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Contd.
Occurs when two dissimilar
metals are in electrical contact
with each other and are
exposed to an electrolyte
Severity of the corrosion of the
anodic metal depend upon the
relative position of the two
metals in the galvanic series
Contd.
corrosion
Metals are widely used at high
temperatures therefore, behaviour of
metals at high temperature is of great
interest
High temperature oxide films and
scales are formed
Contd.
Corrosion like rusting of the ferrous
alloys are formed
Oxide films formed or some metals
act as diffusion barriers
Alloying elements like Cr, Al, Si etc.
get oxidized and concentrated in the
scale layer corrosion resistance
improves
passivity
Defined as a phenomenon in which a metal
or an alloy exhibits a much higher
corrosion resistance than its position in
the electrochemical series would indicate
Passive state less reactive
Ti, Cr, Al and stainless steel passive
metals
Contd.
This layer is only one molecule thick and
will be self-healing
Passivation applies only to certain
environmental conditions which tend to
maintain a protective oxide film on the
metal surface.
Depending on metals:
1. Electrode potential of metal or its
position in the galvanic series (usually
anodic metals corrode faster)
2. Hydrogen over voltage (i.e. ease of
hydrogen evolution)
3. Chemical inhomogeneities, e.g.,
inclusions, impurities, different phases,
which promote the formation of anodic and
cathodic sites
Contd.
4. Physical inhomogeneities, i.e., regions
of high residual stress in the metal. This
region tend to become anodic with respect
to those regions which are free from stress
5. Passivity of the metal, i.e., formation of
thin films of oxide
Factors depending on
environment
1. pH of the solution; pH = 7 and
alkali solution less corrosive;
pH<7, more corosive
2. Nature & concn. Of other ions, and
the degree of agitation - excessive
agitation is detrimental because of
abrasion and breakage of the
protective film
Contd.
3. Influence of oxygen in the solution a
constant supply of oxygen is necessary for
corrosion to continue
4. Increase in temperature increases
ionization and fluidity of the solution and
the rate of reaction
5. Presence of stress due to mechanical
working increases corrosion of the
stressed zones due to potential difference
on the metal surface
1. Atmospheric corrosion
Primarily due to the combined effects of film formation
Contd.
Electrolyte usually rain water and humid
atmosphere; dissolved gases such as CO2
or SO2 increases the acidity of the
atmospheric moisture
Rain supplies the moisture necessary for
electrochemcial attack; washes a large
part of the film from a metal surface; the
surface is exposed for the attack
Atmospheric corrosion is severe on ferrous
metals, while non-ferrous metals form dull
surfaces in the presence of natural
environment
2. Underground corrosion
Also
Contd.
In underground soil corrosion, galvanic
corrosion arising from contact between
different metals happens frequently
Ex : Cu pipe service line connected to a cast
iron main, galvanic cell is formed
Ground rod of bare Cu connected to a steel
piping, galvanic corrosion cell is formed
Concentration cells are responsible for much
of the corrosion taking place in the soil
Contd.
Pipelines pass through different
soils; when two different soils are in
contact with a single piece of metal,
concentration cell is formed
That portion of the pipe lying in more
concentrated soil is the anode and
that in less concentrated cell is the
cathode
Moisture acts as the electrolyte,
pipe itself furnishes the connecting
circuit
Contd.
Oxygen
Microbial corrosion
Contd.
The corrosion product is iron sulphide
instead of rust
Bacteria attack is fast and localized
Contd.
Occurs in devices for nuclear power
Here, corrosion (essentially a process of mass transfer) is not
dependent upon local cell local cell potentials for its driving force
Corrosion occurs by simple dissolution of the reactor components at
the high temperature
In the heat exchanger the liquid metal temperature drops solubility
of the metal in the coolant liquid metal is lowered and is deposited
on the surface
Thus hot zones are continuously thinned and the heat exchanger
tubes are clogged resulting in frequent shut down
Usually inhibitors are added in to the liquid metal to slow down such
a corrosion
5. Uniform corrosion
Uniform
6. Pitting corrosion
Serious type of localized corrosion through
Contd.
Corrosion products may form caps over pit
cavities
Shapes of the pits vary widely usually
these are saucer shaped, conical or
hemispherical
Only a small amount of metal is corroded
but perforations or holes that are
developed can lead to costly repair of
expensive equipment
Pitting causes more unexpected corrosion
loss than other types of corrosion
7. Crevice corrosion
Contd.
Crevice corrosion results as a result of
differential aeration cell
Occurs only at film protected metals
such as Al, Mg, stainless steel and
titanium
8. Intergranular corrosion
A form of localized surface attack in which
a narrow path is corroded out
preferentially along the grain boundaries
of a metal
Driving force is the difference in corrosion
potential that develops between a thin
grain boundary zone and the bulk of the
immediate adjacent grains
The constituent may be anodic, cathodic
or neutral to the base metal or adjacent
zone
Contd.
Example for anodic constituents are Mg5Al8,
MgZn2 in Al alloys and Fe4N in iron alloys
Examples for cathodic constituents are
FeAl3 and CuAl2 in Al alloys and Fe3C in iron
alloys
If the precipitate is anodic to the adjacent
zone, precipitate corrodes preferentially
and if the precipitate is cathodic, the
adjacent zone is corroded
Occurs most commonly in Al, Cu and 18/8
stainless steel (18% Cr, 8% Ni)
environment
One of the causes of failures of metal structure
Known as stress corrosion cracking
Stress may be residual or applied
It may be low enough and will cause no concern in
the absence of the environment
Stress corrosion cracking usually occurs under only
very mild corrosive conditions
No metal loss or general corrosion associated with it
Contd.
Cracks may be intergranular, trans granular or a
combination of both
Occurrence and rate of stress corrosion are
influenced by stress level, corrosive agent, time and
temperature of exposure, structure of the metal,
amount of plastic strain, behavior of protective films
etc.
Usually found in Al alloys, low carbon steels and
brass
Occurs on mild steel exposed to alkaline solution at
high temperature and stresses
11.Corrosion fatigue
Involves