PREVENTION OF

CORROSION
PREVENTION OF
CORROSION
▪ The huge annual loss due to corrosion is a
national waste and should be minimized
▪ Materials already exist which, if properly
used, can eliminate 80 % of corrosion loss
▪ Proper understanding of the basics of
corrosion and incorporation in the initial
design of metallic structures is essential
METHODS

▪ Material selection
▪ Improvements in material
▪ Design of structures
▪ Alteration of environment
▪ Cathodic & Anodic protection
▪ Coatings
MATERIAL SELECTION
▪ Most important method – select the appropriate
metal or alloy .
▪ “Natural” metal-corrosive combinations like
c. S. S.- Nitric acid,
d. Ni & Ni alloys- Caustic
e. Monel- HF, Hastelloys- Hot HCl
f. Pb- Dil. Sulphuric acid,
g. Sn- Distilled water
h. Al- Atmosphere,
i. Ti- hot oxidizers
j. Ta- Ultimate resistance
▪ Corrosion Tables available for various materials
in different corrosive environments
IMPROVEMENTS OF
MATERIALS
▪ Purification of metals- Al , Zr
▪ Alloying with metals for:
▪ Making more noble, e.g. Pt in Ti
▪ Passivating, e.g. Cr in steel
▪ Inhibiting, e.g. As & Sb in brass
▪ Improving other properties
▪ Change of microstructure. e.g. desensitization of s. s.
welds
▪ Elimination of tensile stress-improves
DESIGN OF STRUCTURES

▪ Avoid sharp corners

▪ Complete draining of vessels
▪ No water retention
▪ Avoid sudden changes in section
▪ Avoid contact between dissimilar metals
▪ Weld rather than rivet
▪ Easy replacement of vulnerable parts
▪ Avoid excessive mechanical stress
ALTERATION OF
ENVIRONMENT
▪ Lower temperature and velocity
▪ Remove oxygen/oxidizers
▪ Change concentration
▪ Add Inhibitors
▪ Adsorption type, e.g. Organic amines, azoles
▪ Polymeric Inhibitors
▪ Oxidizers, e.g. Chromates, nitrates, ferric salts
CATHODIC & ANODIC
PROTECTION
▪ Cathodic protection: Make the structure
more cathodic by
– Use of sacrificial anodes
Used extensively to protect marine
structures, underground pipelines, water
heaters and reinforcement bars in concrete
▪ Anodic protection: Make Passivating metal
structures more anodic
COATINGS
▪ Most popular method of corrosion protection
▪ Coatings are of various types:
– Metallic
– Inorganic like glass, porcelain and concrete
– Organic, paints, varnishes and lacquers
▪ Many methods of coating:
– Electrodeposition
– Flame spraying
– Cladding
– Hot dipping
– Diffusion
– Vapour deposition
– Ion implantation
– Laser glazing
CONCLUSIONS

▪ Many methods are available to

prevent/mitigate corrosion
▪ One or a number of methods may be
used simultaneously for effective
protection
▪ Proper selection of methods is
essential for optimizing cost.
MECHANISM OF UNIFORM CORROSION

Corrosion mechanism in aqueous solution has been amply

demonstrated. In atmospheric corrosion which also exemplifies
uniform corrosion, a very thin layer of electrolyte is present.
It is probably best demonstrated by putting a small drop of seawater
on a piece of steel. On comparing the atmospheric corrosion with
aqueous corrosion, the following differences are observed:
On a metal surface exposed to atmosphere, only a limited quantity of
water and dissolved ions are present, whereas the access to oxygen
present in the air is unlimited.
Corrosion products are formed close to the metal surface, unlike the
case in aqueous corrosion, and they may prevent further corrosion
by acting as a physical barrier between the metal surface and
environment, particularly if they are insoluble as in the case of
copper or lead.
The following is a simplified mechanism of aqueous
corrosion of iron. At the anodic areas, anodic
reaction takes place: