Module 8, Objective 2

(part 2/3)
Types of Corrosion, pg. 16-21

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Objectives
• Identify the corrosion mechanisms for given conditions.

1) General or Uniform
2) Galvanic
3) Crevice and Pitting
4) Temperature gradient
5) Velocity gradient
6) Cavitation
6) Cavitation 7) Fretting
7) Fretting
8) Atmospheric (dry, damp, wet) 8) Atmospheric
9) Stray current
10) Biological 9) Stray current
11) Intergranular (IGC), Exfoliation
12) Stress corrosion cracking (SCC) 10) Biological
13) Hydrogen induced (HIC/SSC), Hydrogen blistering
14) Corrosion fatigue cracking
11) Intergranular
15) Graphitization
16) Selective leaching

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 6) Cavitation Corrosion
• Cavitation is the result of collapsing bubbles creating shockwaves in a fluid.
➢As the fluid goes through a constriction, the velocity increases, but pressure decreases.
➢Lower pressure means liquids boil at a lower temperature.
➢If the flow is restricted enough, water can boil at room temperature, creating bubbles in the
low pressure zone.
➢When the fluid re-enters the low velocity (high pressure) region, the bubbles implode
violently.
➢Implosion creates a shockwave.
➢Shockwave damages the metal surface.

➢ If you’d like to take a break to see cavitation in action,

search YouTube for “True Facts About The Mantis Shrimp”

Cavitation in a gate valve showing the bubbles forming in the high velocity, 3
low pressure region and then imploding in the low velocity of region.
 6) Cavitation Corrosion
• Cavitation alone will cause surface damage, which is enhanced by corrosion
➢Cavitation strips the oxide layer from the surface
➢Cavitation can also initiate pits in the surface
Note the concentrated damage on the
outer edges where the speed of the
impeller or propeller would be fastest.

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Cavitation damage on a pump’s impeller. Cavitation damage on the propeller of a personal watercraft.
6) Cavitation Corrosion Prevention
• Cavitation can occur anywhere there is a sudden change in fluid velocity.

Controlled by:
• Using a proper design to ensure that the
pressure does not drop below the liquid
vapor pressure.
• Gate valves should never be used as volume
control valves; needle valves are better.

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A needle valve
7) Fretting Corrosion
• Fretting corrosion results from a slight motion or vibration between two
parts that wears away the surface oxide.
• False Brinelling is fretting caused by bearing contact with the race

Prevention
• Tightening to eliminate the motion
• Lubrication to reduce friction

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8) Atmospheric Corrosion
• Atmospheric corrosion is the corrosion of a material
exposed to the air and its pollutants.
• Relatively minor, but it’s everywhere!
• Most common type of corrosion
• Responsible for more failures, and higher costs, than from
any other type of corrosion.
• Atmospheric corrosion is generally divided into three
categories:
a. dry
b. damp
c. wet
The Thinker, by Auguste Rodin
7 c.
1902, Bronze, Copenhagen, Denmark
8a) Dry Atmospheric Corrosion
• Dry atmospheric corrosion occurs in the absence of moisture.
• Air is a terrible electrolyte!
• Very slow corrosion rate at ambient temperature
• No water present… What is our oxidation reaction? What is our
reduction reaction?
Oxidation: Fe → Fe2+ +2e-
Reduction: ½O2 +2e- → O2-
Overall cell reaction: Fe + ½O2 → FeO
• FeO is not rust (Fe(OH)2) but an iron oxide film.
➢ FeO oxide acts like a passive layer, protecting against further corrosion!

• Special case: high temperature corrosion

• Reactivity of oxygen increases at high temperature.
• Initially, an oxide layer forms, but it eventually gets so thick that it cracks.
• Further oxidation can occur between the cracks
➢ Forms a thick black oxide “scale” on the metal’s surface The Thinker, by Auguste Rodin
8 c.
1902, Bronze, Copenhagen, Denmark
8b) Damp Atmospheric Corrosion
• Damp atmospheric corrosion occurs when the relative
humidity of the atmosphere is above 70%
• Humidity is high enough that a thin film of
moisture forms on metal surfaces

• The film of moisture is a stronger electrolyte than air

• Increases corrosion rate
• Higher humidity and higher temperature will also
increase corrosion rate further

The Thinker, by Auguste Rodin

9 c.
1902, Bronze, Copenhagen, Denmark
8b) Damp Atmospheric Corrosion, continued
Damp Atmospheric Corrosion can also be affected by:
• Salt content in the air
• Salt increases the ionic conductivity of the electrolyte,
which increases the rate of corrosion
➢ Atmospheric corrosion is higher near the ocean due
to salt spray

• Pollutants = acid rain

• Sulphur dioxide (SO2), is produced by the burning of fuel containing
sulphur (ex: coal contains sulphur impurities)
• In humid conditions, metal oxide surface acts as a catalyst to
change SO2 to SO3: ½ O2 + SO2 → SO3
• SO3 reacts with water to form sulphuric acid: H2O + SO3 → H2SO4
• The iron is then corroded by the acid: H2SO4 + Fe → FeSO4 + H2 The Thinker, by Auguste Rodin
10 c.
1902, Bronze, Copenhagen, Denmark
8c) Wet Atmospheric Corrosion
• Wet atmospheric corrosion occurs when water is held
on the metal surface
• Rain will cause corrosion, but the worst corrosion will
be where crevices or other traps cause water to form
into pools.
• Those areas continue to corrode even when most other
surfaces are dry.
• Even corrosion products (ex: rust) contain pores that can trap
moisture

• More water present = better electrolyte!

• Fastest corrosion rate
The Thinker, by Auguste Rodin
11 c.
1902, Bronze, Copenhagen, Denmark
9) Stray Current Corrosion
• Stray current corrosion is caused by an external source of current.
• Caused by poor electrical designs, damaged insulation, and dirty or loose
electrical connections
• The electrical current can travel through water, soil or any suitable electrolyte to find the
path of least resistance
• If the current reaches your piece (ex: underground metal pipes or tanks), they can be
severely corroded.
Mechanism:
• Electricity is the movement of electrons. Corrosion runs on electrons.
Oxidation (anode): M → M + + e-
Reduction (cathode): O2 + 2H2O + 4e- → 4(OH)-
• Where the stray current enters the piece will become the cathode (protected)
• Where the stray current leaves the piece will become the anode (corroded)
Note: This is incorrectly stated in your Module, including the figure on page 19
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Stray Current Corrosion in DC Rail Lines

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9) Stray Current Corrosion
• The corrosion is localized to one area that is severely attacked
• Looks similar to galvanic corrosion.
• Often indicated by a concentration of pits in an unusual location.

Prevention
• Look for damage to electrical equipment nearby (but not touching) the
corroded areas.
• Stray currents may sometimes be located by measuring the voltage drops
and the current flows along the buried structure.
• Stray current corrosion is not influenced to any great extent by
environmental conditions such as pH and entrained oxygen.
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10) Biological Corrosion
• Biological corrosion occurs due to bacterial growth on the surface.

• Three types of bacteria that may cause corrosion:

a) Sulphate reducing bacteria
b) Iron bacteria
c) Slime forming bacteria

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10a) Biological Corrosion – Sulphate Reducing
• Sulphate Reducing Bacteria are less common than others since they are
“anaerobic” (thrive best in the absence of oxygen)
• Mostly can be found growing in crevices or beneath surface deposits

• Less common, but they can lead to much worse corrosion!

• The reduction of sulphates (SO4-2) by the bacteria creates sour gas (H2S)
• H2S reacts with iron directly: H2S + Fe → FeS + 2H
• The free hydrogen produced from that reaction can also cause hydrogen induced
cracking! (we’ll learn about HIC later)

• The yellow colour of FeS (and the smell of H2S) at a failure site may indicate
that sulphate reducing bacteria are the cause of the failure.
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10b&c) Biological Corrosion – Iron and Slime
• Most common bacteria grow in colonies
• Blocks access to oxygen under the colony
➢ oxygen concentration cell → pitting

• Iron bacteria are “aerobic” (require oxygen to live and grow)

• Could be iron-oxidizing (forms Fe2O3) or iron-reducing (forms Fe(OH)2)
• Both types create a layer of oxide or hydroxide around themselves as they
grow, creating the surface deposit (oxygen concentration cell, pitting).

• Slime forming bacteria produce a dense mass of slime on a solid surface.

• Slime blocks oxygen = oxygen concentration cell = pitting.
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10) Biological Corrosion Prevention

Prevention of biological corrosion requires that we kill the bacteria.

• Physical removal of the bacterial colonies
• Pasteurization (heating)
• Chemical treatment

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11) Intergranular Corrosion
• In intergranular corrosion (IGC), the grain boundaries become anodic and the
grains become the cathode.
• Small anodes, large cathodes = fast corrosion rate!

• Example, intergranular corrosion in stainless steel

• Sensitization between 500 - 900°C
• Chromium carbide precipitates form at the grain boundaries (no oxide layer)
• More reactive grain boundary = rapid intergranular corrosion

• Grain boundary precipitates are the most common cause

• Change in chemical composition creates very small galvanic cells
• IGC will not affect pure metals, but most alloys can form a second phase at grain
boundaries if improper heating creates precipitates
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11) Intergranular Corrosion - Exfoliation
• Exfoliation is a form of intergranular corrosion most commonly seen in high
strength aluminum alloys
Where do the highest strength aluminum alloys get their strength?
➢ Precipitation Hardening and Cold Rolling
• Precipitation Hardening: many precipitates, but even more at the grain
boundaries (due to coring).
• Causes corrosion along the grain boundaries
• Cold Rolling: elongates the grains in the rolling direction
• Allows the corrosion to run along the length of the piece, creating long crevices
➢ Eventually the grains separate along the grain boundaries
• Like sheets of paper separating along their length
• The failure has a ropey appearance

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Exfoliation
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 Exercise 2 (pg. 28,29)

4. Stray current corrosion is caused by an ________________ source.

5. Biological organisms can change the ______________ content of the

local environment and in turn change ________________ rates.

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 Bonus Questions
Cavitation and fretting have a similar corrosion mechanism.
What is their similarity?

What is the primary difference between dry, damp and wet

atmospheric corrosion? Put them in order from most to least
corrosion.

What is the most common cause of intergranular corrosion?

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 Bonus Questions
Cavitation and fretting have a similar corrosion mechanism.
What is their similarity?
• Both result from the removal of the surface oxide layer.

What is the primary difference between dry, damp and wet atmospheric
corrosion? Put them in order from most to least corrosion.
• The effectiveness of the electrolyte.
1. Wet (water is a good electrolyte)
2. Damp
3. Dry (air is a poor electrolyte)

What is the most common cause of intergranular corrosion?

• Precipitates forming at the grain boundaries (making them more
reactive).
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