‫‪Corrosion‬‬

‫أعداد الطالب مصعب جبار محسن و بأشراف األستاذة زينب حسن‬

‫الجامعة التكنلوجية‬
‫القسم‪:‬هندسة االنتاج و المعادن‬
‫الفرع‪:‬االستخالص‬
‫للعام الدراسي ‪٢٢٢٢-٢٢٢٢:‬‬
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Introduction:
Corrosion can be defined as the loss of materials as a result of chemical or
electrochemical reaction with the environment for example iron exposed to air and
moisture will oxidizes over time and becomes rust(iron oxide).

Types of corrosion:

Corrosion is a major problem especially in the construction industry where various metals
are used for structural purposes. Different types of corrosion are :

1. Atmospheric Corrosion
2. Erosion Corrosion
3. Selective Corrosion
4. Uniform Corrosion
5. Pitting Corrosion
6. Fretting Corrosion
7. Stress Corrosion
8. Inter-granular Corrosion
9. Corrosion Fatigue

1. Atmospheric Corrosion
Atmospheric corrosion is a type of wet corrosion caused by the action of electrolytes.
In this case, moisture present in the atmosphere, rainwater, etc. acts as electrolytes
triggering corrosion of the exposed metal surface.
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2. Erosion Corrosion
Erosion corrosion is caused by mechanical abrasion due to the relative movement
between metal surfaces and corrosive fluids. In this case, the surface of metal gets
deteriorated gradually by the abrasion of fast-moving fluids and cavities are also formed.
This type of corrosion commonly seen in metal tubes carrying moving fluids in it.

3. Selective Corrosion
Selective corrosion occurs in alloys where one of the component metals is de-alloyed by
the corrosive environment. This type of corrosion can be seen in brass alloy pipes where
zinc is commonly used as another component and here zinc is de-alloyed. Similarly in the
case of copper-nickel alloy tubes where nickel is de-alloyed by selective corrosion.

4. Uniform Corrosion
In case of uniform corrosion, a uniform layer of rust is formed on the surface of metals
and it is extended over the whole surface area of metal. This type of corrosion can be
seen in metals which are not protected by surface coating. Aluminum, zinc, lead, etc. are
some metals commonly affected by uniform corrosion.

5. Pitting Corrosion
Pitting is the formation of rust pits or holes on the surface. Pitting corrosion is a localized
form of corrosion where the corrosion is limited to small areas. The shapes of rust pits
may not be similar but in most of the cases, they are hemispherical in shape.

Pitting corrosion occurs when the protective oxide layer of the surface gets damaged or
due to structural defects in metal. It is considered more dangerous because it causes the
failure of structure with a relatively low overall loss of material. It can be observed in
steel, aluminum, nickel alloys, etc.
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6. Fretting Corrosion
Fretting corrosion occurs at the contact area of the two materials which are joined
together. This is developed when the contact area is subjected to slips and vibrations.
This type of corrosion can be seen in bolted and riveted joints, clamped surface, etc.

7. Stress Corrosion
Stress corrosion caused by the combined action of a corrosive environment and
mechanical stress on the surface of the material. In its initial stage, small cracks are
developed and these finally leads to failure of the whole structure. This type of corrosion
can be seen in stainless steel when they are stressed in chloride environments, in brass
materials when they are stressed in the presence of ammonia, etc.

8. Inter-granular Corrosion
Inter-granular corrosion is the corrosion occurs along the grain boundaries and the grains
are not affected in this case. It is caused when there is a noticeable difference in reactivity
against impurities exists between grain boundaries and grains. This difference in
reactivity occurs due to defective welding, heat treatment stainless steels, copper, etc

9. Corrosion Fatigue
Fatigue of materials is defined as the failure of a material due to repeated application of
stress. When the fatigue of metal is developed in the corrosive environment then it called
corrosion fatigue. This can be prevented by improving the fatigue resistance of a
material.

Corrosion measuring devices:

One of the corrosion control companies is “metal sampels” which offers a complete line
of corrosion monitoring instruments / meters for both electrical resistance (ER) and linear
polarization resistance (LPR) probes, and for specialized monitoring we use them to
know when a material is damaged by corrosion.
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ER Instrumentations:

MS0500 ER Corrosion Meter:

The MS0500 is a battery-powered, portable corrosion meter capable of measuring all

types of electrical resistance (ER) corrosion probes. Combining light weight with ease of
operation, the MS0500 is a simple and effective tool for gathering corrosion data from
one or many probe locations.

Corrosion rate measurements are made using the electrical resistance method. Essentially,
the instrument measures the resistance of the probe element which changes over time as
metal loss occurs. The rate of change is directly proportional to the corrosion rate. This
method finds a wide variety of applications since it can be used in conductive and
nonconductive environments, such as petroleum, chemical, water and soil.

Figure 1 the MS0500 ER Corrosion Meter:

MS2600E High Resolution ER Transmitter:

Metal Samples’ new compact MS2600E ER Transmitter (ERT) measures all types of
electrical resistance (ER) corrosion probes. The new high-resolution, 16-bit
measurement provides faster response, obtaining corrosion rates in hours instead of
days. The transmitter can be remote or direct-mounted
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The transmitter is available in a weather-proof (IP66) stainlesssteel enclosure

Figure 2 the MS2600E High Resolution ER
designed for applications which do notpermit Transmitter

aluminum enclosures (such as offshore

environmentsor Zone 0 hazardous areas).
Alternatively, a weather-proof(IP66) and explosion
proof cast aluminum enclosure is also available.

MS2601E High Resolution ER Transmitter:

Figure 3 the MS2601E High Resolution ER Transmitter

Metal Samples' new compact MS2601E ER Transmitter(ERT) measures all types of

electrical resistance (ER)corrosion probes. The new high-resolution, 16-
bitmeasurement provides faster response, obtainingcorrosion rates in hours instead of
days.
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The transmitter is provided in a weather-proof(IP 66 / NEMA-4X) and explosion

proof cast aluminumenclosure. It is designed to be mounted directly tothe probe, but
can also be mounted nearby usingthe optional mounting kit and a customer-supplied
mounting pole.

LPR Instrumentation:

MS1000 LPR Corrosion Meter:

The MS1000 is a hand-held, battery powered corrosion meter. This versatile instrument
measures the instantaneous corrosion rate and electrochemical current between the
electrodes of any standard 2-electrode linear polarization resistance (LPR) probe.

Corrosion rate measurements are made using the linear polarization resistance
technique. The instrument measures the current required to polarize the electrodes of a
probe to a known potential. From the polarization potential and the measured current,
polarization resistance can be calculated. Then, using Faraday’s law, instantaneous
corrosion rate is calculated from polarization resistance

Figure 4 the MS1000 LPR Corrosion Meter

MS1500L Handheld LPR Corrosion Data Logger:

The MS1500L is a hand-held, battery-powered, intrinsically safe corrosion meter capable

of measuring and storing data from all types of 2- or 3-electrode linear polarization
resistance (LPR) corrosion probes. The instrument is light weight, microprocessor-based,
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and features a simple, menu-driven interface using a 12-key keypad and a 4-line LCD
display.

Corrosion rate measurements are made using the linear polarization resistance
technique. The instrument measures the current required to polarize the electrodes of a
probe to a known potential. From the polarization potential and the measured current,
polarization resistance can be calculated. Then, using Faraday’s law, the instantaneous
corrosion rate can be calculated from polarization resistance.

Figure 5 the MS1500L Handheld LPR Corrosion Data Logger

MS2001L Continuous LPR Corrosion Meter:

The MS2001L is a microprocessor-based, field-mountable corrosion rate meter. This

versatile instrument measures the instantaneous corrosion rate and electrochemical
current between the electrodes of any standard 2-electrode linear polarization
resistance (LPR) probe. Corrosion rate is displayed on the LCD display.
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Corrosion rate measurements are made using the linear polarization resistance
technique. The instrument measures the current required to polarize the electrodes of a
probe to a known potential. From the polarization potential and the measured current,
polarization resistance can be calculated. Then, using Faraday’s law, instantaneous

corrosion rate is calculated from polarization resistance.

Figure 6 the MS2001L Continuous LPR Corrosion Meter

CORROSION PREVENTION METHODS:

It is essential to protect metallic structures form corrosion to avoid them being

worn out and destroyed.

There is different methods to prevent corrosion Depends on the type of metallic

structure, We'll take four methods of corrosion prevention that eoncoat company
presents:

1. BARRIER COATINGS

One of the easiest and cheapest ways to prevent corrosion is to use barrier coatings like
paint, plastic, or powder. Powders, including epoxy, nylon, and urethane, adhere to the
metal surface to create a thin film. Plastic and waxes are often sprayed onto metal
surfaces. Paint acts as a coating to protect the metal surface from the electrochemical
charge that comes from corrosive compounds. Today’s paint systems are a
combination of different paint layers that serve different functions. The
primer coat acts as an inhibitor, the intermediate coat adds to the paint’s
overall thickness, and the finish coat provides resistance to environmental
factors.
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The biggest drawback with coatings is that they often need to be stripped and
reapplied. Coatings that aren’t applied properly can quickly fail and lead to
increased levels of corrosion. Coatings contain volatile organic compounds,
which make them hazardous to people and the environment

2. HOT-DIP GALVANIZATION

This corrosion prevention method involves dipping steel into molten zinc.
The iron in the steel reacts with the zinc to create a tightly bonded alloy
coating which serves as protection. The process has been around for more
than 250 years and has been used for corrosion protection of things like
artistic sculptures and playground equipment.
Unfortunately, galvanization can’t be done on-site, meaning companies must
pull equipment out of work to be treated. Some equipment may simply be too
large for the process, forcing companies to abandon the idea altogether. In
addition, zinc can chip or peel. And high exposure to environmental elements
can speed up the process of zinc wear, leading to increased maintenance.
Lastly, the zinc fumes that release from the galvanizing process are highly
toxic.
3. ALLOYED STEEL (STAINLESS)

Alloyed steel is one of the most effective corrosion prevention methods

around, combining the properties of various metals to provide added strength
and resistance to the resulting product. Corrosion-resistant nickel, for
example, combined with oxidation-resistant chromium results in an alloy that
can be used in oxidized and reduced chemical environments. Different alloys
provide resistance to different conditions, giving companies greater
flexibility.
Despite its effectiveness, alloyed steel is very expensive.
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4. CATHODIC PROTECTION

Cathodic protection protects by electrochemical means. To prevent corrosion,

the active sites on the metal surface are converted to passive sites by
providing electrons from another source, typically with galvanic anodes
attached on or near the surface. Metals used for anodes include aluminum,
magnesium, or zinc.
While cathodic protection is highly effective, anodes get used up and need to
be checked and/or replaced often which can drive up costs of maintenance.
They also increase the weight of the attached structure and aren’t always
effective in high-resistivity environments.
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The Sources:
a) Types of corrosion
https://theconstructor.org/structural-engg/steel/different-types-corrosion/35536/
b) Corrosion measuring devices
https://www.metexcorporation.com/aspi/instrument.htm
c) corrosion prevention methods
https://eoncoat.com/corrosion-prevention-methods/