Corrosion Prevention

and Control II
 Hello!
◇Bautista, Cesar D. Jr.
◇Carolino, Ramil Jessie N.
◇Castro, Edrian Mark N.
◇Gacayan, Marc Christian R.
◇Lomibao, Patrick John A.
◇Manuel, Anthony Carl C.

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1 introduction
Marc Christian R. Gacayan
 Corrosion Control and
Prevention
◇ The characteristics of a system design to avoid or decrease
corrosion, materials selection, non-destructive inspections
for corrosion detection, coatings, finishes, cleaning
materials and washings, repairs, and other maintenance
operations are all part of corrosion prevention and control
(CPC).

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 A Corrosion Prevention and Control (CPC) Plan should be
created as early as feasible in the program and updated as
needed. The CPC requirements should be defined in the
plan, as well as the program's goals and metrics.
◇ Effectiveness metrics must be quantitative.
◇ If the Plan is prepared during the acquisition process, it
should incorporate corrosion-related design requirements.
◇ A specific period of fielded time that the system is
corrosion-free, or the maximum amount of dollars spent on
corrosion maintenance for the first five or fifteen years of a
system's life, are examples of program goals.

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 After a system has been in service for a long
time and significant corrosion has developed
throughout the fleet, as is the situation with
many military aircraft, it becomes a matter
of eliminating the corrosion first, then
implementing design or maintenance
adjustments to reduce future corrosion.

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 The Corrosion Prevention and Control Planning
Guidebook
◇ The Corrosion Prevention and Control Planning Guidebook
contains numerous documents that should be used by
individuals planning new systems or repairing old ones.
Due to a lack of training and knowledge of basic material
and design concerns for corrosion prevention and control,
the same mistakes are made over and over again.

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 3 Stages of Corrosion
Failure Analysis
1. Obtaining and gathering information related to a
component or piece of equipment's history.
2. Conducting a detailed examination of the failed part.
3. Addressing the reasons that caused the failure.

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 Failure Analysis
◇ Failure analysis is a vast concept that includes different
fields such as electronics, mechanics, metallurgy, corrosion
and so forth. However, for a corrosion engineer, failure
analysis is defined as the study of a specific case of
component or equipment failure due to corrosion or the
mechanical aspects of corrosion which is conducted to
determine the root causes for this failure and how it may be
prevented in the future.
◇  Key benefits of failure analysis include avoiding costly
future instances of corrosion-induced failure and providing
evidence for any litigation proceedings.

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 Creating a record of the
component and equipment
background
◇ Detailed information about both the failed component and the
environment to which the component had been exposed is necessary
for failure analysis.
◇ For the failed components, it is important to know the 
metallurgical data about them, including chemical composition, 
microstructure, continuity, mechanical deformation and heat treatment
 history. Environmental conditions is the other issue that has to be
considered in this stage.
◇ The inspection reports and related dates are other important factors. It
is important to know the last time that the component was investigated
and was found to have no significant corrosion. This will help
determine the approximate time frame in which the corrosion
occurred.

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 Examination of Failed Part
◇ The failed components, and in some cases the adjacent
components, are examined to obtain more information
about the failure.
◇ Generally, the corroded components in industrial equipment
are sent to the lab for more detailed investigation. In order
to preserve the original form of samples and minimize
sample damage, very careful sampling and sectioning
practices are required. All the samples should be identified
and placed in suitable packaging before being shipped to
the laboratory.
◇ In the lab, investigators can use various types of
instrumental tools to examine the corroded samples. The
simplest way to start is with a visual inspection. This
should be focused on the type of corrosion present and its
intensity.
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 ◇ Metallurgical optical microscopes or 
scanning electron microscopes are used to achieve more
detailed information. Sometimes, the examination of a
cross-section of a corroded sample can provide helpful
clues to understanding the reasons behind corrosion.

◇ Conducting mechanical tests is necessary when mechanical

aspects such as wear or fracture contributed to a failure.
Commonly,  hardness test along with metallographic
structures provide enough information about the
mechanical properties of the metallic samples in corrosion
failure analysis.

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Reporting Data, Deriving
Conclusions, Making Suggestions
 When all the information is collected and reviewed, corrosion
engineers should analyze the data in a rational manner. It is very
important that all the data be considered to avoid misinterpretation.
This step needs sufficient knowledge and experience in order to
prevent generating new failures or extra expenses due to the
incompetence of the analyst.
 Corrosion Rates
◇ Corrosion rate is the speed at which any metal in a specific
environment deteriorates. It also can be defined as the
amount of corrosion loss per year in thickness. The speed
or rate of deterioration depends on the environmental
conditions and the type and condition of the metal under
reference.

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 ◇ The total amount of lost thickness in micrometers is:
d = total Loss occurrence
t = time in years.
◇ This rate may vary if the rate expressed by the function
above is used to compare corrosion rates for a period of
time not less than one year with rates calculated over short
periods. This is because the short time rates are prone to
fluctuating environmental changes from season to season
and also from day to day. This method involves the
exposure of a weighed piece of test metal or alloy to the
specific environment for a specific time. This is followed
by thorough cleaning to remove the corrosion products and
then determining the weight of the lost metal due to
corrosion.

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 Parameters to be tested
◇ Weight loss (the decrease in metal weight during the
reference time period)
◇ Density (density of the metal)
◇ Area (total initial surface area of the metal piece)
◇ Time (the length of the reference time period)

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 Formula
The rate can also be calculated as follows:
R = KW/ (?AT)
where,
◇ K = constant
◇ W = total weight lost
◇ T = time taken for the loss of metal
◇ A = the surface area of the exposed metal
◇ ? = the metal density in g/cm³

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 Why Corrosion Rates
Matter

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 Why Corrosion Rates Matter

◇ Corrosion rates determine the lifespan of metal-based structures. This

variable dictates the choice of metals used for different purposes, and in
different environments.

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 Why Corrosion Rates Matter
◇ The rate of corrosion also determines the maintenance requirements
for structures. A metal structure in a wet environment (e.g., a metal
bridge in Florida) may require more frequent maintenance than a
similar structure in a drier location (e.g., a metal bridge in New
Mexico).

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Concentration Cell
Corrosion
 Concentration Cell Corrosion
◇ This corrosion occurs when two or more areas of a metal surface are in
contact with different concentrations of the same solution. It is the
deterioration of parts of a metal surface at different rates, due to the parts of
the surface coming into contact with different concentrations of the same
electrolyte. The differing concentrations result in some parts of the metal
acquiring different electric potentials. The extent of this corrosion reaction is
proportionate to the difference in concentrations at contact points. It also
varies with the type of electrolyte.

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 Types of Concentration Cell
Corrosion

◇ Metal-ion concentration cells

◇ Oxygen concentration cells
◇ Active-passive cells

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 Metal ion Concentration Cell
 In the presence of water, a high concentration of metal ions will exist
under faying surfaces and a low concentration of metal ions will exist
adjacent to the crevice created by the faying surfaces. The area of the
metal in contact with the low concentration of ions will be cathodic and
will be protected, and the area of metal in contact with the high ion
concentration will be anodic and corroded. Proper protective coating
application with inorganic zinc primers is also effective in reducing
faying surface corrosion.

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 Metal ion Concentration Cell

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 Oxygen Concentration Cell
 An oxygen cell can develop at any point where the oxygen in the air is
not allowed to diffuse uniformly into the solution, thereby creating a
difference in oxygen concentration between two points. Typical
locations are under metallic or nonmetallic deposits (dirt) on the metal
surface and under faying surfaces. Oxygen cells can also develop under
gaskets, wood, rubber, plastic tape, and other materials in contact with
metal surface. Corrosion will occur at the area of low-oxygen
concentration (anode).

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 Oxygen Concentration Cell
 

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 Active-passive Cell
 Metals that depend on a tightly adhering passive film (usually an
oxide) for corrosion protection; e.g., austenitic corrosion-resistant steel,
can be corroded by active-passive cells. The corrosive action usually
starts as an oxygen concentration cell; e.g., salt deposits on the metal
surface in the presence of water containing oxygen can create the
oxygen cell. If the passive film is broken beneath the salt deposit, the
active metal beneath the film will be exposed to corrosive attack. An
electrical potential will develop between the large area of the cathode
(passive film) and the small area of the anode (active metal). Rapid
pitting of the active metal will result.

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 Active-passive Cell

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 GALVANIC CORROSION
It occurs when two material having different electrical potentials and nobilities
(dissimilar metals) are electrically connected, either through physically touching
each other or through electrically conducting medium, such as
electrolyte(chemical that carries electric charge when dissolve to water).
 The lower the nobility of the metal the higher the chances to corrode
because it acts as an anode while in the other hand, the metal that
has a high nobility, the higher the chances that it will not corrode. It is
always the anode that corrode. Therefore, in general, corrosion occurs
due to the electrochemical reaction between anode and cathode.

• Corrosion reaction or corrosion current (flow of electrical

current) is driven by an electrical potential gradient

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 The greater the cathode area
in relation to the anode, the
faster the anode will corrode.
The bigger the difference
(EP) the more rapid the rate
of galvanic corrosion
It may also occur between
parts of the same metal if the
parts is situated in different
surroundings, such as areas
with different Ph values. The
higher the ph value the
metals become passive and
it acts as a cathode while
lower ph value the higher the
acid it have that is why it acts
as an anode and promote
corrosion.
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 https://youtu.be/JrtpZ5qZ-Ao
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