‫ْ‬ ‫ْ‬ ‫َ‬ ‫ْ‬ ‫َ‬

‫َوأن َزلنا ٱل َح ِدي َد فِي ِه بَأ ٌ‬

‫س‬
‫س‬
‫ِ‬ ‫ا‬ ‫َّ‬ ‫ن‬ ‫ل‬ ‫ل‬ ‫ع‬
‫ُ‬ ‫ف‬ ‫ا‬‫َ‬
‫ش ِدي ٌد َو َمن ِ ِ‬
‫َ‬
‫نظرة طائر على‬
‫أساسيات هندسة التآكل والحـماية‬
‫دكتور مهندس جمال الشربينى‬
‫خبيرهندسة التآكل والحماية‬
‫وتحليل اإلنهيارات والمشاكل من جذورها‬
Leaking Underground Storage Tank
Close-Up of Leaking Underground Storage
Tank
This is a classic example of normal galvanic
corrosion experienced on USTs.
 ‫ين َكفَ ُروۤا ْ أ َ َّن‬ ‫ذ‬ ‫ِ‬ ‫َ‬
‫أَ ْ ََ ّ َ‬‫ل‬ ‫ٱ‬ ‫ر‬ ‫ي‬ ‫م‬ ‫َ‬ ‫ل‬‫و‬ ‫َ‬
‫ت َوٱأل َ ْر َض َكانَتَا َرتْقا ً‬ ‫ٱلس َٰم َٰو ِ‬ ‫َّ‬
‫اه َما َو َج َعلْنَا ِم َن ٱل َْمآ ِء‬ ‫َففَتَقْن َ ُ‬
‫ون‬
‫ُْ ُ َ‬ ‫ن‬ ‫ِ‬
‫م‬ ‫ؤ‬‫ي‬ ‫َ‬ ‫ال‬ ‫ف‬
‫َ‬ ‫َ‬ ‫ي‬
‫ح ٍّ أ‬
‫َ‬ ‫ء‬
‫ٍ‬ ‫ي‬ ‫ُك ّ ْ‬
‫ش‬ ‫َ‬ ‫ل‬ ‫َ‬
‫سورة األنبياء ‪30‬‬
Wate
r for
Life
 ‫َوٱ ْل َخ ْي َل َوٱ ْلبِ َغا َل َوٱ ْل َح ِمي َر‬
‫ق َما الَ‬ ‫لِتَ ْر َكبُو َها َو ِزينَةً َويَ ْخلُ ُ‬
‫تَ ْعلَ ُم َ‬
‫ون‬
‫سورة النحل ‪8‬‬
Microorganisms such as bacteria,
fungi, moulds and mildews
Microbialogical Corrosion Attack

Above ground storage tanks (AST) where the ambient

summer temperatures are ideal for bacterial colony growth
Microbially-influenced corrosion of metals at sea is a
big safety and financial problem caused by the
production of damaging substances such as hydrogen
sulphide by sulphate-reducing micro-organisms within
biofilms on the surfaces.
There are manifold reasons to avoid corrosion in maritime applications
above-sea or sub-sea. Suitable standards to protect parts like boltings and
fasteners for many years from corrosion are the cathodic corrosion
protection or the use of cost intensive duplex and super duplex steels.
 Scrap
Yard

Steel Life Cycle

Electric Arc Steel

  Scrap

Furnace Making By-

products

Fencing
Products Rebar
Ladle
(refining)

Hot
Rollers

Continuous
Casting

Steel
Billet
 Why Metals Corrode

Refining-Corrosion Cycle
Why Metals Corrode

Corrosion Cycle Example

Basic Interactions that Result in Corrosion
 Crystalline Structure of
Perfect Solids

Unit Cells for Body-Centered Cubic, Face-Centered

Cubic, and Hexagonal Close-Packed Structures
Crystalline Structure of Imperfect Solids
Self-interstitial
impurity atom Matrix atom

Substitutional
impurity atom

Interstitial
impurity atom

Vacancy
(Void)

Point Defects in a Crystalline Structure

Half-Cell Potential Measurement and
Cu/CuSO4 Reference Electrode
Electromotive Force Series

Half-Cell Potential Measurement

Electromotive Force Series

Electromotive Force Series for Metals

Measurement of Pipeline Potentials
Corrosion Cell Between Dissimilar Metals
‫‪َ  ‬بيْن َ ُه َما َب ْر َز ٌخ‬
‫ان‬ ‫ي‬ ‫ِ‬
‫ال ّ َ ْ َ ِ‬
‫غ‬ ‫ب‬‫ي‬ ‫َ‬
‫سورة الرحمن ‪20‬‬
Corrosion Cell
http://www.corrosionclinic.com/corrosion_online_lectures/dl.gif
Forms of Corrosion
 General Corrosion
Original surface
before corrosion

Surface after
corrosion
 General Corrosion
Methods to Control General Corrosion
1. Use corrosion-resistant materials.
2. Apply coatings.
3. Use corrosion inhibitors.
4. Remove oxygen from the system.
5. Use cathodic protection.
6. Add corrosion allowance.
 Galvanic Corrosion

Original
surface Cathodic
Anodic metal metal

Surface after
corrosion
 Galvanic Corrosion

Current Flow

Old Pipe New Pipe Old Pipe

Dissimilar Metal Couple Mechanism

Galvanic Series
of Some
Commercial
Alloys in
Seawater
 Highly conductive electrolyte

Widespread corrosion

Cathodic
metal
Anodic metal

Galvanic Corrosion in a Highly

Conductive Solution
 Galvanic Corrosion
Mildly conductive electrolyte

Concentrated Cathodic
corrosion metal

Anodic metal

Galvanic Corrosion in a Mildly

Conductive Solution
Area Principle for Galvanic Corrosion
 Galvanic Corrosion
Methods to Control Galvanic Corrosion
1. Select metals that are close together in the
galvanic series.

2. Do not use small anodes with large cathodes.

3. Insulate dissimilar metals completely.

4. Apply and maintain coatings.

 Galvanic Corrosion
(cont’d)
5. Use corrosion inhibitors.

6. Avoid threaded joints for materials

that are far apart in the galvanic series.

7. Use cathodic protection.

8. Use thicker anodic parts or design

them for easy replacement.
 Intergranular Corrosion
Intergranular Grain
corrosion boundary

Grain

A Representation of Intergranular
Corrosion
 Intergranular Corrosion
Grain
boundary
Grain
Grain

Chromium Chromium-
carbide depleted
Grain precipitate area

Representation of a Sensitized Grain Boundary

in Type 304 Stainless Steel
Intergranular Corrosion
Chromium
Carbide

Grain Grain

Cross-sectional View of the Grain

Boundary Area
 Intergranular Corrosion
Methods to Control Intergranular Corrosion
For Austenitic Stainless Steels:
1. Avoid temperatures that cause
sensitization (400 – 900°C).
2. Add alloying elements that form carbides
easier than chromium (e.g., titanium or
niobium).
3. Lower the carbon content below 0.02%.
4. Follow special welding procedures.
 Pitting

Original surface

Pit Pit

Representation of Pitting Mechanism

 Pitting
Sodium Chloride
Na+
Solution Na+ Na+
O2 O2
O2
CI- CI-
- O2
O2 O2 CI O2 O2

OH- OH- CI- OH- OH-

M+ CI -
-
CI
M+ CI- M+
CI-
+
H+ CI- H
M+ M+ M+
+
M

e e
e e

Growth of a Pit in an Aerated Sodium

Chloride Solution
 Pitting
Methods to Control Pitting Corrosion
1. Use cathodic protection.

2. Coat vessels and pipe.

3. Keep equipment clean.

4. Use corrosion inhibitors or oxygen scavengers

5. Select the proper alloys.

 Crevice Corrosion
Active corrosion in Metal oxide Drop of
unaerated area deposits electrolyte

Aerated
area
Fe++ O2

e
e

Concentration Cell at the Air-Water Interface

of an Electrolyte Droplet
 Crevice Corrosion
Anodic Areas
in Crevices

Concentration Cell in the Crevices of a Bolted Flange

 Crevice
Corrosion

Concentration
Cell in the
Crevices of a
Bolted Flange
 Crevice Corrosion
O2 OH -

e
O2 OH -
Na +
e

O2 OH - e
O2 Na +

CI - CI - M+
M+ M+
CI - CI - CI -
- +
O2 CI H CI -
O2 O2
M+ H+
H+ CI -
- M+ + M+
OH -
OH -
OH M

e e e

The Later Stages of Crevice Corrosion

Between Two Bolted Plates
 Crevice Corrosion
Methods to Control Crevice Corrosion
1. Avoid crevices in new construction.
2. Close existing crevices by continuous welding,
caulking, or soldering.
3. Prevent solids from precipitating out of
solution if possible.
4. Inspect equipment and remove deposits
frequently to prevent solids buildup.
 Filiform Corrosion

Tail Head

Motion

Parts of a Filament
 Filiform Corrosion

Direction of growth
Protective
coating
O2 H2O O2 H2O
Filament
head
high pH
O2
low pH
Fe (OH)3

Steel Corroded track Fe2+

The Reactions in a Corrosion Filament on a

Steel Surface
 Filiform Corrosion
Method to Control Filiform Corrosion
1. Reduce the humidity of the environment,
if possible.

2. Use coatings that are less permeable to

water vapor.

3. Cleaner metal surfaces may reduce filiform

corrosion.
 Erosion-Corrosion
Original surface Surface after
corrosion Flow

Representation of Erosion-Corrosion
•Smooth groves or waves
•Turbulent fluid flow
•Tubing inlets for condensers
 Erosion-Corrosion
Method to Control Erosion-Corrosion
1. Use metals that form a more protective
corrosion film.
2. Design systems to reduce or prevent
turbulent flow.
3. Use corrosion inhibitors.
4. Reduce the velocity of the fluid, if possible.
5. Apply coatings.
Sulfide Stress Cracking

Tensile Tensile
Forces Forces
Hydrogen
atoms

H
H
H
H
H
H
H

H H
H
Advancing H Metal
crack

Sulfide Stress Cracking

Stress Corrosion Cracking

Corrosion
product
film

M2+
M2+

Tensile Tensile
Forces Forces

Advancing
Metal crack

Stress Corrosion
Cracking
 Stress Corrosion Cracking
Methods to Control Stress Corrosion Cracking
1. Change the design or reduce the load to lower
the stress.
2. Remove corrosive agents.
3. Use cathodic protection only when SCC is
known to cause failures.
4. Apply coatings.
5. Use corrosion inhibitors.
6. Select materials that are resistant to SCC.
 Corrosion Fatigue
Load

Compression

Tension
Bearing Bearing
Support Support

Alternating Tensile and Compressive

Stresses in a rotating Member
 Corrosion Fatigue
Initiation site
( corrosion pit or
mechanical damage )

Smooth surface
( with beach marks )

Rough fracture
surface

Appearance of Corrosion Fatigue Failure

of a Rotating Member
 Corrosion Fatigue
Methods to Control Corrosion Fatigue
1. Use more corrosion resistant metal.
2. Remove water from the system.
3. Reduce stresses on the structure as follows:
• change the design.
• heat treat the material to relieve
internal stresses
• shot-peen the surface to create
compressive stresses.
4. Use corrosion inhibitors to prevent the
start of pits.
 De-Alloying
(Selective Leaching)

Dezincified
plugs

Plug Type
Dezincification
 De-Alloying (Selective Leaching)

Methods to Control Selective Leaching

1. Use an alloy that is less susceptible to
selective leaching.

2. Use corrosion inhibitors to make the

environment less corrosive.

3. Remove oxygen to make the environment

less corrosive.
How Cathodic Protection Works

An Electrochemical Corrosion Cell on the

Surface of a Metal
How Cathodic Protection Works

Electrons Introduced from an External Source

How Cathodic Protection Works

Cathodic Polarization Caused by

Direct Current
How Cathodic Protection Works

After Cathodic Protection Current is Applied

Operation of Impressed Systems

A Typical Impressed Current System with a

Surface Anode Bed
Corrosion Solution
Remove the Oxygen