7.

0 Corrosion of Metals
Lecturer : Mohd Yusri bin Ibrahim
CORROSION

DEFINITION

Corrosion is the degradation and loss of a material and

its critical properties due to chemical, electrochemical
and other reactions of the exposed material surface
with the surrounding environment.

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 CORROSION
TWO MAIN
CATEGORIES

Dry Corrosion Wet Corrosion

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 CORROSION

What is
CORROSION
Corrosion? MECHANISM
DRY CORROSION WET CORROSION

DIRECT CHEMICAL ELECTROCHEMICAL

ATTACK CORROSION

Represents the direct In which chemical change /

chemical attack between the reaction is accompanied by
metal and atmospheric an electrical current
oxygen

OXIDATION CONCENTRATION
GALVANIC CELL
CELL

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 occurs when a damage/ crack surface reacts with
oxygen in the atmosphere.

DRY
CORROSION

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 occurs when a different type of metals in contact
and are submerged in an electrolyte.

IRON COPPER
WET Anode Cathode
ELECTRICAL
CORROSION
BRIDGE

ELECTROLYTE

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 Difference between dry and wet corrosion
Dry corrosion
• Corrosion occurs in the
absence of moisture.
• It involves direct attack of
chemicals on the metal
surface.
• The process is slow.
• Corrosion products are
produced at the site of
corrosions.
• The process of corrosion is
uniform
Wet corrosion
• Corrosion occurs in presence
of conducting medium.
• It involves formation of
electrochemical cells.
• It is a rapid process
• Corrosion occurs at anode but
rust is deposited at cathode.
• It depends on the size of the
anodic part of metal.
 CORROSION

TYPES OF CORROSION

UNIFORM GALVANIC

CREVICE PITTING

STRESS CORROSION
INTERGRANULAR CRACKING

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 is the attack of a metal at essentially the same at
all exposed areas of its surface.

• Most metal corrode

UNIFORM because of chemical
reaction with oxygen in
CORROSION atmosphere (air and
moister).

• Produce oxide layer on

the surface – corrode
the surface.

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 Galvanic corrosion is an electrochemical process
in which one metal corrodes preferentially when
it is in contact with a different type of metal and
both metals are in an electrolyte as discussed in
GALVANIC Wet Corrosion / Electrochemical Corrosion.
CORROSION

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 is a form of localized electrochemical corrosion
that can occur in crevices and under shielded
surfaces where stagnant solutions can exist.

It’s usually occurs

CREVICE between cracked parts or
in the crevice of same or
CORROSION different metal surfaces
that attached together
weather the crevice of a Solution
metal and a metal or trapped
between a metal and a
non-metal.

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 is a form of extremely localized attack that
results in holes in the metal.

The pit acts as the anode

PITTING while the undamaged
part of the metal is the
CORROSION cathode. It begins with a
chemical breakdown in
the form of a scratch or
spot.

Solution
trapped

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 is localized corrosion attack at and / or adjacent
to the grain boundaries of an alloy due to
welding, stress, heat treating or improper
service.

INTERGRANULAR
It is occur when different
CORROSION potential between atoms
at the grain-boundaries
and create the boundaries
of anode and cathode.

Intergranular corrosion

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 is a complex form of corrosion which arises due
to stress and corrosive environment

The stress is developed in the material due to bending or

stretching of the material.
STRESS
CORROSION
CRACKING

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 CORROSION REMEDIAL

CATHODIC
DESIGN
PROTECTION
MATERIAL
ALLOYING
SELECTIONS

COATING

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5.4 CORROSION

CATHODIC
PROTECTION

is the protection of a metal by connecting it to a

sacrificial anode or by impressing a direct current
voltage to make it a cathode.

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 CORROSION
MATERIAL SELECTION DESIGN ALLOYING

• Choose material that • Use welding process • Alloying of metals can

corrosion resistance instead of rivet, bolt
(noble metal, and nut, screw to joint
polymers, ceramics) two metals.
• Use one type of • By adding small
• If using different type material only for the
of metals, choose whole structure to
metals that are prevent galvanic
potentially close in corrosion.
electrochemical • Avoid sharp edge in
series. design because it can
caused the stress
change their corrosion
behaviour.
amounts of another
metal to an alloy, it
can shift its position in
the galvanic series
making it more
cathodic than it was
previously.

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