Extra things to remember

Chapter 1)

 Iron below 570C has duplex oxide

 Presence of H2S will retard the recombination of H atoms, giving it higher residence time to
reach M/O surface for hydrogen attack.
 Hydrogen attack is formation of blisters (due to recombination of H at GB) and also
formation of hydride at GB, and also decarburization at high temperature (steel has less
carbon)
 Material with Mo and V are susceptible to corrosion because they form liquid beneath the
scale, which is less protective. Use higher Cr and Ni content allow.

Type of corrosion

 Types of corrosion
o Uniform corrosion
o Local corrosion
 Intergranular
 Galvanic
 Pitting
 Impingement
 Crevice
 Selective leaching
o Mechano-Chemical Corrosion (Need chemical to induce tensile stress)
 Stress corrosion cracking
 E.g. ammonia causes intergranular of brass to crack
 NaOH in water cause Fe to crack
 Cr-Ni subjected to acidic chloride exhibit trans crystalline cracking
 Hydrogen embrittement
 Corrosion fatigue
 Also requires chemical to be present for the fatigue to be damaging
 Hydrogen damage (as as above.) use Ni, Mo to enhance the material.
o Mechanical corrosion
 Wear
 Abrasive wear (between hard and soft material)
 Adhesive wear (sliding and rolling, without pits or scratches. Some
microstructures are plucked out)
 Fatigue wear
 Chemical wear
 Fretting (vibrational)
 Cavitation
 Erosion
o Macrobiological corrosion
 Metabolic activities produce corrosive environment (oxygen concentration
cell)
 Create electrolyte concentration near metal surface
  Alter the resistance of metal
 Have an influence on the rate of anodic/cathodic reactions.
o Stray current corrosion
o Exfoliation corrosion
o Marine corrosion

Corrosion prevention

 Modification of environment
o Neutral/alkaline
 Inhibitor
 Cathodic inhibitor (grow porous oxide to retard the diffusion of
oxygen
 Anodic inhibitor (grow protective oxide)
 Remove oxygen (deaeration)
o Acidic
 Inhibitor (adsorption of molecules to form a blanket in cathode/anode.
Retard the anodic/cathodic process.
o Gaseous
 Use solid inhibitor
 Environmental control (e.g. RH control, removal sulphur containing
compound and etc)
 Modification of material properties
o Alloying to prevent corrosion (e.g.
 Cr for freshwater.
 Mo for marine condition,
 Ti/Nb for intergranualar corrosion
 Cu/P for dry corrosion

o Correct composition may remove second phase
o Heat treatment to remove residual stress
 Use of protective coating
o Non-metallic
 Resin or inorganic based. Pigment may maintain alkaline condition,
passivating Fe in steel.
 Chemical coating (must react with metal and not just blanket cover like
paint) e.g. anodic and chromate/ phosphate coating
o Metallic
 Al cladding
 Either by providing galvanic protection or by separating base material from
corrosive environment.
 If the coating is more cathodic, it has to be away from mechanical damage
or else the scratch exposed metal will corrode very fast.
 Cathodic protection
o Turn the material into cathode using impressed DC, and connect it to an auxiliary
anode
o Attach sacrificial anode at fixed interval
 o Only for mild corrosive environment
 Anodic protection
o Turn base material into anode
o Use electric current to raise the potential to passive zone, controlled by electronic
potentiostat.
o Cost is higher but no need to switch on all the time.
o Can work on both mild and severe corrosive environment.
 Use of non-metal material
 Better design
o Create drainage to prevent crevice
o Welding to seal crevice
o Streamlining shape for pipes
o Prevent Cr dilution due to steel and stainless-steel welding
o Prevent splashing
o Use insulator to separate 2 dissimilar metal

Corrosion characteristic of Fe

 Different Fe phase can cause galvanic corrosion

 For cast iron (higher carbon content), carbon flakes form can cause faster wet corrosion and
due to larger anodic/cathodic site
 Rural condition corrodes slower
 PVC fire gives off Cl and this can cause catastrophic corrosion on Fe indoor.
 Under wet condition, Cl can worsen pitting and crevice corrosion. Cl will form HCl at local
region, providing acidic medium and exuberate corrosion. Passive oxide may be destroyed
too

Corrosion characteristic of Al

 Al-Mg can cause exfoliation corrosion

 pH 4 to 9 good for passivation
 Al and Cu will corrode, need Al cladding

Testing

 Lab test
 Field test
 Accelerated test
o Humidity test
o Fog spray test
o Simulated atmosphere (chamber test)
o Immersion test
 How to assess the extent of corrosion
o Weight change
o Dimension change (change in thickness)
 Measured using eddy current, ultrasonic, microscopic measurement
o Pitting/sensitisation chart