REPORT ON CORROSION

SUBMITTED TO: AR. MEHAK MANRAO SUBMITTED BY: PRAFULL DEEPENDER MEHTAB NAKUL

Definition of Corrosion

Corrosion is the deterioration of materials by chemical interaction with their environment. The term corrosion is sometimes also applied to the degradation of plastics, concrete and wood, but generally refers to metals.

Corrosion is the oxidation of a metal due to an ELECTROCHEMICAL reaction. The oxidizing agent is most often O2 (atmospheric corrosion) or H+ (chemical corrosion) or both.

Why is it a problem?
Financial - $80 Billion Dollar Annual Problem in India. (4.25% of GNP) Department of Defense spends $6 8 Billion

Active metal Water

Oxygen (atmospheric corrosion)

Acid (chemical corrosion) Salt

High temperature

Chemical vs. Atmospheric Corrosion (H+ vs. O2) Anodic Reaction: Fe0(s) Fe2+(aq) + 2e- Deterioration of metal

Eo red (V)

-0.44

Cathodic Reaction: 2H+(aq) + 2eO2 (g) + 2H2O (l) + 4eO2 (g) + 4H+(aq) + 4eH2 (g) Chemical 4OH-(aq) Atmospheric 2H2O (l) Combination 0.00 +0.40 +1.23

Which of these will oxidize copper? Silver? Gold? Eocell (V) Overall Reaction:

Fe0(s) + 2H+(aq)

Fe2+(aq) + H2 (g) Chemical

2Fe2+(aq) + 4OH-(aq) Atmospheric 2Fe2+(aq) + 2H2O (l) Combination

+0.44 +0.84 +1.67

2Fe0(s) + O2 (g) + 2H2O (l) 2Fe0(s) + O2 (g) + 4H+(aq)

Anodic & Cathodic Reactions

Causes of Corrosion
Corrosion in the distribution system is a very complex situation which is influenced by many water characteristics, by the metals used, and by any stray electrical current.

Primary Water Characteristics

Corrosive Water

Scale-forming Water

low pH soft or with primarily noncarbonate hardness low alkalinity

high pH hard with primarily carbonate hardness high alkalinity

Physical Water Characteristics

Bacteria

A colony of iron bacteria.

 DRY CORROSION :- It involves direct attack of dry gases (air oxygen) on the metal through chemical reaction. As a result an oxide layer is formed over the surface. This type of corrosion is not common.

TYPES OF CORROSION :-

WET CORROSION :- It involves direct attacks of aqueous media strong or dilute acid or alkaline on the metal through Electrochemical Reactions. The moisture & oxygen are also responsible. This type of corrosion is quite common.

UNIFORM CORROSION:This corrosion is also called General Corrosion. Effect produced by most direct chemical attacks. Corrosion over the entire exposed surface at a uniform rate.eg: Atmospheric Corrosion. Maximum metal loss by this form. This type of corrosion is first seen as a general dulling of the surface and, if allowed to continue; the surface becomes rough.

PREVENTION:
Use thicker materials for corrosion allowance. Use paints or metallic coatings such as plating, galvanizing or anodizing. Use corrosion inhibitors or modifying the environment.

GALVANIC CORROSION:This is also called as Dissimilar Metal Corrosion. This take place when two metals are in physical contact with each other and are immersed in a conducting fluid. Corrosion damage induced when two dissimilar materials are coupled in a corrosive electrolyte.

DIFFERENTIAL AERATION CORROSION:This type of corrosion takes place when a metal is unevenly exposed to different oxygen/air concentrations. The part which is exposed to less oxygen undergoes corrosion.

PITTING CORROSION:Pitting corrosion is a localized form of corrosive attack that produces holes or small pits in a metal. The bulk of the surface remains unattacked. Pitting is often found in situations where resistance against general corrosion is conferred by passive surface films. Localized pitting attack is found where these passive films have broken down.

STRESS CORROSION:This type of corrosion is observed in fabricated articles which are subjected to various mechanical operations. This corrosion is usually unpredictable is nature. Static tensile stress and specific environments produce cracking.

Effects of corrosion
LOSSES ARE ECONOMIC AND SAFETY: Reduced Strength Downtime of equipment Escape of fluids Lost surface properties Reduced value of goods
The consequences of corrosion are many and varied and the effects of these on the safe, reliable and efficient operation of equipment or structures are often more serious than the simple loss of a mass of metal. Failures of various kinds and the need for expensive replacements may occur even though the amount of metal destroyed is quite small.

Underground corrosion

Buried gas or water supply pipes can suffer severe corrosion which is not detected until an actual leakage occurs, by which time considerable damage may be done.

Electronic components

In electronic equipment it is very important that there should be no raised resistance at low current connections. Corrosion products can cause such damage and can also have sufficient conductance to cause short circuits. These resistors form part of a radar installation.

Corrosion influenced by flow-1

The cast iron pump impeller shown here suffered attack when acid accidentally entered the water that was being pumped. The high velocities in the pump accentuated the corrosion damage.

Corrosion influenced by flow 2

This is a bend in a copper pipe-work cooling system. Water flowed around the bend and then became turbulent at a roughly cut edge. Downstream of this edge two dark corrosion pits may be seen, and one pit is revealed in section.

Safety of Aircraft

The lower edge of this aircraft skin panel has suffered corrosion due to leakage and spillage from a wash basin in the toilet. Any failure of a structural component of an aircraft can lead to the most serious results.

Influence of corrosion on value

A very slight amount of corrosion may not interfere with the usefulness of an article, but can affect its commercial value. At the points where these scissors were held into their plastic case some surface corrosion has occurred which would mean that the shop would have to sell them at a reduced price.

Motor vehicle corrosion and safety

The safety problems associated with corrosion of motor vehicles is illustrated by the holes around the filler pipe of this petrol tank. The danger of petrol leakage is obvious. Mud and dirt thrown up from the road can retain salt and water for prolonged periods, forming a corrosive poultice.

Corrosion at sea

Sea water is a highly corrosive electrolyte towards mild steel. This ship has suffered severe damage in the areas which are most buffeted by waves, where the protective coating of paint has been largely removed by mechanical action.

Aluminium Corrosion
The current trend for aluminium vehicles is not without problems. This aluminium alloy chassis member shows very advanced corrosion due to contact with road salt from gritting operations or use in coastal / beach regions.

Damage due to pressure of expanding rust

The iron reinforcing rods in this garden fence post have been set too close to the surface of the concrete. A small amount of corrosion leads to bulky rust formation which exerts a pressure and causes the concrete to crack. For structural engineering applications all reinforcing metal should be covered by 50 to 75 mm of concrete.

Corrosion of plastics
Not only metals suffer corrosion effects. This dished end of a vessel is made of glass fibre reinforced PVC. Due to internal stresses and an aggressive environment it has suffered environmental stress cracking.

Galvanic corrosion

This rainwater guttering is made of aluminium and would normally resist corrosion well. Someone tied a copper aerial wire around it, and the localised bimetallic cell led to a knife-cut effect.

Galvanic corrosion

The tubing, shown here was part of an aircrafts hydraulic system. The material is an aluminium alloy and to prevent bimetallic galvanic corrosion due to contact with the copper alloy retaining nut this was cadmium plated. The plating was not applied to an adequate thickness and pitting corrosion resulted.

Galvanic corrosion
This polished Aluminium rim was left over Christmas with road salt and mud on the rim. Galvanic corrosion has started between the chromium plated brass spoke nipple and the aluminium rim.

Galvanic corrosion
Galvanic corrosion can be even worse underneath the tyre in bicycles used all winter. Here the corrosion is so advanced it has penetrated the rim thickness.

Corrosion prevention

THANK YOU