DESIGN FOR

(PREVENTING)CORROSION

o Presented By

G.SARAVANA
200725716
CORROSION
AGENDA
o Introduction- What is Corrosion
o Mehanism of Corrosion
o Types of Corrosion
Introduction
o Corrosion is the disintegration of an engineered material
into its constituent atoms due to Chemical Reactions
with its surroundings.

o In the most common use of the word, this means

electrochemical oxidation of metals in reaction with an
oxidant such as oxygen.

o Formation of an oxide of iron due to oxidation of the iron

atoms in solid solution is a well-known example of
electrochemical corrosion, commonly known as
RUSTING.

o Examples: Rusting of automobiles, buildings and

bridges, Fogging of silverware, Patina formation on
copper.
Corrosion – only in Metals??

o Corrosion can also refer to other materials than metals,

such as CERAMICS or POLYMERS, although in this
context, the term DEGRADATION is more common.

o Not only metals, but non-metals like plastics, rubber,

ceramics are also subject to environmental degradation

o Even living tissues in the human body are prone to

environmental damage by free radicals-Oxidative stress-
leading to degenerative diseases like cancer, cardio-
vascular disease and diabetes.
Corrosion – only in Metals??

Not only metals suffer “corrosion”

effects. This dished end of a vessel is
made of glass fibre reinforced
PVC. Due to internal stresses and an
aggressive environment it has suffered
“environmental stress cracking”.
Economic impact

o The US Federal Highway Administration released a

study, entitled Corrosion Costs and Preventive Strategies
in the United States, in 2002 on the direct costs
associated with metallic corrosion in nearly every U.S.
industry sector.
The study showed that for 1998 the total annual
estimated direct cost of corrosion in the U.S. was
approximately $276 billion (approximately 3.2% of the
US GDP).
COST OF CORROSION
o Annual loss due to corrosion is estimated to be 3 to 5 %
of GNP, about Rs.700000 crores
o Direct & Indirect losses
o Direct loss: Material cost, maintenance cost, over-
design, use of costly material
o Indirect losses: Plant shutdown & loss of production,
contamination of products, loss of valuable products due
to leakage etc, liability in accidents
Corrosion Mitigation Strategies
o Experience
o Design
o Materials Selection
o Protective Coatings
o Cathodic Protection
o Modification of Environment
CORROSION EFFECTS
o Disfiguration or loss of appearance
o Loss of material
o Maintenance cost
o Extractive metallurgy in reverse- Loss of precious
minerals, power, water and man-power
o Loss in reliability & safety
o Plant shutdown, contamination of product etc
WHY DO METALS CORRODE?
o 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
o 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
o All metallic corrosion are electrochemical reactions i.e.
metal is converted to its compound with a transfer of
electrons
o The overall reaction may be split into oxidation (anodic)
and reduction (cathodic) partial reactions
o Next slide shows the electrochemical reactions in the
corrosion of Zn in hydrochloric acid
ELECTROCHEMICAL REACTIONS IN
CORROSION

DISSOLUTION OF ZN METAL IN HYDROCHLORIC ACID,

Zn + 2 HCl = ZnCl 2 + H 2 -------------------- -(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
 ELECTROCHEMICAL THEORY
o The anodic & cathodic reactions occur simultaneously at different
parts of the metal.
o The electrode potentials of the two reactions converge to the
corrosion potential by polarization
PASSIVATION
o Many metals like Cr, Ti,
Al, Ni and Fe exhibit a
reduction in their
corrosion rate above
certain critical potential.
Formation of a
protective, thin oxide
film.
o Passivation is the reason
for the excellent
corrosion resistance of Al
and S.S.
FORMS OF CORROSION
o Corrosion may be
classified in different CORROSION
ways
o Wet / Aqueous WET CORROSION DRY CORROSION
corrosion & Dry
Corrosion
o Room Temperature/
High Temperature
Corrosion
CORROSION

ROOM TEMPERATURE HIGH TEMPERATURE

CORROSION CORROSION
WET & DRY CORROSION
o Wet / aqueous corrosion is the major form of
corrosion which occurs at or near room temperature and
in the presence of water
o 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
o Uniform or General
o Galvanic or Two-metal
o Crevice
o Pitting
o Dealloying
o Intergranular
o Velocity-assisted
o Environment-assisted cracking
UNIFORM CORROSION
o Corrosion over the entire
exposed surface at a
uniform rate. e.g..
Atmospheric corrosion.
o Maximum metal loss by
this form.
o Not dangerous, rate can
be measured in the
laboratory.
GALVANIC CORROSION
o 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
o Fig. Al sheets covering
underground Cu cables
CREVICE CORROSION
o Intensive localized
corrosion within crevices
& shielded areas on
metal surfaces
o Small volumes of
stagnant corrosive
caused by holes,
gaskets, surface
deposits, lap joints
PITTING
o A form of extremely
localized attack causing
holes in the metal
o Most destructive form
o Autocatalytic nature
o Difficult to detect and
measure
o Mechanism
DEALLOYING
o Alloys exposed to
corrosives experience
selective leaching out of
the more active
constituent. e.g.
Dezincification of brass.
o Loss of structural
stability and mechanical
strength
INTERGRANULAR CORROSION
o 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
o Fast moving corrosives
cause
o a) Erosion-Corrosion,
o b) Impingement attack ,
and
o c) Cavitation damage in
metals
CAVITATION DAMAGE
o Cavitation is a special
case of Erosion-
corrosion.
o 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
o When a metal is subjected to a tensile stress and a
corrosive medium, it may experience Environment
Assisted Cracking. Four types:
o Stress Corrosion Cracking
o Hydrogen Embrittlement
o Liquid Metal Embrittlement
o Corrosion Fatigue
STRESS CORROSION CRACKING
o Static tensile stress and
specific environments
produce cracking
o Examples:
o 1) Stainless steels in hot
chloride
o 2) Ti alloys in nitrogen
tetroxide
o 3) Brass in ammonia
HYDROGEN EMBRITTLEMENT
o High strength materials
stressed in presence of
hydrogen crack at
reduced stress levels.
o Hydrogen may be
dissolved in the metal or
present as a gas outside.
o Only ppm levels of H
needed
LIQUID METAL EMBRITTLEMENT
o Certain metals like Al
and stainless steels
undergo brittle failure
when stressed in
contact with liquid
metals like Hg, Zn, Sn,
Pb Cd etc.
o Molten metal atoms
penetrate the grain
boundaries and
fracture the metal
o Fig. Shows brittle IG
fracture in Al alloy by
Pb
 CORROSION FATIGUE
S-N DIAGRAM

o Synergistic action of
corrosion & cyclic stress.
Both crack nucleation and

Stress Amplitude
propagation are
accelerated by corrodent Air
and the S-N diagram is Corrosion
shifted to the left
log (cycles to failure, Nf)
 CORROSION FATIGUE,
CRACK PROPAGATION

log (Crack Growth Rate, da/dN)

o Crack propagation
rate is increased by
the corrosive action

Log (Stress Intensity Factor Range, -K

PREVENTION OF CORROSION
o The huge annual loss due to corrosion is a national waste
and should be minimized
o Materials already exist which, if properly used, can
eliminate 80 % of corrosion loss
o Proper understanding of the basics of corrosion and
incorporation in the initial design of metallic structures is
essential
MATERIAL SELECTION
o Most important method – select the appropriate metal or
alloy .
o “Natural” metal-corrosive combinations like
o S. S.- Nitric acid, Ni & Ni alloys- Caustic
o Monel- HF, Hastelloys- Hot HCl
o Pb- Dil. Sulphuric acid, Sn- Distilled water
o Al- Atmosphere, Ti- hot oxidizers
o Ta- Ultimate resistance
IMPROVEMENTS OF MATERIALS
o Purification of metals- Al , Zr
o Alloying with metals for:
o Making more noble, e.g. Pt in Ti
o Passivating, e.g. Cr in steel
o Inhibiting, e.g. As & Sb in brass
o Scavenging, e.g. Ti & Nb in S.S
o Improving other properties
DESIGN OF STRUCTURES
o Avoid sharp corners
o Complete draining of vessels
o No water retention
o Avoid sudden changes in section
o Avoid contact between dissimilar metals
o Weld rather than rivet
o Easy replacement of vulnerable parts
o Avoid excessive mechanical stress
ALTERATION OF ENVIRONMENT
o Lower temperature and velocity
o Remove oxygen/oxidizers
o Change concentration
o Add Inhibitors
n Adsorption type, e.g. Organic amines, azoles
n H evolution poisons, e.g. As & Sb
n Scavengers, e.g. Sodium sulfite & hydrazine
n Oxidizers, e.g. Chromates, nitrates, ferric salts
CATHODIC & ANODIC PROTECTION
o Cathodic protection: Make the structure more cathodic
by
n Use of sacrificial anodes
n Impressed currents
Used extensively to protect marine structures,
underground pipelines, water heaters and reinforcement
bars in concrete
o Anodic protection: Make passivating metal structures
more anodic by impressed potential. e.g. 316 s.s. pipe in
sulfuric acid plants
COATINGS
o Most popular method of corrosion protection
o Coatings are of various types:
n Metallic
n Inorganic like glass, porcelain and concrete
n Organic, paints, varnishes and lacquers
o Many methods of coating:
n Electrodeposition
n Flame spraying
n Cladding
n Hot dipping
n Diffusion
n Vapour deposition
n Ion implantation
n Laser glazing
CONCLUSION
o Corrosion is a natural degenerative process affecting
metals, nonmetals and even biological systems like the
human body
o Corrosion of engineering materials lead to significant
losses
o An understanding of the basic principles of corrosion and
their application in the design and maintenance of
engineering systems result in reducing losses
considerably
 “Dos”
o Design on the assumption that moisture and other corrosive
mechanism will be present.
o Seal all dissimilar metal (galvanic) couples.
o Use conformal coating on printed wiring boards.
o Use as easily replaceable anodic (consumable) part in
assembling grounding or bonding connections.
o Use only electrical connector boots that can be sealed with
adhesives.
o Carefully select a protective system for use on magnesium.
o Complete the working of aluminum, steel, etc (drilling, cutting,
grinding) prior to surface treatment.
o Use surface treatments (anodize and conversion coatings) on
aluminum.
o Carefully select the metal plating use to provide sacrificial
protection, barrier protection, as a third metal between two
otherwise incompatible metals, or as a substitute surface.
 “Dos”
o Use a nickel strike under gold plating.
o Use solder flux with lowest possible acid content.
o Use metallic materials with the most corrosion resistant
configuration (passivated) with minimum possible residual
stressing.
o Use fluorocarbon or fluorosilicone type materials for gaskets,
“O” rings an seals.
o Use low point drains. Mount equipment an components at
least 1/2 inch above potential standing water level.
o Use hermetic sealing where possible.
o Design for maintainability.
o Mount electrical connectors horizontally.
o Use drip loops on electrical cables and piping.
o Use desiccant systems with visual indicators.
 “Dos”
o Use cooling systems that remove moisture and
particulate matter.
o Use “O” rings to seal around control shafts that must
penetrate into an corrosive environment.
o Be aware of various interior and exterior fluids which
your product will be exposed to.
o Recognize the operational environment. Recognize the
maintenance environment. Be aware of maintenance
procedures and materials.
 “DON’T’s”
o Don’t use dissimilar metal (galvanic) couples if it can be
avoided.
o Don’t use RTV that contains acetic acid.
o Don’t use heat shrink (non-sealed) electrical connector
boots to stop moisture fluid intrusion.
o Don’t mate magnesium to a metal more cathodic than
aluminum.
o Don’t use acrylic, RTV or varnish type conformal
coatings.
o Don’t use gold over silver or copper.
o Don’t use organic materials that outgas, support fungi,
absorb moisture or are degraded by maintenance and
operational fluids.
o Don’t use an EMI gasket without a seal on both sides of
the conductive element.
 “DON’T’s”
o Don’t use top mounted lid fasteners.
o Don’t mount PWBs horizontally.
o Don’t mount electrical connectors (multicontact or coaxial)
vertically.
o Don’t place edge connectors on the bottom edge of a vertically
PWB.
o Don’t create side loads or cable tension on the rear seal of
electrical connectors.
o Don’t use direct air cooling on active electronic components.
o Don’t mount equipment less than 1/2 inch above the
compartment floor.
o Don’t use hygroscopic materials.
o Don’t use nickel plated electrical connector shells in salt or
high humidity environments. (Use cadmium plated shell).
o Don’t use foam cushioning material that can deteriorate
(revert).
o Don’t permit the presence of water trap areas.