Corrosion

What is corrosion
Corrosion is the oxidation of a metal due to an
ELECTROCHEMICAL reaction. The oxidizing
agent is most often O2 (atmospheric corrosion) or
H+ (chemical corrosion) or both.
Corrosion is defined as the deterioration of a
material, usually a metal, because of a reaction
with its environment.

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 Corrosion is:

A natural phenomenon that occurs over time.

An electrochemical reaction (on metals)

Happens at different rates with different metals

and in different environments

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Effects of corrosion

Reduced Strength
Downtime of equipment
Escape of fluids
Lost surface properties
Reduced value of goods

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 Types of Corrosion
Uniform Attack General Corrosion
Galvanic Corrosion
Crevice Corrosion
Pitting
Intergranular Corrosion
Selective Leaching
Erosion Corrosion
Stress Corrosion
Uniform Corrosion

Formerly a ship

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 It is characterised by chemical or electrochemical
reaction which proceeds uniformly over the entire
exposed area.
It is indicated by general wasting of surface.
The corrosive product may form protective layer on
the metal.

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 Galvanic corrosion
Dissimilar metals are
physically joined in the
presence of an electrolyte.
The more anodic metal
corrodes.
 This occurs when two dissimiliar metals and alloy are
placed in contact with each other in conducting
medium.
The less resistant metal become anodic and more
resistant metal become cathodic.
To minimize galvanic corrosion
a)Select combination of metals as close together as
possible from galvanic series.
b)Insulate dissimilar metals whenever possible
c)Apply coatings

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Galvanic series of metal
1)Magnesium 10)copper
2)aluminium 11)Titanium
3)Manganese 12)Silver
4)zinc 13)gold
5)Chromium 14)Platinum
6)steel
7)Nickel
8)Tin
9)lead

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Stress Corrosion Cracking,
A structure if subjected to stresses and then
exposed to a corrosive environment, may
initiate cracks and crack growth well below
the yield strength of the metal.
Consequently, no corrosion products are
visible, making it difficult to detect or
prevent; fine cracks can penetrate deeply
into the part.
 This corrosion is the result of internal or external
stresses and corrosive environment.
It manifests itself in the form of crack.
The important variables affecting stress corrosion are
temperature, solution composition, metal composition
and structure.

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Crevice Corrosion
 This is an intense,localised corrosion which occurs
within crevices and other shielded areas on metal
surfaces exposed to corrosive.
This type of attack is usually associated with small
volume of stagnant solution caused by holes,
gasket, lap joints and crevices under bolt and rivet
heads.
It can be minimized by using welded joints instead
of riveted or bolted joints.

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Pitting corrosion:
Pitting is a localized form of
corrosive attack. Pitting
corrosion is typified by the
formation of holes or pits on the
metal surface. Pitting can cause 304
stainless
failure of material steel / acid
chloride
solution

5th Century sword

Boiler tube
 It occurs due to presence of impurities, rough
spots and scratches.
Pitting seldom occur with extreme suddenness.
It occurs due to stagnant condition.
Adding inhibitors to metals is helpful in reducing
pitting.

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 Intergranular
Corrosion along
grain boundaries,
often where precipitate
particles form.
 It is intercrystalline cracking along the grain
boundaries of metal.
It is caused by impurities at the grain boundaries.

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Erosion-corrosion
Combined chemical attack and
mechanical wear (e.g., pipe
elbows).

Brass water pump

 This is caused due to combination of corrosive
fluid and impingment of liquid or abrasion of slid
particles.
This effect mainly depends on liquid velocity and
contained air.
All types of equipment exposed to moving fluids
like valves, pumps ,blowers agitators heat
exchangers are subject to erosion corrosion.

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Cavitation corrosion
It occurs due to repeated collapse of vpour bubbles
on metal surface.
This causes mild physical damage to protective
films.
Cavitations occurs in equipment where high
velocity liquid flow and pressure changes occur
such as pump impellers.

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Fretting corrosion
This occurs at contact areas between materials
under load subjected to vibration and slip.
It appears as pits
This type of corrosion can be minimized by
lubricating contact areas or increasing the
hardness of both the contacting materials..

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