PREVENTION OF

CORROSION
Dr. T. K. G. Namboodhiri
[Retd. Professor., Inst. Techno. , Banaras Hindu University]

Consultant-Metallurgy & Corrosion,

Tiruvalla, Kerala
PREVENTION OF
CORROSION
 The huge annual loss due to corrosion is a
national waste and should be minimized
 Materials already exist which, if properly
used, can eliminate 80 % of corrosion loss
 Proper understanding of the basics of
corrosion and incorporation in the initial
design of metallic structures is essential
METHODS

 Material selection
 Improvements in material
 Design of structures
 Alteration of environment
 Cathodic & Anodic protection
 Coatings
MATERIAL SELECTION
 Most important method – select the appropriate
metal or alloy .
 “Natural” metal-corrosive combinations like
c. S. S.- Nitric acid,
d. Ni & Ni alloys- Caustic
e. Monel- HF, Hastelloys- Hot HCl
f. Pb- Dil. Sulphuric acid,
g. Sn- Distilled water
h. Al- Atmosphere,
i. Ti- hot oxidizers
j. Ta- Ultimate resistance
 Corrosion Tables available for various materials
in different corrosive environments
IMPROVEMENTS OF
MATERIALS
 Purification of metals- Al , Zr
 Alloying with metals for:
c) Making more noble, e.g. Pt in Ti
d) Passivating, e.g. Cr in steel
e) Inhibiting, e.g. As & Sb in brass
f) Scavenging, e.g. Ti & Nb in S.S
 Improving other properties
h) Change of microstructure. e.g. desensitization of s. s.
welds.- prevents I.g. corrosion
i) Elimination of tensile stress-improves SCC
j) Introduction of surface compressive stress-improves
corrosion fatigue and SCC.
DESIGN OF STRUCTURES
 Avoid sharp corners
 Complete draining of vessels
 No water retention
 Avoid sudden changes in section
 Avoid contact between dissimilar metals
 Weld rather than rivet
 Easy replacement of vulnerable parts
 Avoid excessive mechanical stress
ALTERATION OF
ENVIRONMENT
 Lower temperature and velocity
 Remove oxygen/oxidizers
 Change concentration
 Add Inhibitors
 Adsorption type, e.g. Organic amines, azoles
 H evolution poisons, e.g. As & Sb
 Scavengers, e.g. Sodium sulfite & hydrazine
 Oxidizers, e.g. Chromates, nitrates, ferric salts
CATHODIC & ANODIC
PROTECTION
 Cathodic protection: Make the structure
more cathodic by
– Use of sacrificial anodes
– Impressed currents
Used extensively to protect marine
structures, underground pipelines, water
heaters and reinforcement bars in concrete
 Anodic protection: Make Passivating metal
structures more anodic by impressed
potential. e.g. 316 s.s. pipe in sulfuric acid
plants
COATINGS
 Most popular method of corrosion protection
 Coatings are of various types:
– Metallic
– Inorganic like glass, porcelain and concrete
– Organic, paints, varnishes and lacquers
 Many methods of coating:
– Electrodeposition
– Flame spraying
– Cladding
– Hot dipping
– Diffusion
– Vapour deposition
– Ion implantation
– Laser glazing
CONCLUSIONS

 Many methods are available to

prevent/mitigate corrosion
 One or a number of methods may be
used simultaneously for effective
protection
 Proper selection of methods is
essential for optimizing cost.