION

WET CORROSION

DRY CORROSION

CORROSION

ROOM TEMPERATURE
CORROSION

HIGH TEMPERATURE
CORROSION

WET & DRY CORROSION

Wet / aqueous corrosion is the major form of
corrosion which occurs at or near room
temperature and in the presence of water
Dry / gaseous corrosion is significant mainly
at high temperatures

WET / AQUEOUS CORROSION

Based on the appearance of the corroded metal, wet
corrosion may be classified as
Uniform or General
Galvanic or Two-metal
Crevice
Pitting
Dealloying
Intergranular
Velocity-assisted
Environment-assisted cracking

UNIFORM CORROSION
Corrosion over the
entire exposed surface
at a uniform rate. e.g..
Atmospheric corrosion.
Maximum metal loss by
this form.
Not dangerous, rate can
be measured in the
laboratory.

GALVANIC CORROSION
When two dissimilar metals
are joined together and
exposed, the more active of
the two metals corrode
faster and the nobler metal
is protected. This excess
corrosion is due to the
galvanic current generated
at the junction
Fig. Al sheets covering
underground Cu cables

CREVICE CORROSION
Intensive localized
corrosion within
crevices & shielded
areas on metal surfaces
Small volumes of
stagnant corrosive
caused by holes,
gaskets, surface
deposits, lap joints

PITTING
A form of extremely
localized attack causing
holes in the metal
Most destructive form
Autocatalytic nature
Difficult to detect and
measure
Mechanism

DEALLOYING
Alloys exposed to
corrosives experience
selective leaching out of
the more active
constituent. e.g.
Dezincification of brass.
Loss of structural
stability and mechanical
strength

INTERGRANULAR CORROSION
The grain boundaries in
metals are more active than
the grains because of
segregation of impurities
and depletion of protective
elements. So preferential
attack along grain
boundaries occurs. e.g.
weld decay in stainless
steels

VELOCITY ASSISTED CORROSION

Fast moving corrosives
cause
a) Erosion-Corrosion,
b) Impingement attack ,
and
c) Cavitation damage in
metals

CAVITATION DAMAGE
Cavitation is a special case
of Erosion-corrosion.
In high velocity systems,
local pressure reductions
create water vapour
bubbles which get attached
to the metal surface and
burst at increased pressure,
causing metal damage

ENVIRONMENT ASSISTED CRACKING

When a metal is subjected to a tensile stress
and a corrosive medium, it may experience
Environment Assisted Cracking. Four types:
Stress Corrosion Cracking
Hydrogen Embrittlement
Liquid Metal Embrittlement
Corrosion Fatigue

STRESS CORROSION CRACKING

Static tensile stress and
specific environments
produce cracking
Examples:
1) Stainless steels in hot
chloride
2) Ti alloys in nitrogen
tetroxide
3) Brass in ammonia

HYDROGEN EMBRITTLEMENT
High strength materials
stressed in presence of
hydrogen crack at
reduced stress levels.
Hydrogen may be
dissolved in the metal
or present as a gas
outside.
Only ppm levels of H
needed

LIQUID METAL EMBRITTLEMENT

Certain metals like Al and
stainless steels undergo
brittle failure when
stressed in contact with
liquid metals like Hg, Zn,
Sn, Pb Cd etc.
Molten metal atoms
penetrate the grain
boundaries and fracture
the metal
Fig. Shows brittle IG
fracture in Al alloy by Pb

CORROSION FATIGUE

S-N

Synergistic action of
corrosion & cyclic
stress. Both crack
nucleation and
propagation are
accelerated by
corrodent and the S-N
diagram is shifted to the
left

Stress Amplitude

DIAGRAM

Air
Corrosion

log (cycles to failure, Nf)

 Crack propagation rate is

increased by the
corrosive action

log (Crack Growth Rate, da/dN)

CORROSION FATIGUE, CRACK

PROPAGATION

Log (Stress Intensity Factor Range, K

PREVENTION OF CORROSION
The huge annual loss due to corrosion is a
national waste and should be minimized
Materials already exist which, if properly
used, can eliminate 80 % of corrosion loss
Proper understanding of the basics of
corrosion and incorporation in the initial
design of metallic structures is essential

METHODS

Material selection
Improvements in material
Design of structures
Alteration of environment
Cathodic & Anodic protection
Coatings

MATERIAL SELECTION
Most important method select the
appropriate metal or alloy .
Natural metal-corrosive combinations like
S. S.- Nitric acid, Ni & Ni alloys- Caustic
Monel- HF, Hastelloys- Hot HCl
Pb- Dil. Sulphuric acid, Sn- Distilled water
Al- Atmosphere, Ti- hot oxidizers
Ta- Ultimate resistance

IMPROVEMENTS OF MATERIALS
Purification of metals- Al , Zr
Alloying with metals for:
Making more noble, e.g. Pt in Ti
Passivating, e.g. Cr in steel
Inhibiting, e.g. As & Sb in brass
Scavenging, e.g. Ti & Nb in S.S
Improving other properties

DESIGN OF STRUCTURES

Avoid sharp corners

Complete draining of vessels
No water retention
Avoid sudden changes in section
Avoid contact between dissimilar metals
Weld rather than rivet
Easy replacement of vulnerable parts
Avoid excessive mechanical stress

ALTERATION OF ENVIRONMENT

Lower temperature and velocity

Remove oxygen/oxidizers
Change concentration
Add Inhibitors
Adsorption type, e.g. Organic amines, azoles
H evolution poisons, e.g. As & Sb
Scavengers, e.g. Sodium sulfite & hydrazine
Oxidizers, e.g. Chromates, nitrates, ferric salts

CATHODIC & ANODIC PROTECTION

Cathodic protection: Make the structure more
cathodic by
Use of sacrificial anodes
Impressed currents

Used extensively to protect marine structures,

underground pipelines, water heaters and
reinforcement bars in concrete
Anodic protection: Make passivating metal structures
more anodic by impressed potential. e.g. 316 s.s.
pipe in sulfuric acid plants

COATINGS
Most popular method of corrosion protection
Coatings are of various types:
Metallic
Inorganic like glass, porcelain and concrete
Organic, paints, varnishes and lacquers

Many methods of coating:

Electrodeposition
Flame spraying
Cladding
Hot dipping
Diffusion
Vapour deposition
Ion implantation
Laser glazing

CONCLUSION
Corrosion is a natural degenerative process
affecting metals, nonmetals and even
biological systems like the human body
Corrosion of engineering materials lead to
significant losses
An understanding of the basic principles of
corrosion and their application in the design
and maintenance of engineering systems
result in reducing losses considerably