Introduction Corrosion is natural phenomenon which attacks metal by chemical, electrochemical action converts metal into metallic compound, such as an oxide , hydroxide or sulphate. Destruction or deterioration and consequent loss of solid metallic materials , starting at its surface due to chemical or electro chemical attack, by their environment. Corrosion is major problem worldwide in all industrial sectors. It impacts on safety , health and environmental issues .Corrosion Lice t Corrosion cycleCauses of Corrosion * Pure or noble metals such as gold, silver, platinum, aluminum , copper do not corrode since they are chemically uncombined in their natural state. ¢ Following conditions must exist before corrosion. i) Presence of metal that will corrode (anode) ii) Presence of cathode iii) Presence of conductive liquid (electrolyte) iv)Electrical contact between cathone anode and cathode ¢ Elimination of any one of these condition will reduce or stop corrosion. Anode ElectrolyeCorrosion TriangleClassification of Corrosion * on the basis of working temperature i) Low temperature Corrosion / Dry Corrosion ii) High temperature Corrosion ,,, * onthe basis of working Corrosion environments Product i) Dry or Chemical Corrosion ii) Wet or Electrochemical Wet Corrosion Corrosioni) Dry or Chemical Corrosion It occurs when oxygen in air reacts with metal , without presence of liquid. It is very sensitive to temperature Rate of dry corrosion varies from metal to metal , as a result of mechanisms involved. Oxide layer on steel & iron is known as rust. |In aluminum, copper oxide layer formed due to reaction with atmospheric oxygen ,stops further corrosion. As oxide layer formed , prevents further contact of oxygen as film is non porous. This stopping is known as Passivations. Active Corrosion- steel, Cl, Mg. M+O—~ MO oxygen - non-porous oxide layer (aluminium)ii) Wet or Electrochemical Corrosion It is electrochemical phenomenon , which occurs in galvanic cell. Particularly when two metals are in contact with a liquid , liquid containing salt and electric potential is formed between the metals. in some cases in single metal , when comes in contact with liquid or electrolyte , a anode and cathode areas are created. When anode area starts corroding with respect to cathode areas , is termed as wet corrosion.DRY CORROSION | WET CORROSION = * Corrosion occurs in the | * Corrosion occurs in absence of moisture. presence of conducting + It involves direct attack medium. of chemicals on the «It involves formation of metal surface. electrochemical cells. + The process is slow. «It is a rapid process. * Corrosion products are | * Corrosion occurs at produced at the site of anode but rust is corrosion. deposited at cathode. + The process of + It depends on the size of corrosion is uniform. the anodic part of metal.Factors Influencing Corrosion Type of Metal Heat treatment & Grain direction Presence of dissimilar metal Anode & cathode surface area Temperature presence of electrolyte Availability of oxygen time of exposure to corrosive environmentTypes of corrosion 1. Pitting Corrosion- Aluminum, Mg alloys, Cu alloy. SS nel ae ee ee Se —_—. Gy Li LL (a) (b) ee <>Narrow,Deep = Eliptic N Horizontal aeMechanism of pitting Corrosion Pitting Corrosion Cv exe: HCl formed , in pit * Factors influencing pitting Corrosion 1. Alloying elements 2. Surface finish 3.Heat treatment2.Stress corrosion & season cracking * It is combined action of corrosive environment and mechanical stresses which often due to poor design or poor maintenance practice. * Stress corrosion cracking (SCC) is intergranular cracking of metal caused by stress& corrosion. 1 | / Ses Cy. KA] ‘Transgranular Fracture Intergranular FractureControl or Prevention of SCC 1. Control of stress level and Hardness. 2. Avoid chemical corrosion that causes SSC 3. Control of temperature 4. Modification in design , that will reduce SCC — Elbow3. Cavitation Corrosion * Protective films are removed from metal surface during fluid flow. * Low pressure development due to discontinuity in flow path , causes vapour bubbles to form in fluid steam. * Due to collapsing of bubbles shock waves produced and removes protective film from metal surfaceCavitation damage in pump impeller Control of cavitation Corrosion- 1. Careful material selection i.e. high alloy steels containing Ni, Cr, W 2. Use of soft rubber coating , it absorbs cavitation energy 3. | Smooth Surface finish4. Hydrogen Embrittlement ¢ Hydrogen blisters results from hydrogen atoms , formed during sulfide corrosion process on steel. * Hydrogen atom combines to form hydrogen molecule. Hydrogen blisters on steel surface5. Inter Granular Corrosion * Form of corrosion where boundaries of grain of metal are more susceptible to corrosion than inside grain. * Difference in Corrosion potential between grain & and grain boundary. e.g. CuAl, in Al alloys, Cr,3C, in stainless steel. Inter granular corrosion in Austenitic stainless steelPrevention of Intergranular Corrosion * Use of low grade stainless steel (304 L, 316L grades) due to which less carbon will be available for precipitation of chromium carbide. ¢ Use of stabilized grade of stainless steel (321, 322 grade) titanium “san wWeiwienn: Cea * Use of post weld treatment: =) ‘mated metied True hest-attected 20% Knife Line Attack (KLA)