CORROSION

• What is Corrosion?
• It is defined as the natural process that causes the
transformation of pure metals to undesirable substances
when they react with substances like water or air. This
reaction causes damage and disintegration of the metal
starting from the portion of the metal exposed to the
environment and spreading to the entire bulk of the metal.
•
Metals placed higher in the reactivity series such as iron,
zinc, etc. get corroded very easily and metals placed lower
in the reactivity series like gold, platinum and palladium do
not corrode. The explanation lies in the fact that corrosion
involves oxidation of the metals. As we go down the
reactivity series tendency to get oxidized is very low
(oxidation potentials is very low).
•
 oxide film
• The nature of oxide film plays very important role
in oxidation corrosion. a) When oxide film is
stable and tightly adhering , it will act as
protective coating and corrosion is prevented. b)
When oxide film is unstable and has tendency to
decompose back to metal and oxygen , it does
not go into oxidation corrosion.
• c) When film is volatile then metal surface again
come into contact with air and oxidation take
place . d)If film is sufficiently porous then
continuous oxidation take place.
 Corrosion by other gases
• Corrosion by other gases :- Some gases react with certain
metal and forms a protective or non-protective layer on
metallic surface . Due to chemically combination of metals
with gases metals undergo corrosion .
•
• The extent of corrosion depends upon – A- Nature of
environment . B- Nature of oxide film formed .

• Corrosion By Other Gases (SO2, H2S,CO2,F2,Cl2) :- - This

type of corrosion mainly depends on chemical affinity
between metal & the gas involved. ... - If the film is non-
protective or porous, the volume of metal oxide layer is
lesser than that of metal so further corrosion takes place.
• For galvanic corrosion to occur, three
conditions must be present: Electrochemically
dissimilar metals must be present. These
metals must be in electrical contact, and. The
metals must be exposed to an electrolyte
• . A common example of galvanic
corrosion occurs in galvanized iron, a sheet of
iron or steel covered with a zinc coating. ...
Instead, the zinc is corroded because it is less
"noble"; only after it has been consumed can
rusting of the base metal occurs
 Pitting corrosion
• Pitting corrosion is a localized form of corrosion by
which cavities or "holes" are produced in the material.
... Most cases of pitting are believed to be caused by
local cathodic sites in an otherwise normal surface.
Apart from the localized loss of
thickness, corrosion pits can also be harmful by acting
as stress risers.
• There are several potential causes for pitting
corrosion, including: Localized mechanical or chemical
damage to a metal's protective oxide film; Improper
application of corrosion control products; and. The
presence of non-metal materials on the surface of a
metal.
 Stress-corrosion
• Stress-corrosion occurs when a material exists in a relatively
inert environment but corrodes due to an applied stress.
The stress may be externally applied or residual. ... Stress
corrosion is a form of galvanic corrosion,
where stressed areas of the material are anodic to the
unstressed areas of the material.

• Corrosion resulting from the combined action of chemical

attack and mechanical abrasion or wear. Corrosion resulting
from the combined action of an applied tensile stress and
a corrosive environment.
•

•
Intergranular corrosion
 Cathodic protection
• The technique of providing cathodic protection to steel
preserves the metal by providing a highly active metal
that can act as an anode and provide free electrons. By
introducing these free electrons, the active metal
sacrifices its ions and keeps the less active steel from
corroding.
• There are two types of cathodic protection,
galvanic protection and impressed current.
• Cathodic protection prevents corrosion by converting
all of the anodic (active) sites on the metal surface
to cathodic (passive) sites by supplying electrical
current (or free electrons) from an alternate source.
• Cathodic protection is
commonly used to protect numerous structures
against corrosion, such as ships, offshore floaters,
subsea equipment, harbours, pipelines, tanks;
basically all submerged or buried metal structures
• Explanation: Sacrificial anode method is one the
type of cathodic protection in which a metal
(anode) corrodes preferentially than the metallic
structure. ..
• . Explanation: Impressed method current is an
external supply of power to provide electrons to
metallic structure that needs to be protected.
 Protective coating
• A protective coating is a layer of material applied to the surface of
another material with the intent of inhibiting or preventing corrosion.
A protective coating may be metallic or non-metallic. Protective
coatings are applied using a variety of methods, and can be used for
many other purposes besides corrosion prevention.
• Commonly used materials in non-metallic protective coatings include
polymers, epoxies and polyurethanes. Materials used for metallic
protective coatings include zinc, aluminum and chromium.

• Protective coatings are commonly used to protect culturally

significant works, such as outdoor sculptures and architectural
elements. While the cost of damage due to corrosion is much higher
than that of more common coating applications, the same types
of protective coatings are used.
• The Anodic protection is used to protect
metals that exhibit passivation in
environments whereby the current density in
the freely corroding passive state over a wide
range of potentials. anodic coating is a type
of coating material that utilizes anodizing to
thickness, color and protection to aluminum
or any type of substrate.
• This provide increased coating consists of the
oxide film that is created on metal through
electrolysis, with the metal acting as
an anode.
• Cathodic coatings involve coating metal, which
is cathodic with respect to the substrate in an
electrochemical cell. The purpose of this type
of coating is to protect the substrate from
corrosion. In corrosive environments accelerated
corrosion of the substrate occurs if cathodic
coating fails to protect the substrate.
•
Corrosion is an electrochemical process, normally
occurring at the anode but not the cathode.
The principle of cathodic protection is to connect
an external anode to the metal to
be protected and to pass a DC current between
them so that the metal becomes cathodic and
does not corrode.
 Electroplating
• Electroplating is the process of plating one metal
onto another by hydrolysis, most commonly for
decorative purposes or to prevent corrosion of a
metal. There are also specific types
of electroplating such as copper plating, silver
plating, and chromium plating.
• Electroplating is the method of depositing one
metal over another in the presence of a metal
salt (in aqueous solution). The water molecule is
released as the final product in this process. As a
consequence, electroplating is based on the
theory of hydrolysis.
 common applications of electroplating :-

• improving wear resistance.

• Improving the thickness of the metal surface.
• Enhancing the electrical conductivity like
plating a copper layer on an electrical
component.
• Minimizing Friction.
• Improving surface uniformity.
 Electroplating process
• The electroplating is an art of depositing a superior or
more noble metal on a base metal by means of
electrolysis.
For example, metals like iron are coated with deposits
of nickel or chromium by electroplating to protect it
from corrosion. Picture frames and machinery parts are
often chromium-plated to protect them from corrosion
and at the same time to give them a good appearance.
• Cleaning Process
• The surface on which process of electroplating is to be
carried out must be polished and free of grease, scale,
rust and dirt.
• In case, the object to be electroplated is not
cleaned, polished and degreased, the deposit
formed may not well adhere to the base metal
and is likely to peel off.
•
Oils and grease can be removed with the help of
soaps, hot alkali solutions or solvents like CTC and
gasoline. Rust, scale and oxides can be removed
with the help of various acid, alkali and salt
solutions mechanical abrasion and electrolytic
cleaning in hot alkali solutions.
•
Thus , cleaning is one of the most
important electroplating process step.
• In an electroplating process, the object to be
electroplated is made the cathode (i.e.
connected to the negative terminal of DC
source) in the solution of a salt of the coating
metal.

The articles which are to be electroplated are

suspended into the plating solution. The
anode is also generally of the same metal. This
arrangement is connected to a DC power
source.
• The electrolyte used in electrolytic bath depends
upon the nature of the metal to be deposited.
The electrolytic deposits provided by the process
of electroplating are crystalline in nature.

The crystals must be very fine in order to get firm,

coherent and uniform deposits. For this purpose,
suitable electrolytes should be used in
electrolytic bath and current density used should
have an appropriate value. The temperature
should also be maintained at a proper level.
• When DC supply is applied to the two electrodes,
current starts flowing through the electrolyte. The
metal ions begin to move towards the article and get
deposited on it.
• The voltage requirement is small usually of the order
of 1 to 16 volts only.
• The factors, on which quality of deposit formed
in electroplating depends, are given below:

• Nature of Electrolyte: The formation of a smooth

deposit largely depends upon the nature of electrolyte
employed. The electrolytes from which complex ions
can be obtained, such as cyanides, provides a smooth
deposit.
•
• Current Density: The appropriate current
densities for different electroplating processes
are shown in the table. At these current
densities, the deposit of metal will be uniform
and fine-grained. At the other current
densities, the deposits will be coarse and
crystalline in nature.
• Temperature: A low temperature of the
solution favors formation of small crystals of
metals and a high temperature, large crystals.
• Conductivity: The use of a solution of good
conductivity is important
• There is always some potential difference
between the cathode and electrolyte and
between the electrolyte and anode. This
potential difference is a measure of the
tendency of the metal to go into the solution
and is known as electrode potential.
• The electrode potential depends upon the exact
conditions (i.e. temperature and concentration)
and also upon the nature of metal and the
electrolyte. Under ideal conditions, the value of
electrode potential for most of the substances
lies between 0.5 to 1 volt.
• Metal cladding is a method of protecting one
metal (or composite) by forming a layer of a
second metal to its surface by using
techniques such as diffusion, deformation and
lasers.
• The advantage of cladding is that the process
as well as the material can be chosen as per
the needs of the application and the bond
strength required.
• The method is suitable for complex shapes as
well.
 Applications
• Copper-clad aluminum wires are extensively used in
electrical applications due to the cost advantage as
well as an improved electrical conductivity.
• Metal cladding is also used on the outer surfaces of
structures as well as buildings for corrosion and
abrasion protection.
• Aluminum cladding is advantageous for buildings as it
is self-cleaning. The earliest type of metal cladding
used in buildings was called "corrugated sheeting,"
which was used for roofs and walls.
• In some cases, the cladding is chosen for its aesthetic
advantage.
•
 Metal Spraying
• Metal spraying or metallizing means to treat with or coat
with a metal or metallic compound. Metallizing as a process
normally includes the preparation of base material, the
spraying on the metal and finally finishing the surface by
grinding.

• There are two types of equipment used for metal spraying.

• 1) One is the metallic-gun which consists of a gas torch

with a hole in the centre of the tip for the wire, a small air
turbine and gears to feed in the wire through the tip into
the flame as fast as it melts and an air cap around the torch
tip and nozzle which supplies a blast of air to atomise the
molten metal and deposit it on the prepared surface.
• 2) In other method,
• powdered metal is fed from a container through
a rubber hose to spray-gun and out through the
centre of the flame, similar to the wire gun.
• In this case metal is already in the atomised form
and hence air needed is just sufficient to deposit
the molten metal on the surface being coated.
• By spraying metal on the parent metal, the
original properties are changed.
• There is an increase in porosity, compressive
strength and hardness, but the tensile strength
decreases. Also the wearing quality of sprayed
metal is good
• Applications of Metal Spraying
• 1) Corrosion-Protection The most extensive use
of metal spraying is the application of aluminium
and zinc into iron and steel
• 2) Abrasion or wear resistance, corrosion
protection and electrical or magnetic properties
etc. Most of the regular hard surfacing materials
are available in powdered form and can be
sprayed when thin coatings are prepared.
• 3) Soldering Surfaces :Sprayed copper is
frequently used on non-metallic parts when it is
desired to attach parts by soldering.
• 4)To improve Electrical Conductivity , Thermal
Conductivity:
• 5) other applications are in having decorative
films, reflecting surface and special metal forms
• The advantages of Metal Spraying
• Increased durability.
• Modified electrical properties.
• Increased or decreased corrosion protection.
• Increased hardness.
• Increased or decreased friction.
• Increased wear resistance.
• Additional protection to damaged materials
 Diffusion coating OR Cementation
• Diffusion coating is a process in which metal
components that will be subjected to high
temperature conditions and highly corrosive
environments are coated with a non-corrosive
material. The process is normally done at
elevated temperatures in a controlled
chamber.
• The most widely used coatings are chromium,
aluminum or silicone material.
• Substrate materials usually coated include cobalt
and nickel-based super alloys, steels (including
carbon, alloy and stainless steels) and refractory
metals, among other alloys
• As a result, the base metal develops extreme
resistance to corrosion, oxidation and erosion in
its severe working conditions. This makes the
process highly reliable, enhancing the
manufacture of critical components.
• Diffusion coating is normally used to process gas
turbine engine components (vanes, blades and
cases), pump impellers, gate valves and power
generation components.
• The Sherardizing process involves diffusing of the zinc
into the base metal of the object, which is mainly iron.
The temperature of the container is controlled such
that the melting point of zinc is not reached and this
ranges between 608-932ºF (320-500ºC).
• A coating of a uniform thickness of between 15 and
80µm is achievable using this method, which is ideal
for both small and geometrically complex objects.
• In addition to the high corrosion and abrasion
resistance properties, the adherent surface is very
good for:
• Metal to rubber bonding
• Painting
• In addition to the high corrosion and abrasion resistance
properties, the adherent surface is very good for:
• Metal to rubber bonding
• Painting
• Lubricants
• Application of organic coatings
• Sealants
• Oils
• Other advantages include:
• Use of low temperatures for the process
• Suitable for irregularly shaped objects
• Suitable for recessed objects
• No hydrogen embrittlement
• Suitable for sintered material since it is a dry process
 Colorizing
• Colorizing is an industrial surface
modification process used to create aluminum
diffusion coatings. Colorizing is performed by
diffusing aluminum into steel. This process forms
an alloy with ideal heat and corrosion resistance
properties.
• Colorizing refers to the use of pack cementation
diffusion processes to facilitate the production of
aluminized alloys on a base metal surface. These
alloys serve as a coating material to provide
surface protection against corrosion for the base
metal.
• ..
• Colorizing is performed by positioning the
steel in a retort and immersing it in a mixture
of blended aluminum powders. It is then
completely sealed and placed in a
temperature-regulated furnace
• At extremely high temperatures, the
aluminum diffuses into the steel, generating a
steel substrate. Once cooled, the steel is
removed and secondary operations such as
trimming and straightening are performed
• Colorizing is performed by positioning the
steel in a retort and immersing it in a mixture
of blended aluminum powders. It is then
completely sealed and placed in a
temperature-regulated furnace. At extremely
high temperatures, the aluminum diffuses into
the steel, generating a steel substrate. Once
cooled, the steel is removed and secondary
operations such as trimming and straightening
are performed.
 Galvanization
• Galvanization or galvanization (or galvanizing as it is most
commonly called) is the process of applying a protective
zinc coating to iron or steel, to prevent rusting.
• The most common method is hot dip galvanizing, in which
steel sections are submerged in a bath of molten zinc.
•
Hot dip galvanizing is the process of coating iron or
steel with a layer of zinc by immersing the metal in a bath
of molten zinc at a temperature of around 450 °C (842 °F).
• During the process, a metallurgic ally bonded coating is
formed which protects the steel from harsh environments,
whether they be external or internal.
•
• Main steps within the galvanizing process
include :
• a cleaning cycle – decreasing and chemical
clean
• fluxing – helps to wet the surface of the steel
• galvanizing – immersion of steel into bath of
molten zinc
• post treatment (optional)
• Cleaning of the article - It is essential that this is
free of grease, dirt and scale before galvanizing.
These types of contamination are removed by a
variety of processes and common practice is to
degrease first using an alkaline or acidic solution
into which the component is dipped. The article is
then rinsed in cold water to avoid contaminating
the rest of the process.
•
A flux solution is used to cover the molten Zn
bath solution in which the article is dipped –
usually the flux solution is about 30% zinc
ammonium chloride at around 65-80°C
• When the clean iron or steel component is dipped into
the molten zinc (which is commonly at around 450°C) a
series of zinc-iron alloy layers are formed by a
metallurgical reaction between the iron and zinc.
• A typical time of immersion is about four or five
minutes but it can be longer for heavy articles . Upon
withdrawal from the galvanizing bath, a layer of molten
zinc will be taken out on top of the alloy layer. Often
this cools to exhibit the bright shiny appearance
associated with galvanized products.

• After this quenching process is carried out into water

or air cooling. Conditions in the galvanizing plant such
as temperature, humidity and air quality do not affect
the quality of the galvanized coating.
• It should be remembered that galvanized utensils
should not be used for storing and cooking food,
especially acidic one because zinc dissolves in
acid to form highly toxic and even poisonous
compounds
• BENEFITS OF GALVANIZED STEEL
• Less maintenance/Lowest long term cost. ...
• Long life. ...
• Reliability. ...
• Toughest coating. ...
• Automatic protection for damaged areas. ...
• Complete protection. ...
• Ease of inspection.
Tinning
• Galvanization is done using zinc. Zinc provides
a protective layer and does not allows the
material on which it is coated to the outside
solution. Tinning can also sometimes break
and cause corrosion of the material.
So galvanization is better than tinning.
• Due to non-toxic nature and resistant to
atmospheric corrosion tinning is widely used
for coating steel ,copper and brass sheets
• They are used for storing food stuff , ghee,oil,
kerosene and packing food materials