“ A Simple view on a complex matter”

 Corrosion is the deterioration of a metal as a result of chemical

reactions between it and the surrounding environment.
 It is an oxidation process. It causes loss of metal.
 Corrosion comes in many different forms and can be classified by the
cause of the chemical deterioration of a metal.
 Corrosion is the destructive result of electrochemical reaction
between a metal or alloy and its surrounding environment.
 Example: Formation of rust
on the surface of iron and
steel.
 Formation of green film on
the surface of copper.

 Corrsion of metal.
 DIFFERENT THEORIES/CLASSIFICATION OF CORROSION
There Are Three Theories Of Corrosion:
(1) Acid Theory
(2) Dry Or Chemical Corrosion And
(3) Galvanic Or Electrochemical
(1) ACIDTHEORY
 This theory suggests that corrosion of a metal (iron) is due to the presence of
acids surrounding it.
 According to this theory, iron is corroded by atmospheric carbon di-oxide, moisture
and oxygen. The corrosion products are the mixture of Fe(HCO3)2, Fe(OH)CO3
and Fe(OH)3.

The chemical reactions suggested are given 4

 (2) CHEMICAL THEORYOF CORROSION
 According to this theory, corrosion on the surface of a metal is due to direct
reaction of atmospheric gases like oxygen, halogens, oxides of sulphur, oxides
of nitrogen, hydrogen sulphide and fumes of chemicals with metal.
 The extent of corrosion of a particular metal depends on the chemical affinity of
the metal towards reactive gas.
 Oxygen is mainly responsible for the corrosion of most metallic substances
when compared to other gases and chemicals.
There are Three types of main chemical corrosion.
 (i) Oxidation corrosion (Reaction with oxygen)
 (ii) Corrosion by other gases
 (iii) Liquid metal corrosion
(3) WET OR ELECTROCHEMICAL THEORY OF CORROSION
 It is a common type of corrosion of metal in aqueous corrosive environment.
This type of corrosion occurs when the metal comes in contact with a
conducting liquid or when two dissimilar metals are immersed or dipped partly
in a solution.
 According to this theory, there is the formation of a galvanic cell on the surface
of metals. Some parts of the metal surface act as anode and rest act as
cathode.
 The chemical in the environment and humidity acts as an electrolyte.
 Oxidation of anodic part takes place and it results in corrosion at anode, while
reduction takes place at cathode.
 The corrosion product is formed on the surface of the metal between anode and
cathode.
DIFFERENCES BETWEEN DRY AND WET CORROSION
Dry corrosion
•Corrosion occurs in the
absence of moisture.
•It involves direct attack of
chemicals on
the metal surface.
• The process is slow.
•Corrosion products are
produced at the
site of corrosion.
•The process of corrosion is
uniform.
Wet corrosion
•Corrosion occurs in
presence of conducting
medium.
•It involves formation of
electrochemical
cells.
• It is a rapid process.
•Corrosion occurs at anode
but rust is deposited at
cathode.
•It depends on the size of the
anodic part
of metal.
 FACTORS INFLUENCING CORROSION
 The nature and extent of corrosion depend on the metal and the environment.
The important factors which may influence the corrosion process are:-
(i) Nature of the metal (ii) Environment (iii)Concentration of electrolyte
(iv) Electrode potential (v) Temperature (vi) Hydrogen over voltage
EFFECTS OF CORROSION
• Reduces Strength
• Life time is reduced
• Metallic properties are lost
• Wastage of metal
• Due to formation of corrosion product over the machinery, the efficiency of the
machine gets failure leads to plant shut down
• The products contamination or loss of products due to corrosion.
• Corrosion releases the toxic products.
• Health (eg. from pollution due to corrosion product or due to the escaping chemical
from a corroded equipment).
 TYPES OF CORROSION

UNIFORM EROSION

STRESS ATMOSPHERIC

GALVANIC CREVICE

PITTING MICROBAL
  CREVICE CORROSION
• Crevice corrosion is a localized attack on a metal adjacent to the crevice
between two joining surfaces (two metals or metal-nonmetal crevices).

The corrosion is generally confined to one localized area to one metal.

Various factors influence crevice corrosion, such as.

Materials: alloy composition, metallographic structure.

Environmental conditions such as ph, oxygen concentration, halide
concentrations, temperature.
Filiform corrosion is a special type of crevice corrosion.
  PITTING CORROSION
• Pitting corrosion is a localized
phenomenon confined to smaller areas.
• Formation of micro-pits can be very
damaging.
• Chloride ions are damaging to the
passive films and can make pit
formation auto-catalytic. Pitting
tendency can be predicted through
measurement of pitting potentials.
  UNIFORM CORROSION
• Uniform corrosion is a very common
form found in ferrous metals and
alloys that are not protected by
surface coating or inhibitors.
• A uniform layer of “rust” on the
surface is formed when exposed to
corrosive environments .
• Atmospheric corrosion is a typical
example of this type
 GALVANIC CORROSION
• Galvanic corrosion often referred to as
dissimilar metal corrosion occurs in
galvanic couples where the active one
corrodes.
• EMF series (thermodynamic) could be
used for prediction of this type of corrosion.
Eg: - Copper containing precipitates in
aluminium alloys.
Impurities such as iron and copper in metallic
zinc.
 EROSION CORROSION
• Erosion corrosion is the deterioration of metals and alloys due to relative
movement between surfaces and corrosive fluids.
• Depending on the rate of this movement, abrasion takes place.
• This type of corrosion is characterized by grooves and surface patterns
having directionality.
• Typical examples are :- Stainless alloy pump impeller, Condenser tube
walls, pipes , valves, nozzels etc.
 STRESS CORROSION
• Stress corrosion cracking (SCC) refers to
failure under simultaneous presence of a
corrosive medium and tensile stress.
• Two classic examples of SCC are caustic
embrittlement of steels occurring in riveted
boilers of steam-driven locomotives and
season cracking of brasses observed in brass
cartridge cases due to ammonia in
environment.
• Stress cracking of different alloys does occur
depending on the type of corrosive
environment.
• Stainless steels crack in chloride atmosphere.
Major variables influencing SCC include
solution composition, metal/alloy composition
and structure, stress and temperature.
  MICROBIAL CORROSION
Microbial corrosion is another form of corrosion
that often occurs in metals contacted with soil or
sludge. It shows the severe microbial corrosion
beneath the train rails that became in contact with
underlying soil.
The rational causes of the illustrated case of
microbial corrosion are as follows:
a.Direct contact with damp soil
b.Dominant de-aerated sheltered environment.
c.Aerobic and anaerobic soil microbes
condition of soil
d.Dominant presence of sulfate-reducing bacteria
e.Highly resisting and waterlogged
f. Long residence time of water on metal surface
g.Higher clay content of soil
h.Poor drainage facility
i. Removal or leaching of iron
j. Catalyzing effect of biological deposits
 PREVENTION OF CORROSION
1. Maintaining the purity of the metal
2. Alloying with other elements
3. Modification Of Environment
Deaeration of Aqueous environment and decreases the rate
dehumidification ofcorrosion.
4. Protective Coatings For Reinforcing Steel.
Anodic coatings (e.g., zinc-coated steel) very limited use due to concern
regarding the long-term durability.
Barrier coatings (e.g., epoxy-coated steel), long-time performance of epoxy-
coated rebars.
5. Proper Storage & Stacking Of Reinforcing Steel
In case of long storage, reinforcement bars should be stacked above ground
level by at least 150 mm. Also in coastal area or in case of long storage;
a coat of cement wash shall be given to prevent scaling and rusting.
 6. Protective coatings
1.Metallic Coating
2.Non-metallic coatings
3.Organic coatings
i. Metallic Coating
a) Using less active metal
b) Using a more active metal
ii. Non-Metallic Coating
a) Phosphate coating by Alkaline solution of phosphate.
b) Chromate coating using chromate solutions.
iii. Organic Coating
Plastics, polythene, rubber etc, are used for coating to
prevent corrosion.
Mainly on articles like, ship, submarines. Etc.
THANKYOU