Tripura University

(ACentral University)

Material Science &

Engineering
M. Tech 1st Year
Session- 2019-2021
Failure due to Corrosion

Present By- Abhijit Roy

 Content
• Over view of various types of
corrosion .
• Factor influencing corrosion
failures .
• Methods to control corrosion.
 Definition of Corrosion

• Corrosion is the deterioration of materials by interaction

with their environment.
 5 major forms of Corrosion:

• Galvanic Corrosion
• Stress corrosion cracking
• Pitting Corrosion
• Erosion Corrosion
• General Corrosion
 Galvanic Corrosion:
• Possibility when two dissimilar metals are electrically
connected in an electrolyte
• Results from a difference in oxidation potentials of
metallic ions between two or more metals. The greater
the difference in oxidation potential, the greater the
galvanic corrosion.
• The less noble metal will act as the anode
and the more noble metal will acts as cathode.
• Perhaps the best known of all corrosion types is
galvanic corrosion, which occurs at the contact point
of two metals or alloys with different electrode
potentials.
Steel bolt (less noble) is
isolated from copper
plates.
 Pitting corrosion

• Pitting corrosion, or pitting, is a form of extremely localized corrosion

that leads to the creation of small holes in the metal. The driving power
for pitting corrosion is the depassivation of a small area, which becomes
anodic while an unknown but potentially vast area becomes cathodic,
leading to very localized galvanic corrosion. The corrosion penetrates the
mass of the metal, with limited diffusion of ions.
 Stress Corrosion Cracking:
• Spontaneous corrosion induced cracking of a
material under static (or residual) tensile stress.

• When subjected to extreme tensile stress, a

metal component can experience SCC along
the grain boundary—cracks form, which are
then targets for further corrosion.

• There are multiple causes of SCC, including

stress caused by cold work, welding, and
thermal treatment.
Stress Corrosion Cracking:
 EROSION-CORROSION
(“Flow-Assisted” or “Flow-Accelerated” Corrosion)

• An increase in rate of attack on a metal

because of relative movement between a corrosive fluid
and the metal surface.

Removal of the metal may be:

– as corrosion product which “removes” the surface because of the high
fluid shear and bares the metal beneath;

– as metal ions, which are swept away by the fluid flow before they can
deposit as corrosion product.
 EROSION-CORROSION

Erosion-corrosion produces a distinctive surface finish:

grooves, waves, gullies, holes, etc., all oriented with respect to
the fluid flow pattern . . .

Erosion-corrosion of condenser
tube wall.
 General Corrosion

General corrosion is the most common form of

corrosion and is also called uniform corrosion where
the electrochemical reactions (in aqueous or
atmospheric media) proceed uniformly over the entire
exposed metal surface over a large area. As
such, general corrosion represents the greatest
destruction of metal on a tonnage basis. As a result,
the metallic surface becomes rough.

General corrosion is less dangerous than the other

corrosion forms because the life of equipment or
structures can be accurately estimated from simple
corrosion tests and sometimes by visual inspection.
 Factors influencing corrosion
1.More the reactivity of metal, the more will be the possibility
of the metal getting corroded.
2.The impurities help in setting up voltaic cells, which
increase the speed of corrosion.
3. Presence of electrolytes in water also increases the rate of
corrosion.
4. Presence of Co2 in natural water increase rusting of iron.
5. A rise in temperature (with in a reasonable limit) increases
the rate of corrosion.
 Methods to Control Corrosion

There are five methods to control

corrosion:
 material selection
 coatings
 changing the environment
 changing the potential
 design
 REFERENCES:
• Herbert H Uhlig and Winston Revie , "Corrosion and Corrosion
Control – An Introduction to Corrosion Science and Engineering",
Third Edition, John Wiley & Sons,1985.
• Mars G.Fontana, "Corrosion Engineering", Third Edition, McGraw
Hill Inc., 1987.
• Rajnarayan, "Metallic Corrosion and Prevention", Oxford
Publications, 1988.
• Kenneth RTrethewey and John Chamberlain, "Corrosion for Science
and Engineering", Second Edition, Longman Inc., 1996.
• Denny A. Jones, "Principles and Prevention of Corrosion", second
edition, Prentice Hall Inc., 1996.
• ASM Hand book – Vol 13: Corrosion, ASM International, 2001.
Thank You