CORROSION &

some important
Corrosion Types

illustration of essential corrosion basics

 Topics
 Definition of corrosion
 Why corrosion is Important
 Corrosion Electrochemistry
 Corrosive Environments
 Types of corrosion
 Corrosion Control Techniques
 Definition of Corrosion
 In broad terms, the interaction between a
material and its environment that results in
a degradation of the physical, mechanical,
or even esthetic properties of that material.
 More specifically, corrosion is usually
associated with a change in the oxidation
state of a metal, oxide, or semiconductor
 Why Corrosion is Important
 Economics

 Safety

 Conservations
 Economics of Corrosion
 The cost of corrosion in the industrial
countries has been estimated to be on the
order of 4% of the gross national product
Direct Losses

Replacement of Protection against

structures or corrosion
components
 Economics of Corrosion
Indirect Losses

Cost of shutdown Contamination

Loss of product or efficiency

 Economics of Corrosion
Source of corrosion-resistant metals

Engineering systems for

Much of the chromium
service environments require
being used is considered
materials that are chemically
irreplaceable
stable or that can be made
chemically stable
 Corrosion of metals

CORROSION

Of coatings & linings

Of metals
Of polymers,
ceramics, etc ...

“... Is probably the commonest electrochemical phenomenon

encountered in day-to-day life ...”
or : ... METALLURGY IN REVERSE ...
Metal (in-)stability :
Origin of Electrode Potential – E

METAL

M M n+
atom ion

ne
Electrons Nernst :
E = E0 + RT/nF * ln [ aox / ared ]
Corrosion mechanism

Fe +
Corrosive environment

Fe + 2 e
2+ -

anodic (oxidation) reaction

 Reduction reactions
Depending on the nature & components
of the environment :

– acid environment :
2H+ + 2e- H2
– alkaline or neutral environment :

O2 + 2H2O + 4e- 4OH-

Thermodynamics: E-pH Diagrams

“Pourbaix” diagrams …
 Effect of pH
 Magnetite (for example)
Low pH no oxides form
High pH porous Fe(OH)3.xH2O forms
pH 10-12 ideal range for carbon steel
 Different metals require different conditions for uniform
corrosion
 pH is controlled to control uniform corrosion
Kinetics

“Polarization curves” …

Passivating metal
Corrosion Types
Corrosion T ypes Uniform corrosion

G alvanic corrosion

S tress Corrosion
Cracking (S C C )

In te rg ra n u la r Tra n s g ra n u la r

Pitting

Crevice Corrosion

M icrobiological Corrosion
General (uniform) corrosion
 “Rusting”

 “Wastage”

 “White Rust”
General (uniform) corrosion
 Can be a good or a bad thing
 Corrosion occurs evenly over the surface
 Oxide layers can be very tough
Magnetite
Fe3O4
Galvanic corrosion
 Corrosion between a
noble and less noble
metal in the presence
of an aggressive
medium
 The more electro-
positive = cathode, the
least electropositive =
anode
Galvanic corrosion (2)

Selective Leaching (Dealloying)

Bimetallic Corrosion

(Oxygen) Concentration Cell

IGA & Sensitization

Mechanisms ...
Weld Decay …/…
Sensitization & Weld Decay

Mechanism :
Cr23C6
 Pitting corrosion

 Caused by Chlorides
(halides)
 Passive metals &
alloys = susceptible

Mechanism …
 Crevice corrosion

 Accelerated corrosion in a
narrow crevice between
two parts of a component,
...one of which is made
from a metal ...
 Stress Corrosion Cracking
(SCC)
(Sudden) fracture of a
metal upon exposure
to a corrosive
environment

 Intergranular ...
 Transgranular ...
Intergranular Stress Corrosion Cracking
(IGSCC)

Mechanisms …
Transgranular Stress Corrosion Cracking
(TGSCC)

Mechanism (theories) …
Corrosion Fatigue
Corrosion Fatigue (2)
Erosion-corrosion
“MIC” - Microbiologically
Induced Corrosion

 Various ways :
- SRBs
- Iron-oxidizing
- Etc …, etc …
 High-Temperature Corrosion

Oxidation
Sulfidation
Carburization
….
Atmospheric Corrosion
 How to avoid corrosion ?...
 Design
 Material selection
 Coatings
 Changing the environment ...