Corrosion of Materials

and its Prevention

Dr. Abdul Shakoor

Center for Advanced Materials (CAM)
Qatar University
Doha, Qatar
14-10-2021
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 What is Corrosion?
 Eating away or removal of materials by chemical or electrochemical reaction.

An anode is an A cathode is an
electrode on which electrode on which a
an anodic or cathodic or reduction
oxidation reaction is reaction is occurring.
Occurring. 2H+ + 2e- + H2
O2 + 4H+ + 4e- + 2H2O
Zn  Zn2+ + 2e-
Fe  Fe2+ + 2e-

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 Corrosion of Zinc in Acid
● Zinc known as a base or active metal

● Zinc dissolves with hydrogen evolution

Zn + 2HCl  ZnCl2 + H2
 But we can separate metal dissolution
and hydrogen evolution
Zn → Zn2+ + 2e-
2H+ + 2e- → H2

 These are known as electrochemical

reactions

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 Corrosion of a Metal in Acid

Metal HCl solution

M M+n
H+
e- H+ H2
e -

H+ Cl-
H+ Cl-
H+

Anodic Rxn M M+n + n e-

Cathodic Rxn nH+ + n e- n/2 H2
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 Examples of Corrosion

 Rusting of steel
– corrosion product (rust) is solid
but not protective
 Reaction of aluminium with
water
– corrosion product is insoluble in
water, so may be protective
 Burning of magnesium in air Rust on an iron surface

– high temperature oxidation

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Examples of Corrosion

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Examples of Corrosion

Off shore Corrosion 7

Examples of Corrosion

Corrosion has drastically affected the ships, Pipes, tank,

production units, pressure vessel and the valves.

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Corrosion Damages

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Cost of Corrosion

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 Why do Materials Corrode?

 Because metals want to go back to their stable states.

 In the presence of a corrosive environment, Fe tends to
separate (decompose) from steel and reacts with oxygen.

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 Forms of Corrosion
1. Uniform corrosion Uniform and non localized corrosion.

2. Galvanic corrosion
3. Crevice corrosion
4. Pitting corrosion
5. Intergranular corrosion Non-uniform and localized corrosion.

6. Selective leaching
7. Erosion-corrosion
8. Stress corrosion

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Forms of Corrosion

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Forms of Corrosion

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 1. Uniform corrosion

 Uniform corrosion occurs when corrosion is quite evenly

distributed over the surface, leading to a relatively uniform
thickness reduction.
 For example, if a zinc plate is immersed in dilute sulfuric
acid, the metal on the entire surface dipped in sulfuric acid
dissolves.
 Uniform corrosion is assumed to be the most common form
of corrosion

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Uniform corrosion-Examples

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Uniform corrosion-Examples

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Uniform corrosion

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 2. Galvanic Corrosion
 When two dissimilar metals are immersed in a conducting solution
they usually develop different corrosion potentials.
 Corrosion due to two dissimilar metals is called Galvanic corrosion.

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Galvanic Corrosion

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Galvanic Corrosion (Cont.)

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Galvanic Corrosion (Cont.)

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 3. Crevice Corrosion
• Crevice corrosion refers to the attack of metal surfaces by a stagnant solution in
crevices, for example around the edges of nuts and rivet heads.
• It can happen between two metals or between a metal and a nonmetal.

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Crevice Corrosion

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Crevice Corrosion

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 4. Pitting corrosion
• Pitting corrosion is a localized form of corrosion by which cavities or "holes" are
produced in the material.
• Pitting is considered to be more dangerous than uniform corrosion damage because it is
more difficult to detect, predict and design against. Corrosion products often cover the pits.

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Pitting Corrosion

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5. Selective leaching/Dealloying
o Dealloying is the selective corrosion of one or more components of an alloy.
o It is also called parting, selective leaching or selective attack.
o one element or constituent is preferentially removed as a consequence of
corrosion processes
o Common dealloying examples are:
o Dezincification
o Decobaltification
o Denickelification
o Dealuminification
Dealuminification
o Decarburization
o Graphitic corrosion

Graphatic corrosion
Dezincfication 28
 6. Intergranular corrosion
• Intergranular corrosion (IGC) is a localized attack at or near the grain boundaries, with relatively little
corrosion of grains.
• Intergranular corrosion is a selective attack in the vicinity of the grain boundaries of a stainless steel. It
is as a result of chromium depletion, mainly due to the precipitation of chromium carbides in the grain
boundaries.

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Intergranular Corrrosion

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 7. Erosion Corrosion
o Erosion corrosion is the combined effect that occurs due to corrosion and erosion
and is caused by the rapid flow of any turbulent fluid on a metal surface.
o Erosion corrosion consists of the acceleration of or increase in attack to a metal
by differences in the velocity of a corrosive fluid and the metal surface.

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 Steam leakage by pipe erosion

Erosion causes the thinning of the pipe wall that can eventually lead to holes in piping, causing live steam
leaks that can be a serious safety hazard.

https://www.tlv.com/global/TI/steam-theory/piping-erosion.html 32
Piping Damage Caused by Erosion

https://www.tlv.com/global/TI/steam-theory/piping-erosion.html 33
Erosion at Trap Outlet

https://www.tlv.com/global/TI/steam-theory/piping-erosion.html 34
Erosion at Trap Outlet

https://www.tlv.com/global/TI/steam-theory/piping-erosion.html

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Steam separator

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8. Stress corrosion cracking (SCC)
o Stress corrosion cracking results from the combined action of an applied tensile stress
and a corrosive environment.
o The combined effects of stress and corrosion can cause a special type of failure known
as Stress Corrosion Cracking.

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Stress Corrosion

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 Corrosion Prevention
 Corrosion prevention can be accomplished
by the following ways:
o Paints, oil, grease etc.
o Material selection
o Proper designing
o Inhibitors
o Anodic protection
o Cathodic protection
o Coatings
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AMFM Research Group at CAM

https://www.amfml.qa/ 40