ATMOSPHERIC CORROSION

Presented by:

Suhas Y. Nayak Roll No.: 120926004 II Sem. M. Tech (Mfg. Engg.& Tech.) MIT, Manipal

CONTENTS

Introduction Classification Factors affecting atmospheric corrosion Effect of atmospheric factors Mechanism of Atmospheric corrosion Specific Atmospheric Corrodents Atmospheric corrosion of non-metals References
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INTRODUCTION

Atmospheric materials

corrosion by

is air

the and

degradation the

of

caused

pollutants

contained in the air.

It can be precisely defined as an electrochemical process which depends upon the presence of electrolyte which may be rain, dew, humidity or

melting snow.
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INTRODUCTION

Its effect extends from small articles, such as bolts, nuts and fasteners and to industrial structures, plants such and as

equipment

mega

skyscrapers, towers and bridges

CLASSIFICATION Atmospheric corrosion can be classified in the following categories:

Dry corrosion.

Damp corrosion.
Wet corrosion.

DRY CORROSION

This kind of atmospheric corrosion takes place in the absence of significant water vapour.

Seen mostly in non ferrous metals like copper,

silver.

Develops an oxide film in presence of gaseous pollutants.

Is also known as tarnishing

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DAMP CORROSION

This kind of atmospheric corrosion takes place when relative humidity reaches 70%.

70% relative humidity is considered as a critical

value for onset of corrosion.

The precise level of critical humidity varies with the type of contaminants, such as dust and salt particles, and the composition of metals
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DAMP CORROSION

Damp environments promote the corrosion of most metals.

Water saturated with dissolved gases, such as CO2,

H2S and SO2, cause severe corrosion of iron and

steels, copper, nickel, silver and other non-metallic materials and alloys.

Seasonal cracking is another example of combined

influence of a contaminant and water.
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WET CORROSION

Most frequently observed form of atmospheric corrosion.

Takes place when water layers or pockets are

formed on the metal surface, and the metal surface

remains constantly in contact with water.

Patina formation on copper and corrosion of iron and steel structures are common examples of corrosion caused by wet atmosphere.
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FACTORS AFFECTING ATMOSPHERIC

CORROSION The following factors largely affect the corrosion of metals in an atmosphere:

Time of wetness

Water adsorption

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FACTORS AFFECTING ATMOSPHERIC

CORROSION Time of wetness

It is the time during which the metal surface remains covered with water before inducing

corrosion .

At a sufficient thickness of water layer, an emf is generated which exceeds a critical value to induce corrosion.
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FACTORS AFFECTING ATMOSPHERIC

CORROSION Time of wetness

The time of wetness of a metal surface is dependent upon:

Temperature: a high temperature leads to

decreased adsorption.

Porosity voids: the larger the number of voids, the greater the volume of water adsorption.
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FACTORS AFFECTING ATMOSPHERIC

CORROSION Time of wetness

Grain boundaries: More adsorption with a larger number of grain boundaries.

Nature of surface: more adsorption on a rough

surface.

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FACTORS AFFECTING ATMOSPHERIC

CORROSION Water Adsorption

Water may be adsorbed in the molecular or dissociated form on a metallic surface.

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FACTORS AFFECTING ATMOSPHERIC

CORROSION Water Adsorption

The aqueous phase formed on the metal surface acts as a solvent for gaseous constituents of the

atmosphere.

The dissolution of corrosive gaseous species in the adsorbed layer provides sites for promotion of corrosion.
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FACTORS AFFECTING ATMOSPHERIC

CORROSION Water Adsorption

When the thickness of the adsorbed layer reaches three monolayers, the relative humidity approaches

close to 'critical humidity.

Above the critical humidity the rate of corrosion increases significantly and below, it is virtually insignificant.
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EFFECT OF ATMOSPHERIC FACTORS ON

ATMOSPHERIC CORROSION Relative Humidity

This is the primary driving force for atmospheric corrosion.

Relative humidity is expressed as

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EFFECT OF ATMOSPHERIC FACTORS ON

ATMOSPHERIC CORROSION Relative Humidity

Sharp increase in corrosion rates beyond a threshold level of RH.

This level is called critical relative humidity

Level of the critical humidity varies with the nature of the metal and the type of contaminant.

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EFFECT OF ATMOSPHERIC FACTORS ON

ATMOSPHERIC CORROSION Relative Humidity

Clear and uncontaminated atmosphere - corrosion is negligible even at a relative humidity of as high as 99%.

In the presence of contaminants, corrosion begins to increases around 70% RH.

In the presence of contaminants, such as KCl and NaCl critical humidity requirement is considerably reduced.

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EFFECT OF ATMOSPHERIC FACTORS ON

ATMOSPHERIC CORROSION Relative Humidity

For example, steel can corrode even at 35% RH

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EFFECT OF ATMOSPHERIC FACTORS ON

ATMOSPHERIC CORROSION pH

Decreased pH on a metallic substrate leads to acceleration of atmospheric corrosion.

Dew

Dew is more corrosive than rain water because of a higher concentration of atmospheric contaminants, hygroscopic salts and a lower pH value.
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EFFECT OF ATMOSPHERIC FACTORS ON

ATMOSPHERIC CORROSION Fog

Due to the low pH of fog water (1.8-3.5) in highly contaminated regions, fog is a corrosion promoter.

Dust and Soot

Dust has an abrasive effect on metallic surface in combination with wind velocity

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EFFECT OF ATMOSPHERIC FACTORS ON

ATMOSPHERIC CORROSION

Dust and Soot

Impurities from emissions, such as CO2 and CO are adsorbed in dust particles and create micro-

corrosion cells.

Dust particles are hygroscopic in nature and promotes corrosion.

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EFFECT OF ATMOSPHERIC FACTORS ON

ATMOSPHERIC CORROSION Wind velocity

Wind velocity affects the concentration profile of salt particles in a particular area.

It is responsible for the transport of pollutants which

may be deposited on a metallic substrate.

Corrosion is localized in areas with high moisture content.

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EFFECT OF ATMOSPHERIC FACTORS ON

ATMOSPHERIC CORROSION
Wind velocity

It may also dislodge a protective layer formed on a metal surface and promote corrosion.

Corrosion Products

The corrosion products formed on a metallic surface may induce or retard atmospheric corrosion depending

on the thickness, homogeneity and degree of bonding

and solubility of the film.
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EFFECT OF ATMOSPHERIC FACTORS ON

ATMOSPHERIC CORROSION Pollutants

Outdoor pollutants, like SO2, H2S, CO2, HNO3, NH3, HCl and HCOOH, are corrosion promoters.

They act synergistically to accelerate corrosion with

humidity, temperature, wind and weather cycles.

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EFFECT OF ATMOSPHERIC FACTORS ON

ATMOSPHERIC CORROSION Distance from the source

Distance from the contamination source is an important factor in atmospheric corrosion.

Proximity to sea accelerates the corrosion rate due

to abundance of sea salts

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MECHANISM OF ATMOSPHERIC CORROSION

Atmospheric corrosion takes place by means of an

electrochemical process occurring in corrosion cells.

A corrosion cell must have the following essential components:

1. 2. 3.

A metal anode A metal cathode A metallic conductor between the anode and cathode

4.

An electrolyte

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MECHANISM OF ATMOSPHERIC CORROSION

In addition, oxygen will usually be present as a depolarizing agent.

For the cell to function, there must be a difference in potential between the anode and cathode.

Almost any lack of homogeneity on the metal surface or in its environment may initiate attack by causing a

differential in potentials
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MECHANISM OF ATMOSPHERIC CORROSION

Atmospheric corrosion is mainly electrochemical, rather than a

direct chemical attack by the elements.

The anodic and cathodic areas are usually quite small and close together, so that corrosion is apparently uniform.

For electrochemical reaction to proceed, two or more

electrode reactions must take place:

the oxidation of the metal and

the reduction of an oxidizing agent

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For the electrode reactions to take place, it is necessary that an electrolyte be present.

SPECIFIC ATMOSPHERIC CORRODENTS

Some of the specific elements which increase the chances of initiation of atmospheric corrosion are as follows:

Sulphur containing compounds Nitrogen containing compounds Chlorine containing compounds

Carbon dioxide
Oxygen
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SPECIFIC ATMOSPHERIC CORRODENTS

Some of the indoor atmospheric compounds are as follows:

Formaldehyde (HCHO) Formic acid (HCOOH) compound originate from tobacco smoke,

These

combustion of biomass, adhesives, and plastics.

Ammonia
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due to anthropogenic activity

ATMOSPHERIC CORROSION OF NON-METALS

Atmospheric

corrosion

has

been

defined

as

an

electrochemical reaction requiring the presence of an electrolyte.

This is true for a metallic material. However, there are other materials of construction that do not corrode by electrochemical mechanisms.

Among

these

are

such

materials

as

plastics,
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elastomers, masonry materials, ceramics, and wood.

ATMOSPHERIC CORROSION OF NON-METALS

Plastics

Plastic is mostly affected its by exposure to UV radiations.

Can cause embrittlement, fading, surface cracking, and chalking.

Leads to lower impact resistance, lower overall mechanical performance, and a change in appearance.

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ATMOSPHERIC CORROSION OF NON-METALS

Elastomers

Elastomers in outdoor use degrade when exposed to sunlight, heat, oxygen, atmospheric moisture, and atmospheric nitrous oxide.

Elastomers may harden or soften, or may show an initial hardening followed by softening.

All are irreversible reactions.

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ATMOSPHERIC CORROSION OF NON-METALS

Masonry Materials

Concrete and all cement-based products are inherently weak in tension, but are strong in compression.

To overcome the weakness in tension, steel rods are used as reinforcements.

Micro- and macro-cracking are formed in concrete due to its weakness in tensile loading.

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ATMOSPHERIC CORROSION OF NON-METALS

Masonry Materials

Corrosion gains access to the interior of the concrete through these cracks and leads to deterioration of the steel rods.

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ATMOSPHERIC CORROSION OF NON-METALS

Wood

Wood, when exposed outdoors, undergoes a number of physical and chemical phenomena.

These are caused by

moisture influences, sunlight, Temperature and attack by insects and fungi.

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ATMOSPHERIC CORROSION OF NON-METALS

Wood

Swelling and shrinkage stresses, caused by fluctuations in

moisture content, accompany the loss of wood from the surface.

Other effects are:

Grain raising,
Surface roughening, Formation of small parallel cracks

In addition, warpage might occur, and larger and deeper

cracks might develop.
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REFERENCES

Ahmad, Z., 2006. Principles of Corrosion Engineering and

Corrosion Control. Elsevier Science and Technology Books.

Schweitzer, P. A., 2010. Fundamentals of Corrosion. Boka Raton: CRC Press.

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