A TERM PAPER
ON:
Corrosion and its Control Techniques.
BY:
ADEKUNJO JOSHUA. O
MATRIC NO: 231586
LEVEL OF STUDY: 300 LEVEL
DEPT: MECHANICAL ENGINEEERING
COURSE: TME 313 (MATERIAL SCIENCE)
LECTURER: Dr. O.O. Ajide
Faculty of Technology
University of Ibadan
Table of Contents
1.0 Abstract
2.0 Introduction
3.0 Types of Corrosion
4.0 Factors Influencing Corrosion
5.0 Corrosion Control Techniques
6.0 Conclusion
7.0 References
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1.0 Abstract
Corrosion is a pervasive and economically significant phenomenon that affects a broad range of
materials, particularly metals, leading to substantial financial losses and safety hazards. This
paper explores the fundamental mechanisms of corrosion and the contemporary techniques
employed to mitigate its effects. Corrosion occurs through various electrochemical processes
where materials deteriorate due to interactions with their environment, often leading to the
formation of oxides, salts, or other compounds. Understanding these processes is crucial for
developing effective control measures.
The paper provides a detailed overview of corrosion types, including uniform corrosion, pitting,
crevice corrosion, and stress corrosion cracking, highlighting their distinct characteristics and the
conditions under which they occur. It then delves into several control techniques, ranging from
material selection and protective coatings to advanced methods such as cathodic protection and
corrosion inhibitors. Each technique is assessed for its efficacy, application scope, and potential
limitations.
Material selection involves choosing materials with inherent resistance to corrosion, while
protective coatings create barriers between the material and its environment. Cathodic protection
employs electrochemical methods to counteract corrosion, and corrosion inhibitors are chemicals
added to reduce the corrosive effects of the environment. The paper also discusses the role of
environmental factors such as humidity, temperature, and exposure to chemicals in corrosion
rates and control strategies.
Recent advancements in corrosion control are highlighted, including innovative coatings, self-
healing materials, and real-time monitoring systems that leverage technology to enhance
maintenance and prevention strategies. The paper concludes by emphasizing the importance of
an integrated approach to corrosion management, combining various techniques tailored to
specific applications and environments to ensure long-term durability and safety of structures
and systems.
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By offering a comprehensive examination of corrosion and its control techniques, this paper aims
to provide valuable insights for engineers, material scientists, and industry professionals seeking
to enhance their understanding and application of corrosion management strategies.
2.0 Introduction
Corrosion is a natural and inevitable degradation process that affects a wide range of materials,
particularly metals, leading to their gradual deterioration. This process occurs when metals react
with their environment, resulting in the formation of oxides, hydroxides, or other compounds that
weaken the material's structural integrity. The economic and safety impacts of corrosion are
profound, affecting infrastructure, transportation, and various industrial applications. The costs
associated with corrosion and its control measures can be substantial, encompassing repair and
maintenance expenditures, as well as potential safety hazards.
3.0 Types of Corrosion
Corrosion manifests in various forms, each with distinct characteristics and effects on materials.
Understanding these types is essential for implementing appropriate control measures. Here are
the primary types of corrosion:
3.1 Uniform Corrosion
Description: Uniform corrosion, also known as general corrosion, occurs evenly across the
surface of a material. It is characterized by a uniform loss of material thickness and is typically
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predictable. This type of corrosion is common in metals exposed to moisture or corrosive
chemicals.
Examples:
-Rusting of Iron: When iron is exposed to oxygen and moisture, it forms iron oxide (rust)
uniformly over the surface.
-Corrosion of Aluminum: Aluminum in atmospheric conditions can undergo uniform corrosion,
forming a thin layer of aluminum oxide that protects the underlying metal.
3.2 Pitting Corrosion
Description: Pitting corrosion is localized and occurs as small, deep pits or cavities on the
surface of a material. This type of corrosion is often caused by localized chemical or
electrochemical reactions, leading to severe material degradation in small areas.
Examples:
-Stainless Steel: In chloride-rich environments, stainless steel can experience pitting corrosion,
resulting in localized pits.
-Aluminum Components: Pitting corrosion is also common in aluminum exposed to seawater or
saline conditions.
3.3 Crevice Corrosion
Description: Crevice corrosion occurs in confined spaces where the access of the environment is
restricted. It often happens in crevices, joints, or under deposits, where stagnant or low-oxygen
conditions promote localized corrosion.
Examples:
-Under Gaskets or Bolts: In marine or chemical environments, the area under gaskets or between
bolted joints can suffer from crevice corrosion.
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-Corrosion under Clamps: Metallic pipes or tanks with clamps can experience crevice corrosion
in the areas where the clamp contacts the surface.
3.4 Galvanic Corrosion
Description: Galvanic corrosion occurs when two dissimilar metals are in electrical contact in the
presence of an electrolyte. The more active metal corrodes preferentially while the more noble
metal is protected.
Examples:
-Marine Structures: In shipbuilding, when steel and aluminum components are used together, the
steel can corrode more rapidly.
-Galvanic Cells: In electronic devices, different metals used in connectors can experience
galvanic corrosion if not properly insulated.
3.5 Intergranular Corrosion
Description: Intergranular corrosion occurs along the grain boundaries of a metal, rather than
within the grains themselves. This type of corrosion is often caused by improper heat treatment
or the presence of harmful elements at the grain boundaries.
Examples:
-Heat-Treated Stainless Steel: Stainless steel alloys that are improperly heat-treated can suffer
from intergranular corrosion.
-Welded Structures: Welds in certain alloys can experience intergranular corrosion due to the
formation of chromium carbides at the grain boundaries.
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3.6. Stress Corrosion Cracking (SCC)
Description: Stress corrosion cracking is a type of corrosion that occurs under the combined
influence of tensile stress and a corrosive environment. It leads to the formation of cracks in the
material, which can propagate and cause structural failure.
Examples:
-High-Strength Steels: In the presence of chlorides or other corrosive agents, high-strength steels
can develop stress corrosion cracks.
-Aluminum Alloys: Aircraft components made from aluminum alloys can experience SCC when
exposed to certain environments and stresses.
3.7 Erosion Corrosion
Description: Erosion corrosion results from the combined effects of corrosion and mechanical
erosion. It occurs when a flowing liquid or gas removes the protective oxide layer from a metal
surface, accelerating the corrosion process.
Examples:
-Pipelines: In industrial pipelines carrying abrasive fluids, erosion corrosion can lead to
accelerated wear and material loss.
-Propellers: Marine propellers exposed to high-speed water flow can suffer from erosion
corrosion, leading to surface degradation.
4.0 Factors Influencing Corrosion
Corrosion is influenced by a variety of factors that can either accelerate or inhibit the degradation
process.
Below are some of the key factors that affect corrosion:
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4.1 Environmental Conditions
Moisture and Humidity: The presence of water or moisture is a primary factor in corrosion.
Water acts as an electrolyte, facilitating the electrochemical reactions that lead to corrosion. High
humidity levels can increase the likelihood of condensation on surfaces, promoting corrosion.
Temperature: Higher temperatures generally increase the rate of corrosion by accelerating
chemical reactions. However, extreme cold can also affect certain types of corrosion, such as
those involving ice formation and cracking.
pH Levels: The acidity or alkalinity of the environment significantly impacts corrosion. Acidic
environments (low pH) tend to accelerate corrosion, while alkaline environments (high pH) can
either inhibit or promote corrosion depending on the material.
Presence of Salts: Salts, especially chlorides, can exacerbate corrosion. Saltwater environments
are particularly corrosive due to the high concentration of chloride ions, which can lead to
phenomena like pitting and crevice corrosion.
4.2 Material Properties
Material Composition: The chemical composition of a material influences its susceptibility to
corrosion. For instance, stainless steels are more resistant to corrosion due to their chromium
content, which forms a protective oxide layer.
Microstructure: The microstructure of a material, including grain size, phase distribution, and the
presence of inclusions, can affect its corrosion resistance. For example, materials with fine grains
generally show better resistance to corrosion.
Protective Coatings: The application of coatings such as paint, galvanizing, or anodizing can
significantly affect corrosion resistance by providing a barrier between the material and the
corrosive environment.
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4.3 Electrochemical Factors
Electrolyte Concentration: The concentration of electrolytes (e.g., salts or acids) in the
environment can influence the rate of corrosion. Higher electrolyte concentrations typically
increase corrosion rates.
Electrochemical Potential: Different metals have different electrochemical potentials, which can
affect their tendency to corrode when in contact with each other. For example, in galvanic
corrosion, the more active metal corrodes preferentially.
4.4 Mechanical Factors
Stress: Mechanical stress, including tensile stress, bending, or pressure, can accelerate corrosion
processes, particularly in the form of stress corrosion cracking (SCC).
Surface Condition: Surface roughness, welds, and the presence of scratches or abrasions can
create localized areas where corrosion is more likely to occur. Poor surface preparation can
exacerbate corrosion in these regions.
4.5 Chemical Exposure
Pollutants: Industrial pollutants such as sulfur dioxide (SO₂) or nitrogen oxides (NOx) can
contribute to acid rain, which accelerates corrosion of metals and other materials.
Chemical Reactions: Exposure to reactive chemicals can lead to specific types of corrosion. For
example, exposure to strong acids can cause severe uniform corrosion, while exposure to
chlorides can lead to pitting corrosion.
4.6 Biological Factors
Microorganisms: Certain microorganisms, such as bacteria and fungi, can contribute to corrosion
through processes such as microbiologically influenced corrosion (MIC). These microorganisms
can produce corrosive byproducts or create localized environments that promote corrosion.
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4.7 Design Factors
Design Features: Poor design can lead to areas where moisture, chemicals, or pollutants can
accumulate, promoting localized corrosion. Features such as sharp corners, crevices, or joints can
be prone to corrosion.
Drainage: Inadequate drainage or water runoff can result in stagnant water, which creates an
ideal environment for corrosion. Proper drainage design can help minimize corrosion risk.
5.0 Corrosion Control Techniques
Corrosion control techniques are methods used to prevent or mitigate the degradation of
materials caused by corrosion. These techniques can be broadly categorized into preventive,
protective, and corrective measures. Here’s a detailed overview of the main corrosion control
techniques:
5.1 Material Selection
Description: Choosing materials that are naturally resistant to corrosion is one of the most
effective ways to control corrosion. Corrosion-resistant materials include alloys with high
corrosion resistance or those designed specifically for harsh environments.
Examples:
Stainless Steel: Contains chromium, which forms a passive oxide layer protecting the metal.
Aluminum Alloys: Naturally forms a protective oxide layer that resists corrosion.
5.2. Protective Coatings
Description: Applying protective coatings creates a barrier between the material and the
corrosive environment. Coatings can be organic (paints) or inorganic (metallic coatings).
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Types of Coatings:
Paints: Provide a physical barrier and can be tailored to specific environments (e.g., epoxy
coatings for chemical resistance).
Galvanization: Involves coating steel with zinc, which acts as a sacrificial anode to protect the
underlying steel.
Anodizing: An electrochemical process that thickens the natural oxide layer on aluminum or
other metals.
5.3. Corrosion Inhibitors
Description: Corrosion inhibitors are chemicals that, when added to the environment or applied
to the surface of a material, reduce the rate of corrosion. They work by various mechanisms,
such as forming a protective film or altering the electrochemical reaction.
Types of Inhibitors:
Organic Inhibitors: Often used in oil and gas industries; they form a protective layer on the metal
surface.
Inorganic Inhibitors: Include substances like chromates or phosphates, which can provide
protection in cooling water systems.
5.4. Cathodic Protection
Description: Cathodic protection (CP) involves making the metal surface the cathode of an
electrochemical cell, thus preventing corrosion. This can be achieved using two main methods:
Methods:
Sacrificial Anode Protection: Involves attaching a more reactive metal (e.g., zinc) to the
protected metal. The sacrificial anode corrodes instead of the protected metal.
Impressed Current Cathodic Protection (ICCP): Uses an external power source to provide a
constant current to the metal, keeping it at the cathodic potential and preventing corrosion.
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5.5. Design Modifications
Description: Modifying the design of structures and components can minimize corrosion risks by
eliminating areas prone to moisture accumulation or restricting access of corrosive agents.
Examples:
Improved Drainage: Ensures that water or chemicals do not pool in vulnerable areas.
Avoiding Crevices and Sharp Edges: Reduces areas where corrosion can initiate or accelerate.
5.6. Environmental Controls
Description: Controlling the environment around a material can reduce the factors that contribute
to corrosion.
Techniques:
Dehumidification: Reduces moisture levels in enclosed spaces to prevent corrosion.
Water Treatment: Treats water in cooling systems to reduce corrosive properties by controlling
pH and removing impurities.
5.7. Regular Maintenance and Inspection
Description: Routine inspection and maintenance help in early detection of corrosion and timely
application of corrective measures.
Practices:
Visual Inspections: Regular checks for signs of corrosion, such as rust or pitting.
Non-Destructive Testing (NDT): Methods like ultrasonic testing or radiography to assess the
extent of corrosion without damaging the material.
5.8. Use of Corrosion-Resistant Alloys
Description: Using alloys specifically designed to resist corrosion can be effective, especially in
highly corrosive environments.
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Examples:
Nickel Alloys: Used in chemical processing industries for their high corrosion resistance.
Titanium Alloys: Known for excellent resistance to a wide range of corrosive environments.
5.9. Cathodic Protection
Description: This technique involves making the metal surface the cathode of an electrochemical
cell to prevent corrosion. It can be implemented through sacrificial anodes or impressed current
systems.
Methods:
Sacrificial Anodes: Attach a more reactive metal (such as zinc) that corrodes instead of the
protected metal.
Impressed Current Systems: Use an external power source to apply a current that prevents
corrosion.
6.0 Conclusion
Corrosion control is a complex process that requires a multi-faceted approach. By understanding
the mechanisms behind corrosion and employing effective control techniques, engineers can
significantly extend the lifespan of structures and equipment, ensuring safety and reducing
economic losses.
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7.0 References:
1. Fontana, M. G. (1986). *Corrosion engineering*. McGraw-Hill.
2. McCafferty, E. (2010). *Introduction to corrosion science*. Springer.
3. Chilingar, G. V. (Ed.). (1994). *The metal corrosion handbook*. Elsevier.
4. Materials Performance and Characterization. (n.d.). *Journal articles*. ASTM International.
5. National Association of Corrosion Engineers (NACE). (n.d.). *Corrosion control standards
and guidelines*. NACE International.
6. ASTM International. (n.d.). *ASTM standards on corrosion*. ASTM International.
7. International Organization for Standardization (ISO). (n.d.). *ISO standards on corrosion*.
ISO.
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https://www.academia.edu/12281980/CORROSION_CONTROL
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https://byjus.com/jee/corrosion/
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https://www.mdpi.com/2076-3417/13/18/10107
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https://www.researchgate.net/publication/350056220_OVERVIEW_OF_CORROSION_AND_I
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