Factors affecting corrosion

Nature of metal Enviornment

1. Position in galvanic 1. Temperature
series 2. Humidity
2. Overvoltage 3. Impurities
3. Relative area of anodic, 4. Suspended particles
cathodic parts 5. pH
4. Purity of metal 6. Nature of ions
5. Surface film 7. Formation of
6. Passive character concentration cells
7. Solubility & volatility of 8. Polarisation of
corrosion products electrodes

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Passivity

Phenomenon of exhibiting higher

corrosion resistance than expexted from
electrochemical series.
E.g. Ti, Al, Cr
Order Ti, Al, Cr, Mo, Mg, Ni, Co, Fe, Zn,
Sn, Cu
Thin protective film formed

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 Corrosion Prevention
Any one or more methods which are given bellow can be
used to protect the material from corrosion or prevent it
from corrosion.
(A) Internal Measures (B) External Measures

1. Design feature
1. Purification of
metals 2. Application of inhibitors
2. Alloying of metals 3. Alteration of corrosion
environments
3. Proper heat
treatment 4. Protective coatings
Metallic coatings
Non metallic
coatings
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 PREVENTION OF CORROSION

1. Proper designing
2. Using pure metal
3. Using metal alloys
4. Cathodic protection
5. Modifying the environment
6. Use of inhibitors
7. Modifications of the properties of metals
8. Application of protective coatings
9. Potentiostatic anodic protection

4
 The methods used to protect a metal from
corrosion mainly operate by preventing
corrosion reactions from taking place. One of
the best ways of doing this to protect the
metal from water and oxygen.

Before preventive measures are adopted, the

metal should be cleaned or descaled by
degreasing and descaling.

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1. PROPER DESIGNING
The design of the material should be such that
corrosion, even if it occurs, is uniform and does not
result in intense and localized corrosion.
Important design principles
Avoid the contact of dissimilar metals in the
presence of a corroding solution.
When two dissimilar metals are to be in contact, the
anodic material should have as large area as
possible.
If two dissimilar metals in contact have to be used,
they should be as close as possible to each other in
electrochemical series.
Whenever the direct joining of dissimilar metals is
unavoidable, an insulating fitting may be applied in
between them to avoid direct metal-metal electrical
contact.
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 The anodic metal should not be painted or coated,
when in contact with a dissimilar cathodic metal.
Prevent the occurrence of inhomogeneities (crevices)
in metals.
Sharp corners should be avoided since they favour
the formation of stagnant areas and accumulation of
solids.
The equipment should be supported on legs to allow
free circulation of air.
A proper design should prevent condition subjecting
some areas of structure to stress.

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2. USING PURE METAL
Impurities in metal cause heterogeneity which
decreases corrosion-resistance of metal. The
corrosion resistance of a given metal, therefore
may be improved by increasing its purity.
a) In many cases, it is not practical to produce a
metal of high chemical purity
b) Cost consideration
Very pure metal often possess the disadvantages
of inadequate mechanical properties like softness
and low strength.
Purification of metals is of use only under
conditions in which corrosion by a purely
electrochemical mechanism and not by direct
chemical attack.
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3. USING METAL ALLOYS

Corrosion resistance of most metals is best increased

by alloying them with suitable elements, but for
maximum corrosion resistance. Alloys should be
completely homogeneous.

Chromium is the best suitable alloying metal for iron

or steel. Its film is self-healing.

4. CATHODIC PROTECTION

Principle To force the metal to be protected to behave

like cathode.

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(i) Sacrificial anodic protection method

The metallic structure to be protected is connected

by a wire to a more anodic metal (sacrificial anode)
so that all the corrosion is concentrated at this
more active metal. The more active metal itself gets
corroded slowly while the parent structure is
protected.

(ii) Impressed current cathodic protection

An impressed current is applied in opposite

direction to nullify the corrosion current and
convert the corroding metal from anode to cathode.

This kind of protection technique is particularly

useful for large structures for long term operations.
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5. MODIFYING THE ENVIRONMENT

The corrosive nature of the environment can be

reduced either
a) By the removal of harmful constituents or
b) By the addition of specific substances, which
neutralize the effect of corrosive constituents of the
environment.
(i) Deaeration
Expulsion of dissolved oxygen from aqueous
environment by adjustment of temperature, together
with mechanical agitation. This method also
removes CO2.
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(ii) Deactivation
This involves the addition of chemicals capable of
combining rapidly (e.g. sodium sulphite Na2SO3
and hydrazine hydrate NH2.NH2.H2O) with the
oxygen in aqueous solution.

(iii) Dehumidification
This reduces the moisture content of air to such an
extent that the amount of water condensed on
metal is too small to cause corrosion. e.g. Alumina
and silica gel.

(iv) Alkaline Neutralization

Alkaline neutralization is prevention of corrosion
by neutralizing the acidic character of corrosive
environment by injecting alkaline neutralizers (NH3
or NaOH etc.) in vapour or liquid form to the
corroding system.
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6. USE OF INHIBITORS
Inhibitors are chemical substances which reduce
the corrosion rate when added in small quantities
to the corrosive environment.
Corrosion inhibitors are of three types
Anodic inhibitors
Cathodic inhibitors
Vapour phase inhibitors

(i) Anodic Inhibitors

They react with the ions of the anode and produce
insoluble precipitates. The precipitates so formed
are adsorbed on the metal surface, forming a
protective film thereby reducing the corrosion rate.
Examples: Alkalies, molybdates, phosphates,
chromates etc. 14
(ii) Cathodic inhibitors

The corrosion can be slowed down by slowing down

the diffusion of hydrated H+ ions. This can be done
by using organic inhibitors like amines, mercaptans,
heavy metal soaps, substituted ureas and thiourea.
They absorb over cathodic metal surface and act as
protective layer.

(iii) Vapour phase inhibitors

These are the organic inhibitors which readily

sublime and form a protective later on the surface of
metal. e.g. dicyclohexylammonium nitrite is used for
the protection of machineries and sophisticated
equipments.
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7. MODIFICATION OF THE PROPERTIES OF
METAL
Methods used to modify the properties of metals are
(i) Alloying (ii) Refining (iii) Annealing

8. APPLICATION OF PROTECTIVE COATINGS

For protection against corrosion, the metal surface
may be coated with metallic or non-metallic
coatings. A coated surface isolates the underlying
the underlying metal from the corroding
environment.
The coating applied must be chemically inert to
the environment under particular conditions of
temperature and pressure.
Coatings must prevent the penetration of the
environment to the material, which they protect. 16
(A) Metallic Coatings
(a) Anodic coatings (b) Cathodic coatings
(a) Anodic coatings
Metal used for coating is more anodic than the metal
which is to be protected (base metal) e.g. Coating of Al,
Cd and Zn on steel surface.
(b) Cathodic coatings
These coating protect the underlying base metal due to
their noble character and higher corrosion resistance.
Effective protection is possible only when coating is
continuous and free from pores, breaks or
discontinuities.
(B) Inorganic coatings
These are non-metallic protective coatings. Important
inorganic coatings are
Surface Conversion or Chemical Dip coatings
(Phosphate coatings, Chromate coatings, Chemical
oxide coatings)
Anode oxide coating (using anode oxidation process)
Vitreous or Porcelain Enamel Coating 17
(C) Organic coatings

Two most important functions of organic coatings

are

1. To impart decorative and aesthetic appeal.

2. To protect the metal from corrosion.

Organic coating is an inert organic barrier whose

protective value depends on
Its impermeability to gases, salts and water
Its chemical inertness to the corrosive environment
Its good surface adhesion and
Its proper application method.
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9. POTENTIOSTATIC ANODIC PROTECTION

The basic principle of anodic protection is

The growth of protective oxide surface film by the

application of anodic current on the metal / alloy
appliance in a suitable oxidizing atmosphere.

The required potential for protecting the metal / alloy

can be obtained from its potential-current curve.

During anodic protection method, the corrosion

does take place, but at a very slow rate.

This method can be applied only to those metals or

alloys which passivate. 19
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