Problem 3

For each form of corrosion listed below:

(a) describe why, where, and the conditions under which the corrosion occurs; and
(b) cite three measures that may be taken to prevent or control it.
• galvanic corrosion
• crevice corrosion
• pitting
• intergranular corrosion
• leaching
• erosion corrosion
• stress corrosion
• hydrogen embrittlement

Galvanic corrosion: Occurs when two metals with different compositions (EMF) are
electrically connected in presence of an electrolyte. The less inert metal will corrode while
the other metal is protected from the corrosion. Corrosion rate depends on the relative
anode-to-cathode surface areas that are exposed to the electrolyte.
Measures that may be taken to prevent it:
The use a third metal that protects both of the other metals, known as cathodic protection
If coupling of two different metals cannot be avoided, choose metals that are close together
in EMF series
Modifying the anode-to-cathode area ratio so that the metals may be electrically insulated

Crevice corrosion: Occurs due to concentration difference between two regions of same
metal component. Corrosion takes place in the locale that is of lower concentration. Type of
corrosion occurs in crevices and recesses and under scales of dirt or corrosion product.
Measures that may be taken to prevent it are welding instead of riveting, removing
accumulated deposits and avoiding stagnant areas.
Pitting: Result of small pits, and hole formation, as a consequence of localized corrosion.
Occurs in normal direction to the surface exposed and is difficult to monitor. Therefore, it is
an extremely dangerous form of corrosion, as material loss is often undetectable till the
component fails.
Same measures as for crevice corrosion as well as polishing of surfaces

Inter-granular corrosion: Similar to crevice corrosion, as it is due to concentration

difference, but occurs along the grain boundaries, which are usually of different chemical
composition compared with rest of the grains. Thus grain boundaries are highly susceptible
to corrosion. This form of corrosion is particularly severe in stainless steels.
Protective measures include suitable heat treatment, lowering carbon content, addition of
alloying elements

Leaching: Preferential removal of a solid alloy by corrosion process. An example is the

dezincification of brass. It also occurs as the loss of Ni, Sn and Cr from Cu- alloys; Fe from
cast iron; Ni from steel alloys, and Co from satellite. As a result of this corrosion, mechanical
properties of the components are impaired as the component becomes porous.
Protective measures include change of composition, change of environment and the use of
cathodic protection.

Erosion corrosion: The acceleration of corrosion attack in a metal due to relative motion of
a corrosive fluid and a metal surface i.e. is result of combined action of chemical attack and
mechanical abrasion. All metals and alloys are prone to this corrosion form but it has more
damaging influence on soft metals like Cu and Pb and on metals which passivate by forming
a protective film.
Protective measures include modifying the design, choosing different metal for the
component and removal of particulates and bubbles from the fluid.

Stress corrosion: This form of corrosion is a result of combined action of applied tensile
stresses and corrosive environment. During this corrosion, the metal’s surface is usually
attacked very little while highly localized cracks propagate through the metal section. The
stresses which cause SCC can be residual or applied and is specific to certain combinations
of alloys and environments.
Protective measures include the elimination of external stress, the elimination of
detrimental environment or the change of the alloy.
Hydrogen embrittlement: Hydrogen embrittlement also known as hydrogen assisted
cracking or hydrogen-induced cracking, describes the embrittlement of a metal by diffusible
hydrogen. Occurs when metals become brittle as a result of the introduction and diffusion
of hydrogen into the material. The degree of embrittlement is influenced both by the
amount of hydrogen absorbed and the microstructure of the material.
Hydrogen embrittlement of electroplated components can be prevented by baking them at
375 to 430 °F (190 to 220°C) within a few hours after the electroplating process. During
baking, the hydrogen diffuses out of the metal. Other preventative measure are minimising
contact between the metal and any sources of atomic hydrogen and reducing the intake of
hydrogen by applying a coating that acts as a diffusion barriers to prevent the ingress of
hydrogen.