Types of Corrosion:

1. Uniform attack.

Generally accepted as the most common form of corrosion, it is characterized by a chemical or, more usually,
an electrochemical reaction, which proceeds uniformly over the entire exposed surface. Further due to various
corrosive vapors & liquids including Oxygen available in the surroundings are responsible for this type of
corrosion.
A good example of this type of corrosion is the rusting of metal surfaces exposed to the atmosphere.
This type of corrosion can be compared to normal decay of healthy human beings, who live their normal useful
life. While the youthfulness can be prolonged with suitable painting & coating , in the same way we protect the
equipment reasonably by suitable coatings & paintings.

2. Galvanic corrosion.

This type of attack occurs when dissimilar metals are in contact or otherwise electrically connected. When such
a couple is exposed to a conducting solution, the less noble of the two metals is attacked at a faster rate than
would be encountered in absence of conducting solution.

The cathodic member of the cell is attacked at a lower rate than if it was exposed to the corrodent by itself. This
phenomenon is often used to the designer's advantage when sacrificial anodes (constructed of an inexpensive
material) are utilized to increase the life of more expensive (cathodic) parts. For example, in some heat
exchangers the tube sheets are made of thick sections of carbon steel, which support stainless steel tubes.
Corrosion of the tubes is reduced at the expense of the tube sheets.

This type of corrosion can be best compared to the case if you have a weak supervisor; you become sacrificial
anode for any mistake done by your peers.

3. Crevice corrosion.

While galvanic corrosion involves dissimilar metals whereas crevice corrosion involves differences in the
concentration of the corrodent. It occurs in locations such as under rivet/bolt heads or in threaded joints, where
circulation of the corroding medium is hindered. It can also occur in poorly designed vessels/columns/tanks with
stagnant areas. This can also happen to engineers, who are professionally stagnant.

The message is be active, be flowing at a reasonable speed, be “Well-rounded” and don’t allow crevices in your
life. Read NACE-RP-0178 for tips on how to be “Well-rounded”.

4. Pitting.

This is a form of extremely localized attack that is common in our industry. It differs from uniform attack in that
the anodic areas remain fixed and a rapid localized attack occurs. Pitting attack is particularly destructive as; it
can result in the failure of equipment in a short time with a negligible weight loss of the structure. Pitting can be
caused by mechanical damage to the surface, in-homogeneity of the metal and by the failure to remove scale
from the surface. Pitting is often associated with specific anions such as Chlorine with stainless steels. Pitting of
carbon steel often results from improper control of inhibitors.

It is like a healthy man dieing without any apparent loss of health or weight.

5. lntergranular corrosion.

Virtually all metals are susceptible to localized grain boundary attack. The classic example is austenitic
stainless steels that are heated (during welding, for example) within the range from approximately 510 to 760
°C. In this range, according to one theory, carbon diffuses to the grain boundaries and precipitates chromium
carbides. This reaction removes chromium from solid solution leaving a metal with lower chromium content
adjacent to the grain boundaries. The chromium-depleted zone is less resistant to corrosion and is attacked
preferentially. Another theory is that intergranular corrosion results from the formation of connected chains of
grain boundary carbides during sensitization and not from chromium depletion adjacent to grain boundaries.

6. Stress-corrosion cracking.

Residual or applied stresses can accelerate corrosion rates in some media. Localized corrosion is necessary for
the initiation of stress-corrosion cracking (SCC). The localized surface corrosion acts as a stress raiser, and a
combination of corrosive attack plus stress results in propagation of the crack. SCC can occur in a variety of
environments, but the most active environments contain chloride ions. This type of corrosion can be compared
to someone rubbing salt in other's wounds.

7. Hydrogen attack.

Atomic hydrogen (the product of a corrosion reaction or the result of dissociation of molecular hydrogen)
diffuses rapidly through the steel lattice. The diffusing hydrogen atoms can collect in voids or even in
dislocations where molecular hydrogen can be formed. At higher temperatures, hydrogen atoms can react with
carbon atoms to form methane (CH4). Both mechanisms result in internal pressures that can cause blistering,
laminations, cracking, and loss of ductility. The degradation of ductility caused by the solution of relatively low
levels of atomic hydrogen is called hydrogen embrittlement, and damage of this type is reversible. Reactions
resulting in blistering and similar manifestations are classed as hydrogen damage and are, of course, not
reversible. A third type of attack resulting from elevated temperature exposure in hydrogen is surface
decarburization.

8. Oxidation.

Elevated-temperature oxidation is one of the most common forms of attack involving metal-environment
interaction. Oxidation of industrial equipment can occur in combustion gases, as well as in air. The rate at which
oxidation proceeds is influenced by the composition of the metal, the CO-CO2 ratio in combustion gases and by
the presence of contaminants.

Can be best compared to a person going from a cold country to a hot country, and getting oxidized in a matter
of days or weeks. The skin burns out.

9. Erosion-corrosion.

This mode of attack involves accelerated rates of deterioration resulting from the relative movement of the
corrodent and the metal surface. Effectively the passive film that protects metals from corrosive attack is
damaged or removed by erosion. Erosion-corrosion is particularly troublesome in piping systems containing
elbows and other geometric restrictions to flow. Problems can also be encountered in systems handling
abrasive catalysts. A classic case is H2SO4 stored in carbon steel vessels. Ferrous sulphate film is formed.
This film is quite resistive to H2SO4, and prevents further corrosion of carbon steel. However, in the high
velocity areas, such as inlet nozzles, this protective film gets washed away, and the nozzles corrode at very fast
rate, resulting in premature failures.

This type of corrosion can be compared to a person who had gone through bad patches in life, tried to
heal/recover by himself. But, he has friends/ relatives around him, who keep reminding him of his bad times,
and never allow him to heal by himself.