CORROSION

With
Khalid Khattak
“Destruction of a material because of reaction

with its environment”

 Finished
Steel Mill Product

Reduction

Refining

Casting Installed

Rolling
Rust
Iron Ore
Shaping (Iron Oxide)
(Iron Oxide)
 TYPICAL CORROSION CELL

04 Basic Components:
1- Cathode
2-Anode
3-Electrolyte
4-Electrical path between
electrodes
TYPICAL CORROSION CELL- Water Drop
TYPICAL CORROSION CELL – Water Drop Explained
Contd.
DELETERIOUS EFECTS OF CORROSION

MAINTENANCE & OPERATING COSTS

EXPENSIVE OVERDESIGN

PLANT SHUT DOWNS

WASTE OF VALUABLE RESOURCES

CONTAMINATION OF PRODUCT

REDUCTION IN EFFCIENCY

EFFECT ON SAFETY & RELIABILITY

APPEARANCE
 CORROSION CLASSIFICATION

UNIFORM ATTACK

GALVANIC CORROSION

CREVICE CORROSION

EROSION CORROSION

INTERGRANULAR CORROSION

SELECTIVE LEACHING

PITTING

STRESS CORROSION CRACKING

 UNIFORM ATTACK

“Reaction of a material with it’s environment

which proceeds uniformly over the entire

exposed surface or over a large area”

Piece of Iron Placed in Open Air

2Fe + 3O2 2Fe2O3
 GALVANIC CORROSION

“When two different metal are immersed in a

conductive solution and brought in contact

externally, electron flow is produced between

them which results in corrosion of less resistant

metal ”
GALVANIC CORROSION - SERIES
 GALVANIC SERIES- Explained

The potential differences are

expressed in milli-volts.

Below the red line, metal

considered is attacked.
 HOW TO AVOID GALVANIC CORROSION?

 Less difference in Galvanic Series

 Avoid small areas of less noble metal with large area
of more noble metal

 Insulate the metals

 Exclude electrolyte from around bimetallic junction
 Paint both metals where possible
 Provide corrosion allowance to less noble metal
 EROSION CORROSION

“Acceleration or increase of deterioration or

attack on a metal because of relative

movement between corrosive fluid and the

metal surface”
 INTERGRANULAR CORROSION

“Localized attack at and adjacent to grain

boundaries, with relatively little corrosion of the

grains, is intergranular corrosion”

 SELECTIVE LEACHING

“Removal of one element from a solid alloy by

corrosion processes”
 PITTING

“Extremely localized form of corrosion that

results in holes in the metal”

 STRESS CORROSION CRACKING

“Cracking caused by simultaneous

presence of tensile stress and a specific

corrosive medium”
 CREVICE CORROSION

“Localized corrosion occurs within crevices on

metal surface exposed to corrosive medias”

 FACTORS INFLUENCING CORROSION

SOLUTION ACIDITY

TEMPERATURE

VELOCITY

PROTECTIVE FILM NATURE

 CORROSION PREVENTION METHODS

CORROSION INHIBITATION

COATING OF METAL SURFACES

CATHODIC PROTECTION
 CORROSION INHIBITORS

PASSIVATING INHIBITORS

CATHODIC INHIBITORS

ORGANIC INHIBITORS

PRECIPTATION INHIBITORS

VOLATILE CORROSION INHIBITORS

 CATHODIC PROTECTION

SACRIFICIAL ANODE METHOD

IMPRESSED CURRENT METHOD

 SACRIFICIAL ANODE METHOD

Ground Level

e’ Flow

Mg
Steel Pipe Anode
 IMPRESSED CURRENT METHOD

- +
e’ Flow
Rectifier

Mg
Steel Pipe Anode
DISCUSSION
 ELECTROCHEMICAL ASPECTS

Zinc in HCl

Zn + 2HCl ZnCl2 + H2

Oxidation (Anodic) Reaction Zn+2

Zn Zn+2 + 2e’
e’ H+
e’ Cl-
Reduction (Cathodic) Reaction H +

H+
2H+ 2e’ + H2 Cl-
Cl-
Effect of Oxygen concentration, temperature and corrosion of steel pipes
Erosion Corrosion
Erosion Corrosion
Erosion Corrosion
BASIC CATHODIC PROTECTION
BASIC CATHODIC PROTECTION
BASIC CATHODIC PROTECTION
BASIC CATHODIC PROTECTION
BASIC CATHODIC PROTECTION
BASIC CATHODIC PROTECTION
BASIC CATHODIC PROTECTION
BASIC CATHODIC PROTECTION
BASIC CATHODIC PROTECTION
BASIC CATHODIC PROTECTION
BASIC CATHODIC PROTECTION
TYPICAL CORROSION CELL
TYPICAL CORROSION CELL
UNIFORM ATTACK
CORROSION UNDER INSULATION
GALVANIC CORROSION
EROSION CORROSION
 INTERGRANULAR CORROSION

AT HIGH TEMPERATURE (> 750 0C) Cr REACTS WITH C AND FORMS CrC

GRAIN BOUNDARIES

CHROMIUMCARBIDE
(Cr23 C6)
CHROMIUM
INTERGRANULAR CORROSION
 SELECTIVE LEACHING

Brass Condenser Tubes

(Cooling Water Service)
STRESS CORROSION CRACKING
PITTING
CREVICE CORROSION