Introduction to Corrosion

Science and Engineering

-by Abinaya
B.Nanditha
CORROSION
OBJECTIVES OF CORROSION
 Definition of CORROSION.
 CORROSION ENGINEERING.
 To understand the significance and
the factors which influence corrosion.
 To study the different types of
corrosion.
 The protective measure to control
corrosion.
CORROSION
1.Introduction
11.Types of corrosion
1.Dry or chemical corrosion.
2.wet or electrochemical corrosion.
3.galvonic corrosion.
4.concentraction cell corrosion.
5.underground or soil corrosion.
6.pitting corrosion.
7.intergranular corrosion.
8.waterline corrosion.
9.stress corrosion.
10.Microbiological corrosion.
11.Erosion corrosion.
111.Mechanisms.
1V.corrosion control.
V.PH potential.
INTRODUCTION

 Metals and alloys are generally used as

fabrication or construction materials in
engineering. If the metal or alloy
structures are not properly maintained ,
they deteriorate slowly by the action of
atmospheric gases,moisture and other
chemicals. This phenomenon of
deterioration or destruction of metals
and alloys is known as corrosion.
WHAT IS CORROSION ?
“CORROSION is defined as the gradual
destruction or deterioration of metals or
alloys by the chemical or electrochemical
reaction with its environment.”
Simply, the decay or destruction of
metal due to the action of surrounding
medium is called as CORROSION
 Example:
1. Rusting of iron
2. Formation of green layer on copper
surface
Example 1.Rusting of iron
Rust is another name for iron oxide ,
which occurs when iron or alloy that
contains iron,moisture for a long period
of time.over time, the oxygen combines
with the metal at an atomic level,
forming a new compound called an
oxide and weakening the bonds of the
metals.
Rusting of iron
Example 2.Formation of green
layer on copper surface
Copper metal when exposed to air turns
green in colour due to corrosion . When
copper vessel is exposed to air in rainy
season,the metal recats with gases and
moisture and atmospheric gases to
form a mixture of copper carbonate and
copper hydroxide .This gives a green
colour to the surface of copper metal.
Formation of green layer on
copper surface(images)
DIFFERENT THEORIES OF
CORROSION
There are three theories of
corrosion :
1.Acid theory.
2.Dry or chemical corrosion and
3.Galvanic or electrochemical
Reasons for corrosion
 Economic-Due to material losses.
 Saftey-To prevent catastrophic
consequences resulting from
operation failure of equipment.
 Conservation – To conserve metal
resources ,which are limited .
CORROSION SCIENCE.
Corrosion science is the study of
corrosion mechanism to improve
 The understanding of the causes of
corrosion .
 The way to prevent or at least
minimize damage caused by
corrosion.
CORROSION ENGINEERING

The branch of Engineering that

deals with the study of corrosion
mechanisms and to prevent or control it
economically and safely is known as
CORROSION ENGINEERING.
Corrosion scientist Vs corrosion
engineer
For example:
Corrosion engineer uses cathodic
protection on a large scale to prevent
corrosion of buried pipelines ,tests and
develop new and better paints,prescribes
proper dosage of corrosion inhibitors or
recommend the correct coating .
Corrosion scientist develops better criteria
of cathodic protection ,develop efficient
corrosion inhibitors,corrosion-resistant
alloys and recommends heat treatments
and composition of alloys.
CAUSES OF CORROSION

Metals occur in nature in two different

forms.
1.Native state.
2.Combined state.
1.NATIVE STATE

The metals occur in native (or)

free (or) uncombined state are non-
reactive with the environment .They are
noble metals as such in the earth crust.
They have very good corrosion
resistance.
Example:Au,Pt,Ag
2.COMBINED STATE
Expect noble metals,all other metals are
reactive and react with environment and
form stable.Compounds, as their oxides,
sulphides, chlorides and carbonates.
They exist in their form of stable
compounds called ores and minerals.
Example:Zno,PbS etc.,
WHY DO METALS CORRODE?
Most metals(except gold & platinum) exist in
nature in combined forms as their oxides,
chlorides,sulphides,carbonates etc.,
The combined form of the metal are
called as minerals or ores which are reduced to
their metallic states during extraction process.
When ,metals are used in various forms,
they are exposed to environment,(such as dry
gases,moisture, etc.,) the exposed metal
surface begins to decay ie., conversion into
more stable compound.this is the basic reason
for metallic corrosion.
Extraction process
EFFECTS OF CORROSION
 Unpredictable machinery failiure.
 Decrease in efficiency of machine.
 Replacement of corroded equipment
leading to an expensive proposition .
 Contamination of portable water .
 Sudden failure can cause fire explosion.
 Plant gets failure due to corrosion.
 Release or leakage of toxic product and
construction collapse.
Why study corrosion?
 Materials are precious resources.
 Engineering design in incomplete
without knowledge of corrosion .
 Applying knowledge of corrosion
protection can minimize disasters.
 Corrosion-may contaminate stored
food,dairy products,etc.
 Corrosion products cause poiiution.
 Artifical implants for the human body.
CORROSION CONTROL
“It is better to control rather than to
prevent corrosion ,since it is impossible
to eliminate corrosion”.
Some of the corrosion methods are:
1.Proper designing.
2.Using metal alloys.
3.Using pure metal.
4.Cathodic protection.
5.Modifying the environment.
6.Applications of protective coatings.
THANK YOU