05 Corrosion and its prevention

1. What is meant by corrosion

a. The natural tendency of metal to react with the environment. This
reaction create corrosion product with a very similar chemical
composition to the original mineral which the metal is produced
b. Atmospheric corrosion and corrosion due to immersion
i. plates are freely exposed to the atmosphere will receive plenty
of oxygen but little moisture, so the moisture content becomes
the controlling factor
ii. under total immersion, the presence of oxygen becomes the
controlling factor

2. What is meant by erosion of metals, example

a. erosion is a mechanical action and associated with electro-chemical
corrosion
b. The air bubbles in the flow of water striking the metal plate, damaging
the paint, bare metal exposed and become anodic, subject to electro-
chemical corrosion
c. Cavitations, rapid flow of water cause a pressure drop. In the area of
partial vacuum, vapour collapse, releasing a considerable amount of
energy , damaging the metal surface adjacent to it
d. (Sea water discharges from the hull; bow thruster trunk, propeller way
and rudder)

3. Ability to describe the formation of a corrosion cell and to define anode,

cathode and electrolyte, (example)
a. The metal atom transform into a mineral molecule thru solution; the
atom loses electrons and becomes an ion, with the presence of
electron acceptor
b. A corrosion cell is simply formed by two metal of different potential.
It can be two different metal joining together for example aluminum
and steel(galvanic corrosion) or the same metal with physical
difference(steel hull with damaged coating)
c. Anode
i. Electrode which electrons leave the cell by way of corrosion
current(area of defective paintwork), active metal
d. Cathode
i. Electrode which electrons enter the cell by way of corrosion
current(area of well painted plate), passive metal
 e. electrolyte:
i. electrolyte solution allows a flow of negative ions to the anode
and a flow of positive ions to the cathode
ii. Sea water with high salt content is a good electrolyte solution

4. The galvanic series of metals in seawater; Given the galvanic series which of
two metals will form the anode in a corrosion cell
a. Two different metals form a corrosion cell. Galvanic corrosion is
associated with the coupling of metallic parts of different potential
which consequently form corrosion cells under service conditions
b. The galvanic series of metal is a table, which distinguish corrosion
rate of the metal whether it is passive or active. A passive metal shows
no sign corrosion when its surface is exposed to an electrolyte
solution. The oxide film forming a current barrier on the metal
surface, changing the overall potential of the metal
c. Steel hull with the bronze or nickel alloy propeller; the attachment of
bronze and aluminum alloy fittings; aluminum superstructures to steel
hull
5. Ability to explain the differences in surface condition or in stress
concentration can give rise to corrosion cells between two areas of the same
metal; By what corrosion can be controlled
a. surface condition-
i. metal will be anodic in one area(defective paint work, broken
millscale) and cathodic on the other(well painted plate) due to
different potential, as a result of physical differences on the
metal surface;
ii. corrosion current flowing between anode and cathode, carrying
electrons from anode to cathode; corrosion appear on the
surface of anode
iii. to control- cathodic protection by sacrificial anode
system/impressed current system and protective coating
b. stress concentration-
i. either internal stress or applied stress contribute to corrosion
ii. internal stress is caused by non-uniform cold working is more
dangerous, (ex. cold flanged bracket, aluminum magnesium
alloy)
1. the precipitate at the grain boundaries produced by
excessive cold working, is anodic towards the solid
solution forming the grains of the alloy
2. to controlled- lower the magnesium level to below 5% in
the metal alloy

6. Ability to explain that cathodic protection can only be used to protect the
underwater hull or ballasted tank (sacrificial anode + impressed current
system)
a. Only where the metal is submerged in an electrolyte can be protected
by cathodic protection
b. Cathodic protection uses opposing current to suppress the anodic
corrosion reaction. This superimposed direct electric current enter the
metal at every point, lowering the potential of anode metal of
corrosion cell, thus they become cathode and are protected
c. Metal or alloy attached to the hull, more anodic than steel when
immersed in sea water. These anodes supply a cathodic protection
current, but will be consumed eventually and required replacement

7. Ability to explain what mill scale is:

a. flaky surface of hot rolled steel consisted of iron oxide which is
produced by rolling red hot iron in the rolling mill
 b. bluish black color, protect the steel surface from atmospheric
corrosion, provide that no breaks on the mill scale
c. it is cathodic to steel, so any break on the coating will accelerate
corrosion on the exposed bare metal

8. Ability to describe the treatment of steel in a shipyard and the use of holding
primers
a. blast cleaning-
i. an impeller wheel plant which abrasive is thrown at high
velocity against metal surface, it is self-contained and collect
the dusk and re-circulate the clean abrasive;
ii. nozzle type which a jet of abrasive works on the metal surface,
fitted with vacuum recovery equipment;
iii. cast iron and steel grit are preferable abrasives because the fine
dust of sand may cause silicosis
b. pickling
i. immersion of the metal in acid solution to remove millscale rust
from the surface, followed by thorough hot water rinse before
applying primer coating
c. flame cleaning
i. use oxy-acetylene flame to remove millscale and rust from steel
surface;
ii. this method does not entirely remove millscale and rust,
however, it is useful for cleaning and drying out the plate in
cold humid weather
d. holding primers is used to protect the steel from rusting before
applying the final coating, since it may be sit in the ship yard for a
period of time after blast cleaned
i. fast drying to allow handling of the steel plate
ii. non-toxic, will not give off harmful and obnoxious fumes
during welding or cutting
iii. be compatible with any subsequent paint finish

9. List common paint vehicles as: drying oils, oleo-resins, alkyd resins,
polymerizing chemicals and bitumen. What is the suitability of each various
applications
a. drying oil(not suitable for underwater service)
i. Consist of mainly of vegetable oil. ex linseed oil; driers are add
to accelerate the drying with oxygen in the surrounding air
b. oleo-resins
 i. Consist of natural or artificial resins into drying oils, these
resins may react with the oil to give a faster drying vehicle or
with applied heat to dissolve and cause the oil to produce paint
film
c. alkyd resins(not suitable for underwater service)
i. (alcohols + acid) better performance in drying time and film
forming
d. polymerizing chemicals
i. very good resistance to severe conditions of exposure
ii. epoxy resins (suitable for underwater service)
1. two pack product, (epoxy resin + cold curing agent), slow
curing rate at temperature <10°C
2. very good adhesion with excellent chemical resistance
3. expensive, unwanted side products are removed during
manufacture,
4. the gloss finish tend to chalk, not suitable for external
decorative finishes
iii. coal tar/ epoxy resin
1. two pack product,(coal tar pitch resin + cold curing
agent)
2. some chemical resistance with impermeability of coal tar
iv. polyurethane resin (use only on superstructure on steel ship not
underwater)
1. good in toughness, hardness, gloss, abrasion, chemical
and weather resistance
v. vinyl resin (suitable for underwater service)
1. the solid content is low, dry film is thin, therefore more
coats are required
2. poor adhesion to bare steel surface, pretreatment primer
is required
3. the best underwater protection for steel
e. bitumen
i. simple solutions of bitumen or pitch blended by heat with other
material to form a vehicle

10.The action of anti-fouling paint; The use of self-polishing anti-fouling paint

and the proposed banning of Tributyltin; The ban on harmful types of
antifouling paint
a. anti-fouling paint consists of toxic compounds which dissolve slowly
in sea water to prevent marine vegetable and animal growth; once the
 release rate falls below a level necessary to prevent growth of marine
organisms, the anti-fouling function is no longer effective
b. self-polishing anti-fouling paint constantly emits organic toxin and
tends to become smoother; the lifespan is proportional to applied
thickness, smooth rather than roughen to reduce friction drag
c. TBT is extremely active against a wide range of fouling organisms,
with the controlled release of TBT and polishing of paint film.
However, a small concentration of TBT, particularly in enclosed
coastal waters, had a harmful effect on certain marine organisms. This
led to complete prohibition in by Jan-2008. With the development of
TBT-free self polishing anti-fouling, newer paints use copper as active
anti-fouling ingredient or can be biocide free as well
 Impair immune system of organisms & malformation of the
shell of shellfish
 Cause development of male characteristics in female sea snail
 Bio accumulate in marine wildlife with higher level in and
around area of high maritime traffic, remain in the ecosystem
for long time

11.Ability to describe typical paint schemes for: underwater areas, boot

topping, topsides, weather decks, superstructures and tank interiors
a. underwater areas(continuously immersed in water)
i. resist alkaline condition, good electrical resistance to limit flow
of corrosion current between the steel and sea water
1. corrosion inhibiting paint-coal tar resin, epoxy resin,
vinyl resin, pitch
2. anti fouling paint
b. Water line/ boot topping region(immersion is intermittent, lots of
abrasion)
i. complete system for the hull above the water line
1. vinyl resin, alkyn resin, polyurethane
c. Topside/ weather deck/ superstructure(atmosphere laden with sea
spray, damage from cargo handler)
i. lead/zinc chromate(primer)- for aluminum superstructure, use
zinc chromate, do not use lead based paint
ii. oleo resin, alkyn resin(top coat)
d. Cargo tank/ ballast tank (tanks carrying white oil cargoes, suffer more
general corrosion than those carrying crude oil which deposit a film
on the tank surface, providing some sort of protection against
 corrosion , the latter may suffer from severe local pitting and local
corrosion of any bare metal plate when sea water ballast is carried)
i. vinyl resin, zinc rich paint(cathodic protection), epoxy resin

12.The safety precautions when using paint

a. Solvents are flammable, so attention must be given to prevent fire
hazard. They may give off vapor when the temperature exceeds the
liquid’s flash point. When mixed with air in certain proportions, the
gas can be ignited, burn, and cause explosion. Paint to be stored in
approved paint locker fitted with suitable fire extinguishing system
b. When painting is carried out in confined spaces such a tank’s interior,
sufficient ventilation should be provided during painting and during
the drying process. No smoking and naked light in or near adjacent
area
c. To prevent contamination of the skin, protective gloves, clothing,
goggles should be worn. Should paint stain the skin, it should be
wiped off with a suitable thinner and then the area to be washed with
lukewarm water and soap. Face mask and respirator to be used during
paint spray.
d. Refer to the MSDS in case of fire and spillage

13.Ability to describe the system of cathodic protection using sacrificial

anodes; The metals and alloys which may be used as anodes
a. Metal or alloy attached to the hull, more anodic than steel when
immersed in sea water. These anodes supply a cathodic protection
current, but will be consumed eventually and required replacement

14.Why anodes of magnesium and of magnesium alloy are not permitted in

cargo/ballast tanks and in adjacent tanks in tankers
a. Magnesium anodes are not to be used in the cargo-ballast tanks of oil
carriers owing to the ‘spark hazard’. Any part of the anode fall and
strike the tank structure with gaseous conditions can result explosion

15.Why the anodes are insulated from the hull

a. ICCP supplies current to anode which will pass through the
electrolyte(water not the ship’s hull) to the area of hull with paint
breakdown, in order to protect it from rusting
16.Ability to describe the impressed-current system of hull protection
a. Maintain a voltage difference between hull and fitted anodes,
protecting the hull against corrosion. But not to be excessive, as this
will damage the paint coating.
b. An externally mounted cell detects the voltage difference between
itself and the hull.
c. An amplifier controller amplifies the cell current and compare this to
the preset value which to be maintained, thus the current is being
controlled.

17.Ability to explain as the underwater paintwork deteriorates, higher currents

are required for protection; what is the result of a too high current.
a. As underwater paint work deteriorates, protection from paint coating
is less, the density of corrosion current increases. The ICCP current
must always slightly greater than the corrosion current. Therefore, the
ICCP current will also need to be increased at the same time.
b. Too high current will cause hull paint damage, lead to paint peeling
off.

18.Theoretical Paint Consumption

a. Consumption(Litre) = area (m) x desired DFT (micron) /
VS % x 10