Corrosion & it’s

prevention

a. Introduction

b. Historical Background

c. Types

d. Corrosion cell parts

 Introduction

Q :What is Corrosion?
Corrosion is a galvanic process by which
metals deteriorate through oxidation—usually but not
always to their oxides.
Or
It is a natural process which converts a
refined metal into a more chemically stable form such
as it’s oxides, hydroxides or sulfides.
 Examples

• when exposed to air, iron rusts,

silver tarnishes, and copper and
brass acquire a bluish-green
surface called a patina

• Statue of Liberty
 Historical Background
 Has been predicted as early as in 1800.

 Contributions by Evans, Uhlig, Wagner, Traud and

Pourbaix laid a good foundation

 In 1930,Whitney showed it as an E.process.

 In 1930s, Carl Wagner showed that the uniform

dissolution of metals did not require separate
anodic and cathodic sites.
 Need to control corrosion
 Reduces to considerations of safety and economics.

 Machines, equipment, and functional products may

fail due to corrosion

 With all economic decisions, the basis for action is a

compromise between the benefits generated by a
certain level of corrosion control versus the costs that
would result if that level of control were not
maintained.
Chemical & Electrochemical Corrosion
 Electrochemical corrosion would be the forced oxidation or reduction of
something by applying current to it
 Involves two half-cell reactions
 This type of corrosion is also known as Wet corrosion.
 The corrosion of a wire in a circuit would be an example.

 Chemical corrosion occurs when two compounds or elements chemically

react.
 Occurs mainly through the direct chemical action of atmospheric gases
such as oxygen, sulphides, SO2, N2. This type of corrosion is also known
as Dry Corrosion.
 An example would be iron going to rust in air.
 Corrosion and rusting
 Often confused terms

 The word “Rust” is more specifically reserved for

iron, whereas corrosion is commonly defined as
the deterioration of a metal because of a reaction
with its environment

 When iron corrodes, it forms a red-brown

hydrated metal oxide (Fe2O3•xH2O), commonly
known as rust
 Factor Affecting Corrosion
Corrosion can be classified based on one of these factors:
 Nature of the corrodent:
This classification is based on “wet” or “dry” conditions in
which corrosion occurs. The presence of moisture is essential for
wet corrosion and dry corrosion usually involves reaction with gases
at high temperatures.
 Mechanism of corrosion:
Corrosion can occur either electrochemically or with
direct chemical reactions.
 Appearance of the corroded metal:
Corrosion can be either uniform or localized. The metal
corrodes at the same rate over the entire surface for the former and
only small areas are affected in localized corrosion.
 Types
UNIFORM CORROSION
 Considered an even attack across the surface of a material
 Most common type of corrosion
 Typically occurs over relatively large areas of a material’s
surface.

PITTING CORROSION
 One of the most destructive types of corrosion
 Pitting is a localized form of corrosion
 Once a pit has initiated, it grows into a “hole” or “cavity”
that takes on one of a variety of different shapes.
CREVICE CORROSION
 Also a localized form of corrosion
 Usually results from a stagnant microenvironment in which
there is a difference in the concentration of ions between
two areas of a metal.
 Often occur at lower temperatures than pitting

INTERGRANULAR CORROSION
 During solidification of the alloy, as well as the grain
boundaries between them
 Caused by impurities present at these grain boundaries or
by the depletion or enrichment of an alloying element at
the grain boundaries
STRESS CORROSION CRACKING (SCC)
 SCC is a result of the combination of tensile stress and a
corrosive environment, often at elevated temperatures
 May result from external stress such as actual tensile loads on
the metal or expansion/contraction due to rapid temperature
changes.

GALVANIC CORROSION
 It is the degradation of one metal near a joint or juncture that
occurs when two electrochemically dissimilar metals are in
electrical contact in an electrolytic environment
 for example, when copper is in contact with steel in a
saltwater environment.
 Choosing metals that are as close together as practicable on
the galvanic series helps reduce the risk of galvanic corrosion.
 Corrosion cell parts

A corrosion cell consists of four fundamental components:

 Anode
 Cathode
 Conducting environment for ionic movement
(electrolyte)
 Electrical connection between the anode and
cathode for the flow of electron current