TYPES OF CORROSION

Pitting corrosion is a form of extremely localized corrosion that leads to the creation of small
holes in the metal. The driving power for pitting corrosion is the depassivation of a small area,
which becomes anodic while an unknown but potentially vast area becomes cathodic, leading to
very localized galvanic corrosion. The corrosion penetrates the mass of the metal, with limited
diffusion of ions. The mechanism of pitting corrosion is probably the same as crevice corrosion.
Pitting can be initiated by a small surface defect, being a scratch or a local change in
composition, or a damage to protective coating. Polished surfaces display higher resistance to
pitting.

For example, metals like stainless steel and aluminium which are normally protected by a thin
oxide film, are subjected to pitting corrosion in a chloride environment, thus making its unsuitable
for in use in a sea water system.
Classification of Corrosion

Based on the mechanism of corrosion, it is classified into two types

1. Chemical or dry corrosion

2. Electrochemical or wet corrosion

Dry corrosion:
• Corrosion takes place in dry state.
• In occurs due to the direct chemical attack of the metal by the
environment.
• Corrosion products accumulate on the same spot, where corrosion occurs.
• Dry corrosion is self controlled.
• It follows absorption mechanism.
• Homogenous metal surface undergoes corrosion observed.
• Uniform corrosions are observed. Example: Formation of mild iron oxide
on its surface.

Dry corrosion is a form of corrosion, that occurs at elevated

temperature without a liquid phase. It’s a high temperature oxidation
reaction.

Wet corrosion:
• Corrosion takes place in the presence of moisture.
• It occurs due to the setting up of large numbers of galvanic cells.
• Corrosion products accumulate on cathode.
 • Wet corrosion is continuous process.

• It follows electrochemical mechanism.

• Heterogeneous metals bimetallic surface is the condition for corrosion.
• Pitting corrosions are observed. Example: Formation of rust on iron under
moist atmosphere.

Wet corrosion means that there is a liquid phase, for example

condensed humidity, in contact with metal. It’s the most common form
of corrosion.
Some Types of Corrosion
1. Galvanic or Bimetallic
corrosion

Example: Zinc and copper, zinc forms the anode and is attacked and gets
dissolved, whereas copper acts as cathode.
DRY CORROSION

WET CORROSION

RUSTING OF IRON

GALVANIC CORROSION

When 2 different metals or alloys come in contact with each other, the less
noble metal corrodes protecting the other cathodically. This phenomenon is
called galvanic corrosion. Galvanic corrosion occurs when 2 different metals
are electrically connected and are immersed in an electrolyte. In order for
galvanic corrosion to occur, an electrically and ionically conductive path is
necessary. This effects a galvanic couple where the more active metal
corrodes at an accelerated rate and the more noble metal corrodes at a
retarded rate. Galvanic corrosion is often utilized in sacrificial anodes.

For example zinc is often used as a sacrificial anode for steel structure like
pipelines. Factors such as relative size of anode (smaller is preferred), type
of metal and operating conditions (temp, humidity), affect galvanic corrosion.
PITTING CORROSION

INTERGRANULAR CORROSION

Intergranular corrosion is the phenomenon in which there is increased rate

of corrosion along the grain boundaries rather than at the grain interior.
Grains are “crystals” usually on a microscopic scale, that constitute the
(micro)structure of metals and alloys. This selective dissolution may lead to
the dislodgement of grains. Some significant examples include Intergranular
corrosion in sensitized stainless steels and exfoliation in aluminium alloys
etc:-

At the temperature range of 450-850 oC carbon diffuses to the grain

boundary of stainless steel and reacts with chromium to precipitate
chromium carbide. But for stainless steel, the corrosion resistance depends
on the Cr content which due to depletion increases the susceptibility to
corrosion.
WATER LINE CORROSION

It is generally found that when water is stored in a steel tank, the maximum
corrosion occurs along a line just beneath the water meniscus. This is
because of the fact that the highly oxygenated area above the waterline
acts as the cathodic part, while the portion just below the waterline act as
the anodic part undergoing corrosion. This type of corrosion is commonly
seen in water tanks, base of ships etc:-

STRESS CORROSION (figure 3.4 from page 3.6)

Stress corrosion is the part of tensile stress (including residual stress

remaining after fabrication) and localized corrosion which combine to
produce a brittle cracking of metal under certain conditions. During stress-
corrosion cracking, the metal or alloy is virtually unattacked over most of its
surface, while fine cracks progress through it. It generally has serious
consequences.
The stresses can be internal or applied. An example is that of brass
condenser tubes. The reason for this is the moist atmosphere containing
ammonia. The attack is along the grain boundaries which become more anodic
with respect to grain interior.

CONCENTRATION CELL CORROSION

This corrosion is also known as differential aeration corrosion. It occurs

when a metal is partially immersed in a solution or when partially covered by
water drops, dust, sand etc:- Its often combined with stagnant fluid or in
areas with low fluid velocity. Here the more aerated area acts as the
cathode, while the less aerated area acts as the anode undergoing corrosion.

There are 3 general types of concentration cell corrosion:

> Metal ion concentration cell

> Oxygen concentration cell

> Active- passive concentration cell

The common examples in this type of corrosion include corrosion of heater

handles, knives etc:-
MICROBIOLOGICAL CORROSION

Microbiological corrosion is that caused / promoted by microorganisms. It

can apply to both metals and non-metals, in both presence (aerobic) and in
lack of oxygen (anaerobic). The bacterial activities can -> produce a
corrosive environment, -> alter metal film’s resistance, -> create electrolytic
concentration cells on the metal surface, -> affect rate of cathodic and
anodic reaction.
Sulphate reducing bacteria are common in lack of oxygen. They produce
hydrogen sulphide, causing sulphide stress cracking. In presence of oxygen
some bacteria directly oxidize iron to iron oxides and hydroxides, other
bacteria oxidize sulphur and produce sulphuric acid causing biogenic sulphide
corrosion. Microbes like fungi, algae etc:- develop a microbiological film on
iron surfaces. Such films can contain dissolved salts, acids etc:- thereby
creating local biological cells to accelerate corrosion.