2/27/2015

CHAPTER 17:
CORROSION AND DEGRADATION

ISSUES TO ADDRESS...
• Why does corrosion occur?
• What metals are most likely to corrode?
• How do temperature and environment affect
corrosion rate?
• How do we suppress corrosion?

Chapter 17 - 1

THE COST OF CORROSION

• Corrosion:
-- the destructive electrochemical attack of a material.
-- Al Capone's
ship, Sapona,
off the coast
of Bimini.

Photos courtesy L.M. Maestas, Sandia

National Labs. Used with permission.

• Cost:
-- 4 to 5% of the Gross National Product (GNP)*
-- this amounts to just over $400 billion/yr**

* H.H. Uhlig and W.R. Revie, Corrosion and Corrosion Control: An Introduction
to Corrosion Science and Engineering, 3rd ed., John Wiley and Sons, Inc.,
1985.
**Economic Report of the President (1998).
Chapter 17 - 2

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CORROSION OF ZINC IN ACID

• Two reactions are necessary:
-- oxidation reaction: Zn  Zn2  2e
-- reduction reaction: 2H  2e  H2 (gas)
H+
Oxidation reaction
Zn Zn 2+ H+
H+
Acid
Zinc flow of e- 2e -
in the metal H+ solution
H+
H+ Adapted from Fig. 17.1, Callister 7e.
H2(gas) (Fig. 17.1 is from M.G. Fontana,
H+ Corrosion Engineering, 3rd ed.,
reduction reaction McGraw-Hill Book Company, 1986.)

• Other reduction reactions:

-- in an acid solution -- in a neutral or base solution
 
O2  4H  4e  2H2O O2  2H2O  4e  4(OH)
Chapter 17 - 3

STANDARD HYDROGEN (EMF) TEST

• Two outcomes:
--Metal sample mass --Metal sample mass

e- e- e- e-
H2(gas) H+ 2e -
ne - 2e - ne -
H+
Platinum

Platinum

Mn+
metal, M
metal, M

Mn+ H+
ions ions
H+
25°C 25°C
1M Mn+ sol’n 1M H+ sol’n 1M Mn+ sol’n 1M H+ sol’n
--Metal is the anode (-) --Metal is the cathode (+)
V o
metal  0 (relative to Pt) o
Vmetal  0 (relative to Pt)
Adapted from Fig. 17.2, Callister 7e.
Standard Electrode Potential
Chapter 17 - 4

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STANDARD EMF SERIES

• EMF series o
• Metal with smaller
metal Vmetal o
Vmetal corrodes.
Au +1.420 V • Ex: Cd-Ni cell
more cathodic

Cu +0.340
Pb - 0.126 - +
Sn - 0.136
Ni - 0.250
Co - 0.277 V o =
Cd - 0.403 0.153V
Cd 25°C Ni
Fe - 0.440
more anodic

Cr - 0.744
Zn - 0.763 1.0 M 1.0 M
Al - 1.662 2+
Cd solution Ni 2+ solution
Mg - 2.363
Na - 2.714
Data based on Table 17.1, Adapted from Fig. 17.2, Callister 7e.
K - 2.924 Callister 7e.
Chapter 17 - 5

CORROSION IN A GRAPEFRUIT
Cathode Anode
+ -
Cu H+ Zn
H+ Zn 2+

 
reduction 2e - oxidation
2H  2e  H2 (gas)
H+
O2  4H  4e  2H2O H+
Acid H+
H+ H+

Chapter 17 - 6

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EFFECT OF SOLUTION
CONCENTRATION
• Ex: Cd-Ni cell with • Ex: Cd-Ni cell with
standard 1 M solutions non-standard solutions
RT X
VNio  VCd
o
 0.153 VNi  VCd  VNio  VCd
o
 ln
- - nF Y
+ +
n = #e-
per unit
oxid/red
Cd 25°C Ni Cd T Ni reaction
(= 2 here)
F=
1.0 M 1.0 M XM YM Faraday's
Cd 2+ solution Ni 2+ solution Cd 2+ solution Ni 2+ solution constant
= 96,500
• Reduce VNi - VCd by
C/mol.
--increasing X
--decreasing Y
Chapter 17 - 7

GALVANIC SERIES
• Ranks the reactivity of metals/alloys in seawater
Platinum
more cathodic

Gold
Graphite
(inert)

Titanium
Silver
316 Stainless Steel Based on Table 17.2, Callister
Nickel (passive) 7e. (Source of Table 17.2 is
M.G. Fontana, Corrosion
Copper Engineering, 3rd ed., McGraw-
Nickel (active) Hill Book Company, 1986.)
Tin
more anodic

Lead
316 Stainless Steel
(active)

Iron/Steel
Aluminum Alloys
Cadmium
Zinc
Magnesium
Chapter 17 - 8

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Chapter 6 - Corrosion
• What is Corrosion???
• Forms of Corrosion
• How to design for Corrosion

• Dr. Payer ASM video tapes – worth the

effort

Chapter 17 -

METALS WANT TO CORRODE – they want to exist as oxide compounds because oxides
contain less energy and are more stable!!

Chapter 17 -

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What is Corrosion??
• Electrochemical reaction involving an
anode and a cathode.
• Deterioration of a material because of
reaction with the environment.
• Combines many elements of engineering
and impacts ALL engineering disciplines:
Chemical Engineering, Mechanical
Engineering, Material Engineering,
Electrical Engineering and Civil
Engineering

Chapter 17 -

Requirements for Corrosion:

Ionic – Current
Path

ANODE CATHODE

Where Electronic Path

Corrosion
Chapter 17 -
Occurs!!!!

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8 Forms of Corrosion:
• Uniform
• Pitting
• Crevice Corrosion or Concentration Cell
• Galvanic or Two-Metal
• Stress Corrosion Cracking
• Intergranular
• Dealloying
• Erosion Corrosion

http://www.intercorr.com/failures.html Chapter 17 -

Uniform Corrosion
• Most common – i.e. steel exposed to environment.
• Uniform in nature – leaves scale or deposit over entire
exposed area – this is called rust which is really iron-oxide
– Fe(OH)3 or Fe2O3
• Fairly predictable and therefore the effects can be
minimized!
– i.e. corrosion proportional to current, proportional to time
(corrosion rate)
• < 2 mils/yr – necessary for food containment
• 20 mils/yr = conservative estimate for general atmospheric
corrosion.
• Really general form of galvanic corrosion – i.e. anode and
cathode random and in same material!
• Prevented by
– Removing electrolyte (i.e. lower relative humidity below 30%)
– Choose material that doesn’t rust in a particular environment –
look at potential-pH diagram!
– Add design “allowance” for rust

Chapter 17 -

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Uniform (or general) corrosion of

steel in water:

Chapter 17 -

EXAMPLE 3:
Machine Shop Tabl

METAL: Carbon Steel

ENVIRONMENT: Industrial en
FORM OF CORROSION: General
METHOD TO CONTROL! Surface is painted for protection. Aggressive environment (molds dragged across
surface) led to scrapping off of paint. Note corrosion where paint is scraped off in line.
Chapter 17 -

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EXAMPLE 4:
Dumbbell

METAL: Cast Iron

ENVIRONMENT: Indoor (exercise room)
FORM OF CORROSION: General
METHOD TO CONTROL! Surface is painted for protection. Note, portion of dumbbell where paint was
abraded off due to handling shows significant corrosion while areas that are better protected from abrasion
retained paint and therefore show little corrosion.
Chapter 17 -

EXAMPLE 5:
House Drain and
Drain Cap

1 year old
cap

30 year
METAL: Cast Iron
old cap
ENVIRONMENT: Residential basement – water exposure
FORM OF CORROSION: General
METHOD TO CONTROL! Surface is painted for protection. Note the 1 year old cap shows significant
corrosion already!
Chapter 17 -

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Crevice or Concentration Cell

• Local attack (corrosion) in crevice due to
change in chemistry of electrolyte making
it more aggressive – i.e. stagnant fluid =
lower oxygen concentration = decrease in
pH.
• Can be between metal surfaces or non-
metal surfaces in contact with metal.
• Very destructive since highly localized!
• How design around?
– Leak proof weld
– Better gasket design
– Avoid stagnant water

Chapter 17 -

Crevice or Concentration Cell

• Good example – crevices and recesses or
under deposits of dirt or corrosion
products where the solution is stagnet.
– Crevice must be wide enough to allow
solution to penetrate yet narrow enough
for stagnancy (i.e. few thousandths of
an inch).

Chapter 17 -

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Crevice or Concentration Cell

Depending on the environment developed in

the crevice and the nature of the metal, the
crevice corrosion can take a form of:

pitting (i.e., formation of pits),

filiform corrosion (this type of crevice
corrosion that may occur on an aluminium
surface underneath an organic coating),
intergrannular attack, or
stress corrosion cracking.

Chapter 17 -

KEY – In crevice
there are high
concentrations of
H+ and Cl- ions
which are
WHY? Low
especially
oxygen levels
corrosive!
(stagnant) means
ions have Chapter
nothing17 -

t t / t

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Crevice corrosion
between pipe and I- Rubber pads just
beam: accelerated the attack –
why???

Chapter 17 -

Pitting Corrosion:
• Extremely localized corrosion that leads to the
creation of small holes in the metal surfaces
• The driving power again is the lack of oxygen around
a small area. This area becomes anodic while the
area with excess of oxygen becomes cathodic.
• More of a problem in stagnant solutions.
• Very destructive since highly localized.
• Prevention?
– Material selection
– Avoid stagnant flow

Chapter 17 -

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Pitting Corrosion:
• Similar in chemistry to crevice corrosion
except it happens in pits.
• Occurs in “pits” of metal surfaces where
again, electrolyte is aggressive (stagnant).
• More of a problem in stagnant solutions.
• Very destructive since highly localized – may
go undetected until failure occurs.
• Gravity causes pit to grow downward –
corrosion rate can increase with time

Chapter 17 -

Pitting Corrosion:
• A pit can be initiated by a localized surface
defect, scratch or slight variation in
composition.
• Stainless steels are especially susceptable to
this form of corrosion.
• Prevention?
– Material selection
– Avoid stagnant flow
– Alloy SS with about 2% molybdenum.

Chapter 17 -

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Galvanic Corrosion:
• Possibility when two dissimilar metals are
electrically connected in an electrolyte*
• Results from a difference in oxidation potentials of
metallic ions between two or more metals. The
greater the difference in oxidation potential, the
greater the galvanic corrosion.
• Refer to Galvanic Series (Figure 13-1)
• The less noble metal will corrode (i.e. will act as the
anode) and the more noble metal will not corrode
(acts as cathode).
• Perhaps the best known of all corrosion types is
galvanic corrosion, which occurs at the contact
point of two metals or alloys with different electrode
Chapter 17 -
potentials.

Galvanic Series:

Questions:
1. Worst
combination?
2. Aluminum and
steel?
3. Titanium and
Zinc?
4. Stainless Steel
Show
and Demo!
Copper?
5. Mild steel and
cast iron?

Chapter 17 -

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GALVANIC SERIES
Galvanic Series in Seawater (supplements Faraq Table 3.1 , page 65), EIT Review Manual, page 38-2
Tendency to be protected from corrosion, cathodic, more noble end

Mercury
Platinum
Gold
Zirconium Graphite
Titanium
Hastelloy C Monel
Stainless Steel (316-passive)
Stainless Steel (304-passive)
Stainless Steel (400-passive)
Nickel (passive oxide)
Silver
Hastelloy 62Ni, 17Cr
Silver solder
Note,
Inconel 61Ni, 17Cr
Aluminum (passive AI203) positions of
70/30 copper-nickel
90/10 copper-nickel
Bronze (copper/tin)
ss and al**
Copper
Brass (copper/zinc)
Alum Bronze Admiralty Brass
Nickel
Naval Brass Tin
Lead-tin
Lead
Hastelloy A
Stainless Steel (active)
316 404 430 410
Lead Tin Solder
Cast iron
Low-carbon steel (mild steel)
Manganese Uranium
Aluminum Alloys
Cadmium
Aluminum Zinc
Beryllium
Magnesium

Chapter 17 -

Chapter 17 -
Big Cathode, Small Anode = Big Trouble

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Design for Galvanic Corrosion?

• Material Selection: Do not connect
dissimilar metals! Or if you can’t avoid it:
– Try to electrically isolate one from the
other (rubber gasket).
– Make the anode large and the cathode
small
• Bad situation: Steel siding with aluminum
fasteners
• Better: Aluminum siding with steel
fasteners
• Eliminate electrolyte
• Galvanic of anodic protection
Chapter 17 -

Design for Galvanic Corrosion?

• Galvanic severity depends on:
– NOT
• Not amount of contact
• Not volume
• Not mass
– Amount of separation in the galvanic
series
– Relative surface areas of the two.
Severe corrosion if anode area (area
eaten away) is smaller than the cathode
area. Example: dry cell battery

Chapter 17 -

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Steel bolt (less

noble) is isolated
from copper
plates.

See handout! –
Read Payer video
Chapter 17 -
HO

Stress Corrosion Cracking:

• Spontaneous corrosion induced cracking
of a material under static (or residual)
tensile stress.
• Problem w/ parts that have residual stress
– stamping double whammy – residual
stress at bends = SCC + stress
concentration.
• AKA environmentally assisted cracking
(EAC), other forms:
– Hydrogen embrittlement
– Caustic embrittlement
– Liquid metal corrosion Chapter 17 -

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Factors:
• Must consider metal and environment.
What to watch for:
– Stainless steels at elevated temperature
in chloride solutions.
– Steels in caustic solutions
– Aluminum in chloride solutions
• 3 Requirements for SCC:
1. Susceptible alloy
2. Corrosive environment
3. High tensile stress or residual stress
Chapter 17 -

Design for Stress Corrosion

Cracking:
• Material selection for a given environment
(Table 13-2).
• Reduce applied or residual stress - Stress
relieve to eliminate residual stress (i.e.
stress relieve after heat treat).
• Introduce residual compressive stress in
the service.
• Use corrosion alloy inhibitors.
• Apply protective coatings.

Chapter 17 -

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Stress Corrosion Cracking:

See handout,
review HO hydron!
Chapter 17 -

Intergranular Attack:
• Corrosion which occurs preferentially at
grain boundries.
• Why at grain boundries?
– Higher energy areas which may be more
anodic than the grains.
– The alloy chemistry might make the
grain boundries dissimilar to the grains.
The grain can act as the cathode and
material surrounding it the anode.

Chapter 17 -

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Intergranular Attack:
• How to recognize it?
– Near surface
– Corrosion only at grain boundries (note
if only a few gb are attacked probably
pitting)
– Corrosion normally at uniform depth for
all grains.

Chapter 17 -

Example 1: Intergranular Attack:

• Sensitization of stainless steels:
– Heating up of austenitic stainless steel
(750 to 1600 F) causes chromuim
carbide to form in the grains.
Chromuim is therefore depleted near
the grain boundries causing the
material in this area to essentially act
like a low-alloy steel which is anodic to
the chromium rich grains.

Chapter 17 -

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Example: Intergranular Attack:

• Sensitization of stainless steels:
– Heating up of austenitic stainless steel
(750 to 1600 F) causes chromuim
carbide to form in the grains.
Chromuim is therefore depleted near
the grain boundries causing the
material in this area to essentially act
like a low-alloy steel which is anodic to
the chromium rich grains.
– Preferential Intergranular Corrosion will
occur parallel to the grain boundary –
eventually grain boundary will simplyChapter 17 -
fall out!!

Design for Intergranular Attack:

• Watch welding of stainless steels (causes
sensitization). Always anneal at 1900 –
2000 F after welding to redistribute Cr.
• Use low carbon grade stainless to
eliminate sensitization (304L or 316L).
• Add alloy stabilizers like titanium which
ties up the carbon atoms and prevents
chromium depletion.

Chapter 17 -

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Intergranular Attack:

Chapter 17 -

Example 2: Intergranular Attack:

• Exfoliation of high strength Aluminum
alloys.
– Corrosion that preferentially attacts the
elongated grains of rolled aluminum.
– Corroded grains usually near surface
– Grain swells due to increase in volume
which causes drastic separation to
occur in a pealing fashion.

Chapter 17 -

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Dealloying:
• When one element in an alloy is anodic to the
other element.
• Example: Removal of zinc from brass (called
dezincification) leaves spongy, weak brass.
• Brass alloy of zinc and copper and zinc is
anodic to copper (see galvanic series).

Chapter 17 -

Dealloying:
• Danger!
– The alloy may not appear damaged
– May be no dimensional variations
– Material generally becomes weak – hidden to
inspection!

Chapter 17 -

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Dealloying:
• Two common types:
– Dezincification – preferential removal of zinc in
brass
• Try to limit Zinc to 15% or less and add 1% tin.
• Cathodic protection

– Graphitization – preferential removal of Fe

in Cast Iron leaving graphite (C).

Chapter 17 -

Erosion:
• Basically a repeat of Chapter 3 (see-
Erosion Wear)
• Forms of Erosion:
– Liquid Impingement
– Liquid erosion
– Slurry Erosion
– Cavitation

Chapter 17 -

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Methods to Control Corrosion

There are five methods to control corrosion:

 material selection
 coatings
 changing the environment
 changing the potential
 design

Chapter 17 -

How to avoid (or control)

Corrosion?
• Material Selection! Remember –
environment key. Look at potential pH
diagrams!!!
• Eliminate any one of the 4 req’ments for
corrosion!
• Galvanic - Avoid using dissimilar metals.
– Or close together as possible
– Or electrically isolate one from the other
– Or MAKE ANODE BIG!!!

Chapter 17 -

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How to avoid (or control)

Corrosion?
• Pitting/Crevice: Watch for stagnate water/
electrolyte.
– Use gaskets
– Use good welding practices
• Intergranular – watch grain size,
environment, temperature, etc.. Careful
with Stainless Steels and AL.

Chapter 17 -

How to avoid (or control)

Corrosion?
• Consider organic coating (paint, ceramic,
chrome, etc.) – DANGER IF IT GETS
SCRACTHED!!
• OR BETTER YET, consider cathodic
protection:
– such as zinc (or galvanized) plating on steel
– Mg sacrificial anode on steel boat hull
– Impressed current, etc..

Chapter 17 -

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Corrosion Control:

Anodic Protection – Zinc coating of steel. KNOW

HOW THIS WORKS!!

Chapter 17 -

DESIGN for Corrosion

Chapter 17 -

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DESIGN for Corrosion

Bracket
easier to
replace
than pipe!

Chapter 17 -

Surface Treatment (Coatings)

• Organic paints
• Chromating and phosphating:
– The Process - chromating and phosphating are surface-coating processes that enhance the
corrosion resistance of metals. Both involve soaking the component in a heated bath based
on chromic or phosphoric acids. The acid reacts with the surface, dissolving some of the
surface metal and depositing a thin protective layer of complex chromium or phosphorous
compounds

• Anodizing (aluminum, titanium)

– The Process - Aluminum is a reactive metal, yet in everyday objects it does not corrode or
discolor. That is because of a thin oxide film - Al2O3 - that forms spontaneously on its
surface, and this film, though invisible, is highly protective. The film can be thickened and its
structure controlled by the process of anodizing. The process is electrolytic; the electrolyte,
typically, is dilute (15%) sulfuric acid. Anodizing is most generally applied to aluminum, but
magnesium, titanium, zirconium and zinc can all be treated in this way. The oxide formed by
anodizing is hard, abrasion resistant and resists corrosion well. The film-surface is micro-
porous, allowing it to absorb dyes, giving metallic reflectivity with an attractive gold, viridian,
azure or rose-colored sheen; and it can be patterned. The process is cheap, an imparts both
corrosion and wear resistance to the surface.

See – corrosion and surface treatment

word document Chapter 17 -

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Surface Treatment (Coatings)

• Electro-plating
– The Process -Metal coating process wherein a thin metallic coat is deposited on the workpiece by
means of an ionized electrolytic solution. The workpiece (cathode) and the metallizing source
material (anode) are submerged in the solution where a direct electrical current causes the metallic
ions to migrate from the source material to the workpiece. The workpiece and source metal are
suspended in the ionized electrolytic solution by insulated rods. Thorough surface cleaning
precedes the plating operation. Plating is carried out for many reasons: corrosion resistance,
improved appearance, wear resistance, higher electrical conductivity, better electrical contact,
greater surface smoothness and better light reflectance.

• Bluing
– Bluing is a passivation process in which steel is partially protected against rust, and is named after
the blue-black appearance of the resulting protective finish. True gun bluing is an electrochemical
conversion coating resulting from an oxidizing chemical reaction with iron on the surface selectively
forming magnetite (Fe3O4), the black oxide of iron, which occupies the same volume as normal iron.
Done for bolts called “blackening”

• Hot-dip Coating (i.e. galvanizing)

– Hot dipping is a process for coating a metal, mainly ferrous metals, with low melting point metals usually zinc and its
alloys. The component is first degreased in a caustic bath, then pickled (to remove rust and scale) in a sulfuric acid bath,
immersed (dipped) in the liquid metal and, after lifting out, it is cooled in a cold air stream. The molten metal alloys with
the surface of the component, forming a continuous thin coating. When the coating is zinc and the component is steel,
the process is known as galvanizing.
– The process is very versatile and can be applied to components of any shape, and sizes up to 30 m x 2 m x 4 m. The cost
is comparable with that of painting, but the protection offered by galvanizing is much greater, because if the coating is
Chapter
steel 17
will-
Discuss and show
scratched it is the zinc not the underlying steel that corrodes ("galvanic protection"). Properly galvanized
survive outdoors for 30-40 years without further treatment.

Which one is galvanized

and which one is chrome
plated? Chapter 17 -

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Material Selection:
• Importance of Oxide films
• The fundamental resistance of stainless steel to
corrosion occurs because of its ability to form an
oxide protective coating on its surface. This thin
coating is invisible, but generally protects the
steel in oxidizing environments (air and nitric
acid). However, this film loses its protectiveness
in environments such as hydrochloric acid and
chlorides. In stainless steels, lack of oxygen also
ruins the corrosion protective oxide film,
therefore these debris ridden or stagnant regions
are susceptible to corrosion.

Chapter 17 -

The “Right”
material
depends on the
environment.

Polarization can
have a major
effect on metal
stability.

Recall CES Rankings: strong acid, weak acid, water, weak alkali, strong alkali Chapter 17 -

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Corrosion Control for Iron

-2

Chapter 17 -

Often several approaches to control corrosion

Often several “system” constraints pertain

Chapter 17 -

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Cathodic Protection (CP)

• Cathodic protection (CP) is a technique to control the corrosion of a metal
surface by making it work as a cathode of an electrochemical cell. This is
achieved by placing in contact with the metal to be protected another more
easily corroded metal to act as the anode of the electrochemical cell. Cathodic
protection systems are most commonly used to protect steel, water or fuel
pipelines and storage tanks, steel pier piles, ships, offshore oil platforms and
onshore oil well casings.

• Types of CP:
– sacrificial anodes – zinc, magnesium or aluminum. The sacrificial anodes
are more active (more negative potential) than the metal of the structure
they’re designed to protect. The anode pushes the potential of the steel
structure more negative and therefore the driving force for corrosion halts.
The anode continues to corrode until it requires replacement,
– Impressed current CP – done for large structures (pipes, offshore
platforms, etc) where a galvanic (or sacrificial) anode can not economically
deliver enough current.
– Galvanized steel (see above slide) – again, steel is coated with zinc and if
the zinc coating is scratched and steel exposed, the surrounding areas of
zinc coating form a galvanic cell with the exposed steel and protects in
from corroding. The zinc coating acts as a sacrificial anode. Chapter 17 -

See Exxon Mobil example

Chapter 17 -

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Aluminium anodes mounted on a

steel jacket structure – using
galvanic corrosion for corrosion
Chapter 17 -
control! Called cathodic protection
( k ifi i l d )

Why Metals
Corrode –
Recommended!!
http://www.westcoastcorrosion.com
/Papers/Why%20Metals%20Corrod
e.pdf

http://www.corrosionsource.com/

http://www.corrosioncost.com/home.html
http://www.intercorr.com/failures.html
http://www.3ninc.com/Cast_Magne
sium_Anodes.htm
http://en.wikipedia.org/wiki/1992_e
xplosion_in_Guadalajara
Chapter 17 -

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FORMS OF CORROSION
• Stress corrosion
Stress & corrosion
• Uniform Attack work together • Erosion-corrosion
Oxidation & reduction at crack tips. Break down of passivating
occur uniformly over layer by erosion (pipe
surface. elbows).
• Selective Leaching • Pitting
Preferred corrosion of Forms Downward propagation
one element/constituent of small pits & holes.
of Fig. 17.17, Callister 7e.
(e.g., Zn from brass (Cu-Zn)).
corrosion (Fig. 17.17 from M.G.
Fontana, Corrosion
• Intergranular Engineering, 3rd ed.,
Corrosion along McGraw-Hill Book
Company, 1986.)
grain boundaries, • Galvanic
often where special Dissimilar metals are
• Crevice Between two
phases exist. pieces of the same metal.
physically joined. The
Rivet holes
g.b. more anodic one
prec.
corrodes.(see Table
17.2) Zn & Mg
attacked Fig. 17.15, Callister 7e. (Fig. 17.15 is
zones very anodic. courtesy LaQue Center for Corrosion
Technology, Inc.) Chapter 17 - 67
Fig. 17.18, Callister 7e.

CONTROLLING CORROSION
Metal oxide
• Self-protecting metals! Metal (e.g., Al,
-- Metal ions combine with O stainless steel)
to form a thin, adhering oxide layer that slows corrosion.
• Reduce T (slows kinetics of oxidation and reduction)
• Add inhibitors
-- Slow oxidation/reduction reactions by removing reactants
(e.g., remove O2 gas by reacting it w/an inhibitor).
-- Slow oxidation reaction by attaching species to
the surface (e.g., paint it!).
• Cathodic (or sacrificial) protection
-- Attach a more anodic material to the one to be protected.
e.g., zinc-coated nail e.g., Mg Anode
Zn 2+ Adapted from Fig. 17.22(a),
Adapted Cu wire
from Fig.
zinc zinc e- Callister 7e. (Fig. 17.22(a) is
17.23, steel Mg Mg 2+ from M.G. Fontana, Corrosion
Callister 2e - 2e - pipe anode
Engineering, 3rd ed., McGraw-Hill
Book Co., 1986.)
7e. steel Earth Chapter 17 - 68

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SUMMARY
• Corrosion occurs due to:
-- the natural tendency of metals to give up electrons.
-- electrons are given up by an oxidation reaction.
-- these electrons then used in a reduction reaction.
• Metals with a more negative Standard Electrode
Potential are more likely to corrode relative to
other metals.
• The Galvanic Series ranks the reactivity of metals in
seawater.
• Increasing T speeds up oxidation/reduction reactions.
• Corrosion may be controlled by:
-- using metals which form -- adding inhibitors
a protective oxide layer -- painting
-- reducing T -- using cathodic protection.

Chapter 17 - 69

ANNOUNCEMENTS
Reading:

Core Problems:

Self-help Problems:

Chapter 17 - 70

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