Page No.

Date

C0RROSION
Most e wtals uc as Ag, Pt exist in natue u combined
Horms ds tuir oxids, Chltices,sulphides awd carbmatd
Jhes ave yeduced otu wetallie staam their oe during.
extsaction pxoces'n which large omount oj energies requred.
sclatd pUe metal Cau be reded In exkited sBate than thit
back io loweY
OrS Qud tey hae utural tuceucy toretvarioustommd.
ewYgy, Statu Heuee uhw wetalsa u d in
Jhultne expasedto enviTon ment Such asdry gases, moistre,
etc hu expcsed matal kux<oe heqin to deuy iwhiu thuyracesaot
Come in
uy
Contact wrth envisonment&r susrdunding. Ihtvetoethobghuna
destuchion aud los ofsolid metalte uateia
heuind or elechochuical Otock byits environmeufstanting
iIn.
at is suxue us called conrosion,
environmeut
Mothl GastHz0)
Meta metallurgicas Pue metal -
opEYation
CorTOded
meta
Core) Lunstable)
Stable

here are types odcorrosion8- 1.d. Dry /chemical

Wet elechochemica

corr osion t- hua hype CoYYOsim

osin Ccczs mainly thyoul
diveet rhemital
tu dvect . ofenvironment/atmasphere gou
chemicad act6n
Anch as ahalogus,
O ta S, St nitrogeu<inorgaueliaid
uoith wutal su ace uacalld dry lenernical eo vosin.
 Diy Corouin. cau be camied ay foileuinga
Oxidation corTOSLn
da Corosion by othurgass
3.lauid ttl cobsiom
Mechanism doxidalioncoHosiSn &- il is bsought about
by direct acton ejo, at laalhigk tuperalrin the
latseu o oistue!
Keaction o oxidaion CorYOSLSN&
M
tQne

’IM"no
Rx" at Metal - Metal oxidu interae

ro

MetoM)

de
 Page No.
EDate:

Mechausmt oxidation ocurs irst at tu suyace. metal.2

NRAlting metal oxide scale orms abarnierthet etict
rther bxd", Jor oxidaho to se continu, eithur the
Sactal wust dijuuodards fo tu scalk ottu koloeor
Both hawyer occur but thu outatd dijui fthi mtal i
Luuch uote rapid thau incaral di'Y}uien of oxyjen. Sne.
mutal ion us Amallux thau Dxygeu ton duu t6 hiçh'mobilit
Nature ooxidus plays Qu importaut oe ncoOSim pILeSs.
Aheuodatin sttrsa thiu layer layer ooxid afomed
Gn Hhi matal aunlae&natwne
acthion,

) Stadlee stahlu loyer à in shuctueaud geltigkty attacl

to poveut wttal autface huuse Auch aer fomaa
prokche caathing
Unstable s this oxida lhyur decomposes back into metal

Metal axicl y metal+ Oxyqen

Unstable
metg suace
metatorict
Metal Oucair metal dcompost

3) Volatile;-thu onide Volahlized as soon as tu

omad
 (Page No.
AADate :

hurtbylaauiytu muial Aughu txpesd tofurtur atack.ki

apid CortOsin.

exposep auyace e~posed tol

metat oxid, mutal furthtr
attak
utal fo ar wetal votaizes

4 Po1ousEie hauing pored orCrack. hy atmosphiriL OxguBau

through ti gorea aud thu orosiCnContns bte
metal cortd into oxide.
ta +02 cametal meta Oxidi
metat exposud
turtur atbi
Heidalzes
expesed sunae
wetal atal furthur atack throug
poses) crack amtinue

FUlug Baduorth Rude

Accordingthit, oxidt us prokeche ylolome odoidi ça atleast as
great al alume metal hom uhich it formd,on, He
wolume e oxide is le thau voluma mut!
 Page No.
EE(Date:|

Concsin by gaes lik So,,co, Cl, H,s etc. partiipat in th

ComOsLan
Metal.
oces depeuciug upon thit chemical anity with

Lqud wetal corOsiGn us due to chemital ation ing

liouid metal ot hiah teuperatut. Buch corrosin cutin
nicuarpower
plaut
Ne/electrochewtead Cornosini
0CauYSa -

y hure a Concucting liquid i in cmtact with metal

heu 2 dliexet metal are dipped in sol", Bis coosim
CCcuYs duu to tu existeuce o4 separati auodic cathodic
Atanodic
part bluw which cuYeut kous ty conduching sol,
orea oxidation .e "berahion e pee takes place
aud aucdic uutal u cshroyed.
idauhiayd
Anocles- MM+ne
gaL ofe taksplaz,
At,cathodic axea, Yeduchon x, ie. gau
So cthocic T do not atteee aect cathdole, At cathodie
port,disolecl constitaticm in Conducing mdivm accept e
to tom isn.
elecrochemical corYOSiOn involve %
I-oYMatn cucic 4cathodic pats in contact witn each
other.
 (Page No.
Date :

CorToSIGn pracduct, corsitnoauolie. area,

Hdion Aideso calkeie
Feontod leioyt
inclecholl

fe>feë
Octhocic
|Ano e Anccic
|larg) TRoN (luYe)

Curret bl0 Quodic catthode area . Th oclid involed

disoluton ß nutaP ibexoton
t Anoce M
At cathodie ara, th e eleasd inauccic area are
conmd atcatode depeuding upon th nature o!
eueironmet, Cathodio T ual rett into procblses:
)Evolution ef hydrogu
NAhsorpitoh ofongou
Sn abseuce oO, audliu aciclieewirommeut evolhion de
takesplace aud Hton of audicsoluhon bkes wp t k
aud relaeit at cuede'H gas sevolud.
CAqel'e
ecium
 (Page No.

Date

Cnutral Hyt0H
meium)
gTushg of ixon in aciclic mmciwm
fe

fe QHtfe't+ H,g)

Aoptiom:
hia type foffroneeresion
Rust
teks place in prexue foge
in neuhal solution.
duode: fe >fetQe
>OH
Fe to, t Hybfett2DH
FecoH), +o,t Ha0 ’ Feco)a
Rust
fet+20H’RCOH)
Chemical elecrochemical
I tae place inryCond" taku place in wet Cond
a. takes place ky Hudint a. tkes place througk tu farmation
chemialatmck'cfeninaggayauixing cel.
on metal

3. takes place sn homegunu 3. teckelaeonbekrogeuisus

A Unitorm CorroSion 4. Non-unitorm coYosion

5.CorrosIn Praduaunulau 5. cpr ocud acuUmulalst Citho de
at so'spot Wherecoaioy
CCurS
 Page No.
Date:

ypes fcorosioni
LDiyereutad auraioncorYoSin
Gothaic
3. Natliu
4. Drop
5. P ngASeason cracking
6 Shres
> caustic embri tHeniut
Dilerenhal Aerabon Corrsion
I. Hccrs Lsheu on paut of mutal iu exposd tludse
in aiY coneraton om othx paztJt hes buei
tound experimiuntally tht poor oxygenad part behaus.
as uoclcd aadkeisae mere oxqeuatd partbebaE
as cathcclc.e scathodt Cmore oxyusted)
Zn Zn'. + ne

Buode
(povr la )

tacti abaut clilereuta aeraton corrosiN

9Oygesdiut aea serNs aÀ auade.
Q.) CorroSin us aceliratd undir acumulah m o clirt
Scales 4othur contaueiatin&gthis s bhi Caut aud
acunlstsn
dirt vestricb tu extes of oxygeu
3) Metad impsed to aqunus midum corrde uncur block o
wcod onic screen tfhat
porhon tal frm oxyge
 (Page No.
aDate:

Salvauic CoTYOS0GY
Jtus cawsd uhen laoo dis imilas metal are coDmectud totacd.
othin expose dto ligtt. it conthithk agalvatcell toith
loweT electo Chiwtal polenhial cwiu t erocucd. eyz, Cu in
thur electrolyt sol"
|Mehad wohich us highr in elichocheicad senes josma auode,
olectic unev
Z n ’ Zn+2e
+

24 lectrolyte
Pioteetat
lus noble

ttackid ,
Galxanic Sexia,:
Sn the elithrocliuual seris, ie., veducton electod pohmhal
p arauged down in au incyeastng orouy as wtal lislhin
Hhaumitdl
belowit
Actie CAnode)
Magnistom
Mogmeuiomalley
ine
Auminiom
Cac miom
Muminim
Mild ste el clley
Cot Y6n
 Page No.

(Date: | |

gh Ni cast iron
Yb-$n soldar
ad
Tin
Jconel
NMo-fe aloy
Bras metal(tae)
Monel
SilwYsoldi
Coppey
Nickel
ChxomiumStaintex steel
18-1%stainlessteel
8-18 Mas taines steel
Sily
Jtauiom
Gold
Plabnum
Nobie Ccathocde)
Cencettion Cel CorOMSn

O (wodline drop) Corrosisn

Rustiug
wtrsthed in au iY) tah.is s cald a Lwatinline
amay be callud au diferenhad oevothion corosion.
 (Page No.
RDate: | |

NatirlinCorrosioni
tathee Q, 0te
Aneede
ee

Drep corrosien : 3t takes plae wleua chp o eltctroky sol

contoct uith wetal Airfae.OccutEgiigchpe ealyte a lacd
ceutal zegicm underte
drop. Ruig

cathoclh athot
Hrea rade Ahrea
rovtttiode fe - ’ F e e

Piting conosiCn:
4cornosion results in formatn of pits cr heles. Patingq
comoston tahes placedu to Crachki o4 proktucl film dthsx<aue
mitaldu cuode wtormed when heihm has broken, u
on broken partats as cathode,
 (Page No.
ERDate :

factors cHebigconmsimi
I Nature o mctals shu a mutals are in electsical Contaui.
the nanÇ achw wuta gts corroded.
Teduchon in overvoltge,incTtsu Tat
aeDrvaltagei
COYTOSIbn

3. Purity o uatal: the atu corrosLSn increass witie nLeAbing.

Zxjesure fimpurihea.
4. Physical ats ttu Suallr tu size of uetal grear wl
sclukility, qreatri l be cbnrosion.

Aplaic volm ratie qyuaiur

us tu speute volua, les us chmsion Tat.
6a leuperaare w-tth incrase in

Homidity air is aisn adauidig ter in tmaphavi

Buwd atmos plare.
hsIupurihes wi incraast eluchri.
Eonduhinty as a resuet increas Corosim cureut
 Page No.
Date: |

9) Snune o pH comosion matal readily atacked hy ta

acit au be ey'inereasing p atackidg
of
eniromevt

io) NatuYe o ions Qreut: preltuce ot au ions ike Slicatsin th

aktium Ladsto Jormhiaoinsoluble praduct
whica inhibis Juther corosich.
Stres ConYOsim

st us combined elet Atati teusile shes comasin.

envirenmeut on t'mutal. Metal componts are sulbyect D
Uneen sheMS. Duxing thre mauu process whick
nciing caid jergnd quuduig beudiprewing or hut
treatmelt.
Area under shes at as auod1 othur area acts as Cithat
Shess area 84 certa allay beomy cheuically Qcby that
thy axe athckud by mic corosin luuronmiut zeudbng in
estmathn o Crack eluch ndir" 1 oshes.
qroos aud po prgatuw
J exauple shess corzosin a slason Cracking , Causti
dubrittlemutof mid steel.
Seassn Cracking takes place in admosphtse containing NHa
both th allaying compontut o bra~, ii eg.
yçuzn forms complexins, ElLucs),): Tin(n).
Qutaonia sol", wtua lads to clisscuhm c brase
Tudt in Jormton sjcrak.
 Page No.
E(Date: | |

Avea unddar Crack act as aunde Coxdahan) audteother

area actu au cattoce Cveouchon)

’ Caustic Embritttemaut of mitelsteel'- wsheu mild alul u

exposed to alkaline stlutinat high temp presurn aud
Shess t lases failure due to clustii embritementi
CowOsiot Occurs ubeilex atrcntains Na,(9 whie
Utdrgesocompos itimat higl prese. Ihis alhalin wadar
nusn ta Cràck presut in Hu
tuinner surpe f bokrdub.
lcapillary aton toth cone. of
Jhus bolex maerial goes ondiy @oleretconcfalan
cmc celu çs formec he audic iron s cor rode a'by the
action b sodiuh hydroxida forming Soclium tervat DNi, Feal.
Jhis soliom ferrdtu ducahposes to Socdium hydroxid Psyu
for cawies C0rTOSin
M,co, tH,0 NaoH tCo,

Nazfeo, +H20 ’NaoH+fegot H

Cathoce Anode
Fe/concNao4 dlil.NaoH/fe
Controd Rt of corrosion:

Foper dwgrming
Qa Using pue wetal
4.
Cathedie prokhm ky sacrihcialauadi
prakchonmethod
3. 5Mody the enirgmngt
 (Page No.
Date: |

6, Use inhbitm
. Aplcahintprokchtcoating
9. Mutal caingHinig

Tineig
a) Process b< cowering inemar a) Proces o coering
Steel wtha tia coat'y thin coat &y 'tiro praut it
zinc to preucutitomnlr om corxbzioo.
b) Zinc proRcts Huirm b) Tin prohcts base wtal, iron J
,Since iti
Samiiaially .Singeit i corOsion duu bits noblu uaure?
more diehb Hau Fe hiah corr0 SLOM TeMstaue
elecotu thay
Land doem't pexmit ixon
pasinte eutsicu sot",
c) Sn gauauized arhcles zinc c)Tin is uan- taxic audprokcts
Corbinues to prokct Hhe Hu uncirlying inm,tu tucoat
undrlytng izon by gakwau wi pojeet.Any
prrket.Bn break incoabng.
the 0auses

alo wsed Jorsring foude to store fed bcauss t nen

las Zn eshael tors toxic toic adepreuens Conosi nm
 Page No.

EE (Date:

(9 Desn aud natiyial selchon i -

desipn, thugreala thu sumbis ajauyls, conit,edgu
Sn any themore d'iutt it'bomes or"
auu inkrnalAurgab,
hre atmeut

tecurs witthaut ttu preseuce of mastureBu dex'n

No corTosion moi'sture Choud
Ade os tow as possi blee
ky Hu u oa
utal
Digerential wetal coNoSion
co0son Should
should
etal athtythau disinilar
be
redueed olatot
reclueed
metals.dnsulato
metal.
Sheild be placed b<uo two c'ssimilar
depeuols n Telatie size o cahon Pauim.
Rat ot corTOSM sIn
Smala aucde aud targr Cathoc Shoud te &uoided a
be fara
posble,

htheu tuwo dissimilar wwtals are be incom tat:

a) Thuy Should be close to eadothir as possibe in

electrochemie
"Thuy
Serts
pplied
)du inaulaing juting mayb tgdad ketween thusmao
du auodic metal sthould be paintd or coatid, whuin contat
with a olissimar cathodic metal

ete. shoulod b awodld in tu cmytructim

 Page No.

Date:

Prevent the occureue of nm -uniformities in mutal.

Equipment chould be supported n legs fo cloo free cirulakn

Loair.
Proketive Cahing
Metalic Coatingi
modic coatingi protechw uutal Fe.
Metals iiku Zn, M CdA whichan auocit
as compared to thu metal to be protectod ,qet Hhemselves
corTOcLd, sauing Ha mtal fe)

hex metals way be applid on thu Auface yhot dipping

spaying
CCathodle)
expsec Comosi we
paxt environmut
Zn’ Zn2e
J, ZnZp,

*Zinc
Steel
Coating

duod Con exposed part)

Cathadic cocting: Metal suches Sn, Ne, Cu ete ehich
Cathllic as Compared to thu netel Io bi pyoteted
CHose below Fe in galvate series).Ihuybing more eatholie to
ron ae more Yetatat to corvosión audoyr prrkchiom seley
 Page Nc.
KR (Date :

Guaiiy cataciiz Cating

exposedl part
(auoole) CorTOSIn
fef+e
te Fe’fet2e envirommnt
Sncoating
teel

Unexposed
part (cathocle)

Salassiatn:
a thán coat ofzin npretuut Him trom Tsting.
Process
Iron orsteel article irst Cleaud ky dd, HasDq
a. The aboN. pYOce% also YewDNA ACalu, Tust
impurithès .
3. Arhcle is theu washed well aud chried.

4. hu rhcle ws ten dupped into amotem zinc batth

maintainio
at 923-430°C -he &urface ef bath is conered oith ur which
 Page No.

R(Date : |

5. Atur tahingout thuarticle, it id pa through pairo hot

öllers, Hkahtps in proalucinga unilorma'hin fiay zin.
|coaing
inningi- ws Coaing oj tn over mor Steei articles h
proces consist
Treating steel shut incutssog to remove Quoxice

auAtar thi, stkl s pamd through Zncs x.

3Plux helps molten metal to_ adhre h mtal sheet

A Next sheet pased thxouglh atauk o molku tin aud

finally thraugh aseriaof o lu presutit tayer of palnal
nitorm thicknes sn steel Bhe
Elechroplotng s- in this praces, the Coaisg matal iu deposisecdon
wtal by pasing adieik cueot througha
soi", containig
electrolyic Sol", Contain soluku salt cating wutal
sau
plahd cathode
Metal td be placeed
Metal to kike clepsikd’ auode
2rnds tains
plating bau (iecon ims oi metal) lectrolyhesol"n
rhumetal)
pating -icleto beplor ed
 (Page No.
ADate :

Elethical_ ratetion: -

Sacrijiclal duck pro tectn methed uthis protuhion muty

OHhe metl'to be protedd is Connedkya wze to a
Lauodic wetal so tat al tthu coyOsin s ctncertatad at
KTË actine 1Lthl.Ihu nuore actue metal itsey gts conals
Slooty utlathe cathod is protectd. tu ore ali mtal
us lalled auode

mportaut appliations o sacrificial awadit uacthd induda

prokticm ef buried pipins, nolerqrouud cahes, marin
shucturea, ip-hulls, ads- tauks btc

Sil

Ppolins
being
Protected

B bathodc Protection8- ¢M qeuexal, cathodie

appreach where th nmetal
protechon a
made into the Cothede oa corrosin
cell.
 (Page No. DR
(Date: 1

b) Smpresed Qareut cathodle proteein: iu this ethod au

imprened cumut is applied iu au oppasite dizeion to
nuluily th coosion cçrt convert tBhu tormaaig Metal
rom bhode tocadhode. Usualy, thu irpressed curteuts
with a
derivd frm 1a diret urtt'souTeLlie Retifixele)
Corositn proietion
by 'mpresedcurrent
Cathodie
Prctection onit()

aode

nAclubly auode Ciku Qraphite, highsilia irom, SCTapirm), Usually

asuyiciut dc aumuta0ppliÁd to au solubli auode, buid
n tlu sold (orimmersecl to Corrociug hedium) aud coonetd
to-te etallic tructre to bu protectz. he auae is usually
in te
kacteyill Cempcsed foke, branteorgypsum).
increau t electrital contact wth Hu sumouuding soil. Thiu
typ o athodie protechian has been applied to
LBox cobters ete. his typu af protechn eubmiguu s particulaty
dor large stuturts for tmg term apenatians.
 ORAOSION INHIerTDRSE
amj ne
Most corncson inhikitas, which are typically orguic toni
fiim that protecds mital from bornosn Puid, hu chbiest
inhikitün prog1aul tombiuatitn of techaual Reaflen
Considiratir.
TYPE OF NHIBITOR8

Crgpuic înhikitat- an uat aytu ud in costing tuatr

kuatigl oling waluinal, diydrnhin gctsi
utr kull, oater Pgas sytul Roulir
Snorguio inhibitrt n usually wetal sats cohich act to
pasirat thu wital suitae, hau liitol us keeas
thuy auin constaut conceut raton, are oyau
lupHseusitie
Dudt wwwlly aork i than aTe chlorids frenut.
Cenositos- alpha brays whina highly
Shensié bndergoes intr gTainlal bortosin
Contoiwing traes of aumotia ad duieshuattack
gralu bxO udarieA unich hecoms more
wrt giaiv themselneA,
Cuwsdie wit'