CORROSION AND ITS PREVENTION

G. Chowdhury PROF.(MET)

INTRODUCTION:          Corrosion is an inevitable phenomenon. In fact our economy would be directly changed if there were no corrosion. The approximate estimate of loss of metal due to corrosion, 2 to 2.5 billion dollars per annum all- over the world. In India it is Rs600.00 cores. Though corrosion is inevitable, its cost can be considerably reduced. An inexpensive magnesium anode could double the life of a domestic hot water tank. Washing a car to remove road- salt is helpful. Proper selection of materials and good design reduces cost of corrosion. A good maintenance-painting programme pays for itself many times
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Corrosion Theory
Humans have most likely been trying to understand and control corrosion for as long as they have been using metal objects. With a few exceptions, metals are unstable in ordinary aqueous environments. Metals are usually extracted from ores through the application of a considerable amount of energy. Certain environments offer opportunities for these metals to combine chemically with elements to form compounds and return to their lower energy levels.

Corrosion Theory Contd

 Corrosion is the primary means by which metals deteriorate.  Most metals corrode on contact with water (and moisture in the air), acids, bases, salts, oils, aggressive metal polishes, and other solid and liquid chemicals.  Metals will also corrode when exposed to gaseous materials like acid vapors, formaldehyde gas, ammonia gas, and sulfur containing gases.
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Corrosion Theory Contd

 Corrosion specifically refers to any process involving the deterioration or degradation of metal components.  The best known case is that of the rusting of steel.  Corrosion processes are usually electrochemical in nature, having the essential features of a battery.  When metal atoms are exposed to an environment containing water molecules they can give up electrons, becoming themselves positively charged ions, provided an electrical circuit can be completed.  This effect can be concentrated locally to form a pit or, sometimes, a crack, or it can extend across a wide area to produce general wastage.  Localized corrosion that leads to pitting may provide sites for fatigue initiation and, additionally, corrosive agents like seawater may lead to greatly enhanced growth of the fatigue crack.  Pitting corrosion also occurs much faster in areas where microstructural changes have occurred due to welding operations. 5

Corrosion Theory Contd

 Corrosion is the disintegration of metal through an unintentional chemical or electrochemical action, starting at its surface.  All metals exhibit a tendency to be oxidized, some more easily than others.  A tabulation of the relative strength of this tendency is called the galvanic series.  Knowledge of a metal's location in the series is an important piece of information to have in making decisions about its potential usefulness for structural and other applications 6

The corrosion process (anodic reaction) of the metal dissolving as ions generates some electrons, as shown here, that are consumed by a secondary process (cathodic reaction). These two processes have to balance their charges.

The sites hosting these two processes can be located close to each other on the metal's surface, or far apart depending on the circumstances. This simple observation has a major impact in many aspects of corrosion prevention and control, for designing new corrosion monitoring techniques to avoiding the most insidious or localized forms of corrosion. (more advanced reading)    The electrons (e- in this figure) produced by the corrosion reaction will need to be consumed by a cathodic reaction in close proximity to the corrosion reaction itself. The electrons and the hydrogen ions react to first form atomic hydrogen, and then molecular hydrogen gas. If the acidity level is high (low pH), this molecular hydrogen will readily become a gas as it is demonstrated by exposing a strip of zinc to a sulfuric acid solution.
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Corrosion Theory Contd

 As hydrogen forms, it could inhibit further corrosion by forming a very thin gaseous film at the surface of the metal.  This "polarizing" film can be effective in reducing water to metal contact and thus in reducing corrosion.  Yet it is clear that anything which breaks down this barrier film tends to increase the rate of corrosion.  Dissolved oxygen in the water will react with the hydrogen, converting it to water, and destroying the film.
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1.5 MANIFESTATION (FORMS) OF CORROSION.

1.5.1 UNIFORM, OR GENERAL ATTACK 1.5.2 GALVANIC OR TWO- METAL CORROSION. 1.5.3 CONCENTRATION (CREVICE CORROSION). 1.5.4 PITTING CORROSION. 1.5.5 INTERGRANULAR CORROSION. 1.5.6 SELECTIVE LEACHING. 1 1.5.7 EROSION CORROSION. 1.1.5.8 STRESS CORROSION.
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CELL

CORROSION

Contd

1.6 CORROSION PREVENTION. 1.6.1MATERIAL SELECTION. 1.6.2PROTECTION BY DESIGN & FABRICATION PROCEDURE. 1.6.3 ALTERATION / MODIFYING CORROSIVE ENVIRONMENT. 1.6.4 CATHODIC PROTECTION. 1.6.5 APPLICATIONS COATINGS. 1.7 SUMMARY.
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OF

PROTECTIVE

CORROSION : DESTRUCTION OF MATERIALS THROUGH A CHEMICAL OR ELECTROCHEMICAL ATTACK BY ITS ENVIRONMENTS STARTING AT ITS SURFACE.

DESRTUCTION OF MATERIALS BY MEANS OTHER THAN STRAIGHT MECHANICAL.

EXTRUCTIVE METALLURGY IN REVSESE.

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CLASSIFICATION OF CORROSION:-

LOW TEMPERATURE & HIGH TEMPERATURE CORROSION

DIRECT CHEMICAL CORROSION OR DRY CORROSION. OXIDATION CORROSION. CORROSION BY OTHER GASES.

ELECTRO CHEMICAL CORROSION OR WET CORROSION

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OXIDATION CORROSION:-

2Mp2Mn++2neMetal ion

(loss of electron)

nO2+ 2ne- p 2nO2Oxide ion

(Gain of electron)

or

2M+ nO2 p 2Mn+ + 2nO2Metal ion Oxide ion |__________| Metal oxide

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MECHANISM OF OXIDATION OF METAL

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CORROSION BY OTHER GASES: SO2, CO2, CI2 H2S, F2 &OTHER GASSES ALSO CORRODE THE METALS.

IF PROTECTIVE FILM FORMED,THE INTENSITY OF ATTACK DECREASES (c.g.Agcl film)

IN CASE OF NON PROCTIVE OR POROUS FILM THE WHOLE SURFACE IS GRADUALLY DESTROYED (FORMATION OF VOLATILE SnCI4)

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NATURE OF THE OXIDE FORMED. STABLE OXIDE:-METALS LIKE Al,Sn,Cu FORMS STABLE FILMS & RESTRICTS FURTHER OXIDATION. UNSTABLE OXIDES:-Ag,Au& Pt DO NOT GO OXIDATION CORROSION AS OXIDE FORMS BUT DECOMPOSES INTO METALS & OXYGEN. VOLATILE OXIDE;-OXIDE LAYERS VOLATIZES AS SOON AS IT IS FORMEDEXPOSING SURFACE FOR FURTHER ATTACK.(Mo-OXIDE) POROUS OXIDE:-CRACKS AND PORES OF THE FILMS ALLOWS OXYGEN ACCES TO THE METAL SURFACE & CORROSION CONTINUES UNABATED.

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WET OR ELECTROCHEMICAL CORROSION. WHEN A CONDUCTING LIQUID IS IN CONTACT WITH METALS. WHEN TWO DISSIMILAR PARTIALLY IN A SOLUTION. METALS ARE IMMERSED

CONDITIONS FOR ELECTROCHEMICAL CORROSION

   

EXISTANCE OF SEPARATE CATHODIC & ANODIC AREAS. CURRENT FLOW BETWEEN CONDUCTING SOLUTION. THEM THROUGH

IN ANODIC AREA OXIDATION TAKES PLACE & METALS IS DESTROYED. METALS DESTROYED EITHER BY DISSOLVING OR ASSUMING COMBIND STATE. 17

REACTIONS:AT ANODE:Mp Mn+ + (Metal) (Metal ion) n e(oxidation)

M+p Dissolved in solution. (Metal ion) p Forms compound such as oxide AT CATHODE:- REDUCTION ELECTRON TAKES PLACE.) REACTION (GAIN OF

DISSOVE COSTITUENTS IN THECONDUCTING MEDIUM ACCEPTS THE ELECTRON TO FORM SOME IONS (OH-,O2-). THE METALIC & NONMETALIC IONS DIFUSES EACH OTHER & FORMS CORROSION PRODUCTS.
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MECHANISM OF WET OR ELECTRO CHEMICAL CORROSION

TWO TYPES OF REACTION:EVOLUTION OF HYDROGEN. (ACIDIC MEDIUM) FepFe2+ +2e(Oxidation) 2H++ 2e- p H2 o The overall reaction is: Fe +2H+ p Fe2+ +H2 o ABSORPION OF OXYGEN. RUSTING OF IRON IN ATMOSPHERIC OXYGEN IS A COMMON EXAMPLE OF SUCH TYPE OF CORROSION.

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MECHANISM OF WET CORROSION BY HYDROGEN EVOLUTION

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ELECRTOCHEMICAL REACTIONS OF ZINC IN AIR FREE HCI ACID.

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Electro-chemical reactions of Zn in aerated HCl acid 22

OXIDATION CORROSION:AT ANODIC AREAS METALS IONS DISSOLVES FERROUS IONS WITH LIBERATION OF ELECTRONS. Fep Fe2+ + 2e(Oxidation) AS

O2 + H2 O +2 e--p 2OH- (Reduction)

Fe+ +2OH-pFe (OH)2 IF ENOUGH OXYGEN IS PRESENT, FERROUS HYDROXIDE IS EASILY OXIDISED TO FERRIC HYDROXIDE. 4Fe(OH)2 + O2 +2H2Op 4Fe (OH)3 THIS PRODUCT, CALLED YELLOW RUST, CORRESPONDS TO Fe2O3.H2O). IF THE SUPPLY OF OXYGEN IS LIMITED, THE CORROSION PRODUCT MAY BE EVEN BLACK ANHYDROUS MAGNETITE, Fe3O4.. 23

MECHANISM OF WET CORROSION BY OXYGEN ABSORPTION.

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FOUR TYPE OF ELECTROCHEMICAL CELL

* GALVANIC CELL OR DISSIMILAR METAL CELL.

* CONCENTRATION CELL.

* DIFFERENTIAL STRESS CELL.

* DIFFERENTIAL TEMPERATURE CELL.

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Corrosion Cell
 

Definition

Nature can encourage corrosion in many fashions. The force behind the corrosion, attraction of metals towards the formation of stable oxides. Oxidized forms of metals can be divided into three types: 1.Composition Cell 2.Stress Cell 3.Concentration Cell
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1.Composition Cell
Composition cells (also known as Galvanic cells) arise when two metals with dissimilar compositions or microstructures come into contact in the presence of an electrolyte. The two most common examples : 1.1Dissimilar metals 1.2Multi-phase alloy

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1.1 Dissimilar metals:

 Formed by two single-phase metals in contact, such as iron and zinc, or nickel and gold.  The metal that is higher on the Electrochemical Series will be the cathode.  The other metal will suffer anodic reactions and will corrode.
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1.2 Multi-phase alloy:

 Formed by a metal alloy composed of multiple phases, such as a stainless steel, a cast iron, or an aluminum alloy.  The individual phases possess different electrode potentials, resulting in one phase acting as an anode and

subject to corrosion.

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2. Stress Cell
 Stress cells can exist in a single piece of metal where a portion of the metal's microstructure possesses more stored strain energy than the rest of the metal.  Metal atoms are at their lowest strain energy state when situated in a regular crystal array.

The three most common examples: 2.1 Grain boundaries 2.2 High localized stress 2.3 Cold worked

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2.1 Grain boundaries:

By definition, metal atoms situated along grain boundaries are not located in a regular crystal array (i.e. a grain). Their increased strain energy translates into an electrode potential that is anodic to the metal in the grains proper. Thus, corrosion can selectively occur along grain boundaries
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2.2 High localized stress:

 Regions within a metal subject to a high local stress will contain metal atoms at a higher strain energy state.  As a result, high-stress regions will be anodic to low-stress regions and can corrode selectively.  For example, bolts under load are subject to more corrosion than similar bolts that are unloaded.  A good rule of thumb is to select fasteners that are cathodic (i.e. higher on the Electrochemical Series) to the metal being fastened in order to prevent fastener corrosion.

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2.3 Cold worked:

 Regions within a metal subjected to cold-work contain a higher concentration of dislocations, and as a result will be anodic to non-cold-worked regions.  Thus, cold-worked sections of a metal will corrode faster.  For example, nails that are bent will often corrode at the bend, or at their head where they were worked by the hammer
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3. Concentration Cell
Concentration cells can arise when the concentration of one of the species participating in a corrosion reaction varies within the electrolyte. The two most common examples 3.1 Electrolyte concentration 3.2 Oxygen concentration

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3.1 Electrolyte concentration:

 Consider a metal bathed in an electrolyte containing its own ions.  The basic corrosion reaction where a metal atom losses an electron and enters the electrolyte as an ion can proceed both forward and backwards, and will eventually reach equilibrium.   If a region of the electrolyte (adjacent to the metal) were to exhibit a decreased concentration of metal ions, this region would become anodic to the other portions of the metal surface.  As a result, this portion of the metal would corrode faster in order to increase the local ion concentration.   The net affect is that local corrosion rates are modulated in order to homogenize reduction ion concentrations within the electrolyte.

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3.2 Oxygen concentration:

 Perhaps the most common concentration cell affecting engineered structures is that of dissolved oxygen.  When oxygen has access to a moist metal surface, corrosion is promoted.  However, it is promoted the most where the oxygen concentration is the least .  As a result, sections of a metal that are covered by dirt or scale will often corrode faster, since the flow of oxygen to these sections is restricted.  An increased corrosion rate will lead to increased residue, further restricting the oxygen flow to worsen the situation. Pitting often results from this "runaway" reaction.

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EMF SERIES POTENTIAL DIFFERENCE BETWEEN METALS EXPOSED TO SOLUTUION CONTAINING UNIT ACTIVITY ARE MEASURED AT CONSTANT TEMPERATURE. IT IS PRESENTED IN TABULAR FORM KNOWN AS EMF SERIES. ALL POTENTIALS ARE REFERRED AGAINST HYDROGEN ELECTRODE. POTENTIAL BETWEEN METALS ARE DETERMINED BY TAKING THE ABSOLUTE DIFFERENCES BETWEEN THEIR STANDARD EMF POTENTIALS.

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Table 10-1 Standard EMF Series for Metals Electrode potential vs. normal hydrogren electrode at 250C (volts) +1.498 +1.2 +0.987 +0.799 +0.788 +0.337 0.000 -0.126 -0.136 -0.250 -0.277 -0.403 -0.440 -0.744 -0.763 -1.662 -2.363 -2.714 -2.925

Metal-metal ion equilibrium

Noble or cathodic

Au-Au+3 Pt-Pt+2 Pd-Pd+2 Ag-Ag+1 Hg-Hg3+2 Cu-Cu+2 H2-H+ Pb-Pb+2 Sn-Sn+2 Ni-Ni+2 Co-Co+2 Cd-Cd +2 Fe-Fe+2 Cr-Cr+2 Zn-Zn+2 Al-Al+3 Mg-Mg+2 Na-Na+1

Active or anodic

K-K+1

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Source: A.J. deBethune and N.A.S. Loud, "Standard Aqueous Electrode Potentials and Temperature Coefficients at 250C", Clifford A. Hampel, Skokie, 1964

GALVANIC SERIES
MOST ENGINEERING MATRRIALS ARE METALS OR ALLOYS.

GALVANIC SERIES GIVESS MORE ACCURATE PREDICTION OF GALVANIC RELATIONSHIP THAN THE EMF SERIES.

THIS SERIES IS BASED ON POTENTIAL MEASUREMENTS & GALVANIC CORROSION TESTS IN UN POLUTED SEA WATER.

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GALVANIC SERIES
 The relative nobility of a material can be predicted by measuring its corrosion potential.  The well known galvanic series lists the relative nobility of certain materials in sea water.  A small anode/cathode area ratio is highly undesirable.  In this case, the galvanic current is concentrated onto a small anodic area.  Rapid thickness loss of the dissolving anode tends to occur under these conditions.  Galvanic corrosion problems should be solved by designing to avoid these problems in the first place.  Galvanic corrosion cells can be set up on the macroscopic level or on the microscopic level.  On the microstructural level, different phases or other microstructural features can be subject to galvanic currents40

GALVANIC SERIESContd
 Galvanic series relationships are useful as a guide for selecting metals to be joined, will help the selection of metals having minimal tendency to interact galvanically, or will indicate the need or degree of protection to be applied to lessen the expected potential interactions.  In general, the further apart the materials are in the galvanic series, the higher the risk of galvanic corrosion, which should be prevented by design.  Conversely, the farther one metal is from another, the greater the corrosion will be.  However, the series does not provide any information on the rate of galvanic corrosion and thus serves as a basic qualitative guide only.
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Table 10-2 Galvanic Series of Some Commercial Metals and Alloys in Seawater Noble or cathodic Platinum Gold Graphite Titanium Silver 18-8 stainless steel (passive) Nickel (passive) Silver solder Cupronickels (60-90Cu, 40-10Ni) Bronzes (Cu-Sn) Copper Brasses (Cu-Zn) Nickel (active) Tin Lead Lead-Tin solders 18-8 stainless stel (active) Steel or iron 2024 Aluminum (4.5Cu 1.5Mg 0.6Mn) Cadmium Commercially pure aluminum Zinc Active or anodic Magnesium and magnesium alloys

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MANIFESTATION OF CORROSION:THE BASIS FOR THIS CLASSIFICATION APPREANCE OF THE CORRODED METAL. *UNIFORM OR GENERAL ATTACK. *GALVANIC OR TWO-METAL CORROSION. *CONCENTRATION CELL CORROSION (CREVICE CORROSION) * PITTING CORROSION. * INTERGRANULAR CORROSION. * SELECTIVE LEACHING. * ERROSION CORROSION. * STRESS CORROSION
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BEING

THE

FORMS OF CORROSION:1) UNIFORM CORROSION: THE MOST COMMON FORM OF CORROSION CAUSED DUE TO CHEMICAL OR ELECRTROCHEMICAL REACTION & THE ENTIRE EXOPESED SURFACE BECOMES THINNER & EVNETUALLY FAILS. 2) GALVANIC CORROSION: WHEN TWO DISSIMILAR METALS ARE IMMERSED IN CORROSIVE SOLUTION POTENTIAL DIFFERENCE EXISTS BTWEEN THEM. THE LESS CORROSION RESISTANT METAL (ANODE) IS CORRODED. THE MORE CORROSION RESISTANT METAL (CATHOD) IS NOT CORRDED.
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3)CONCENTRTION CELL CORROSION (CREVIS CORROSION) INTENSE LOCALIZED CORROSION OCCURES WITHIN CRIVICS AND SHIELDED AREAS OF METAL SURFACES EXPOSED TO CORROSIVE MEDIUM. 4)INTERGRANULAR CORROSION LOCALISED ATTACK AT AND BOUNDERIES, WITH LITTLE GRAINS. 5)SELECTIVE LEACHING REMOVAL OF ONE ELEMENT FROM THE SOLID SOLUTION BY CORROSION PROCESS.
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ADJACENT TO GRAIN CORROSION OF THE

6)EROSION CORROSION RATE OF DETERIORATION OR ATTACK ON A METAL IS ACCELERATED BECAUSEOF RELATIVE MOVEMENT BETWEEN A CORROSIVE FLUID AND THE METAL SURFACE.

7)STRESS CORROSION BY SIMULTENEOUS PRESENCE OF TENSILE STRESS AND A SPECIFIC CORROSIVE MEDIUM CAUSES STRESS CORROSION CRACKING.

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8) PITTING CORROSION A LOCALISED ACCELERATED ATTACK RESULTING IN THE FORMATION OF CAVATIES AROUD WHICH THE METAL ISRELATIVELY UNATTACHED.

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GENERAL FACTS ABOUT CREVICE CORROSION:CORROSION IS ACCELERATED INACCESSIBLE AREAS. IN APPARENTLY

CORROSION IS ACCELERATED UNDER ACCUMULATION OF DIRT, SAND, OR OTHER CONTAMINANTS.

CONTACTS BETWEEN METALS & NON METALLIC SURFACES ( GASKETS, WOODS, PLASTICS, GLASS, ASBESTOS etc.)

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MECHANISM OF DIFFERENTIAL AERATION ATTACK CAUSED BY PARTIAL IMMERSION OF METAL.

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MECHANISM OF DIFFERENTIAL ATTACK CAUSED BY THE PRESENCE OF DROP OF SALT SOLUTION ON THE IRON SURFACE.

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ANODE IS FORMED AT INACCESSIBLE LOCATION,WHERE OXYGEN IS LESS AVAILABLE.

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FACTORS INFLUENCING CORROSION:NATURE OF METALS.( POSITION IN GALVANIC SERIES)

RELATIVE AREAS OF ANODIC & CATHODIC PARTS. PURITY OF METALS.

PHYSICAL STATE OF METALS.

SOLUBILITY OF CORROSION PRODUCTS.

VOLATILITY OF CORROSION PRODUCTS.

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NATURE OF THE CORRODING ENVIRONMENT.

 TEMPARATURE.

 HUMIDITY OF THE AIR.

 PRESENCE OF IMPURITES IN ATMOSPHERE.

 PRESENCE OF SUSPENDED PARTICLES IN

AIR.
 INFLUENCE OF PFORMATION OF PH.

FORMATION OF OXYGEN CONCENTRATION CELL.

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PREVENTION OF CORROSION:-

- MATERIAL SELECTION.

- DESIGN & FABRICATION PROCEDURE.

- ALTERATON OF ENVIRONMENT.

- CATHODIC PROTECTION. * SACRIFICIAL ANODE METHOD. * EXTERNAL POWER SUPPLY.

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-APPLICATION OF PROTECTIVE COATING:* ELECTRO PLATING. * FLAME SPRAYING. * CLADDING. * HOT DIPPING. * VAPOUR DEPOSITION. * DIFFUSION. *CHEMICAL CONVERSION.(ANDISING. PHOSPHATING, CHROMATIZING.) *ORGANIC COATING.(PAINTS, VARNISHES,ENAMELS, LACQUERS, etc.)

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Corrosion Performance of Metals

The following numbers refer to the corrosion rates, expressed in terms of depth of metal removed in unit time, for mild steel and various stainless steels in different acids. (reference) Penetration rates (mm/year) for various steels in different acids
Steel 70% HNO3 (60 oC) 20% HCl (20 oC) 80% H2SO4 (20 oC)

Mild Steel 13% Chromium

Very high 0.15

38 120

0.4 4.5

12% Chromium 12% Nickel

0.05

0.5

17% Chromium

0.1

35

0.7

18% Chromium 8% Nickel

Nil

25

1.5

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Corrosion Performance of Metals contd..

 Clearly any of the stainless steels would provide better life than mild steel in hot concentrated nitric acid, but in hydrochloric acid only the 12 per cent Chromium 12 per cent Nickel steel is significantly better than the mild steel, which in the sulfuric acid is better than any of the stainless steels, which in the sulfuric acid is better than any of the stainless steels, costing about an order of magnitude more per unit weight.  These differences are largely related to the differing oxidizing characteristics of the acids, the corrosion resistance of stainless steels mainly depending upon the formation of a protective chromium oxide film upon their surfaces, so that in the absence of an adequate supply of oxygen, as with the hydrochloric acids, the chromium addition is of little benefit.

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Essentially the same point can be seen in relation to the atmospheric corrosion of metals, that good corrosion resistance in a particular atmosphere is no guarantee of good resistance in other circumstances, as the following figures indicate Penetration rates (mm/year after 10 year exposure) of various metals exposed to different atmospheric conditions
Metal Atmosphere

Industrial Aluminum Copper Lead Zinc Mild Steel Cor-Ten Steel (0.4 Cu 1 Cr 0.1 P) 0.81 1.19 0.43 5.13 13.72 2.54

Marine 0.71 1.32 0.41 1.60 6.35 3.81

Rural 0.0025 0.58 0.48 0.86 5.08 1.27

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(Cor-Ten is a proprietary material developed by United States Steel Company, and is one of a series of low alloy steels known as weathering steels.)
 The weathering steel, Cor-Ten, owes its improved corrosion resistance over mild steel in industrial and rural atmospheres to the development of an adherent rust film due to the incorporation of low-concentrations of certain alloying elements, but the relative improvement in those atmospheres is not nearly so marked in a marine atmosphere.  When immersed in sea water Cor-Ten is not significantly better than mild steel and its use is not recommended in such conditions, although there are examples of it having been so used, no doubt because of its corrosion resistance in other situations and the assumption that this will be good irrespective of the environment
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 The same point an be made in relation to other forms of corrosion; thus molybdenum additions to ferritic steels are beneficial with respect to stress corrosion cracking resistance in carbonate environments, but are detrimental in hydroxide solutions, and so on.  The general point to be grasped is that in specifying the operating conditions for a component or structure it is vital that the environmental conditions be defined with as much precision as any other parameters, such as stress, temperature etc.  Only by so doing can the selection of a material from the corrosion resistance viewpoint be made satisfactorily.
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M A T E R I A L S E L E C T I O N.
-THE MOST COMMON METHOD OF CORROSION PREVENTION IS THE SELECTION OF PROPER METAL & ALLOYS FOR A PARTICULAR CORROSIVE SERVICE. -STAINLESS STEEL IS NOT STAINLESS,IT IS NOT MOST CORROSIONRESISTANT, & IT IS NOT A SPECIFIC ALLOY. - 30 DIFFERENT ALLOYS ( 11.5-30%Cr, 0-22% Ni). - STAILESS STEELS ARE LESS RESISTANT ALLOYS IN CHOLIRADECONTAINING MEDIUMS & STRESSED STRUCTURES THAN ORDINARY STRUCTURAL STEEL. -STAINLESS STEEL ARE MOST SUSCEPTIBLE TO LOCALISED CORROSION- INTERGRANULAR CORROSION, STRESS CORROSION CRACKING, & PITTING THAN ORDINARY STEELS. - A LARGE NUMBER OF CORROSION FAILURE CAN BE DIRECTLY ATTRIBUTED TO THE INDISCRIMIATE SELECTION OF STAINLESSSTEEL. -STAINLESS SEELS REPRESENTS A CLASS OF HIGHLY CORROSION RESISTANCE STEEL. 61

COMBINATIONS OF METAL & CORROSIVE REPRESENT THE MAXMIMUM AMOUNT OF CORROSION RESISTANCE FOR THE LEAST AMOUNT OF MONEY.
1. STAINLESS STEEL- NITRIC ACID. 2. NICKEL & ICKEL ALLOYS- CAUSTIC. 3. MONEL- HYDROFLUORIC ACID. 4. HASTELLOYS ( CHORIMETS)- HOT HYDROCHLORIC ACID. 5. LEAD-DILUTE SULFURIC ACID. 6. ALUMINUM-NONSTAINING ATOMSPHERIC EXPOSURE. 7. TIN-DISTILLED WATER. 8. TITANIUM-HOT STRONG OXIDIZING SOLUTIONS. 9. TANTALUM-ULTIMATE RESISTANCE. 10. STEEL-CONCENTRATED SULFURIC ACID.
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DESIGN & FABRICATION PROCESS:- WELD RATHER THAN RIVET TANKS & OTHER CONTAINERS. - BOTTOM OF TANK & CONTAINERS SHOULD BE SLOPPED TOWARDS DRAIN HOLES FOR EASY CLEANING. - EASY REPLACEMENT SYSTEMS OF CORROSION PRONE COMPONENTS. - AVOID EXCESSIVE MECHANICAL STRESSES IN COMPONENTS EXPOSED TO CORROSIVE MEDIUM. - AVOID ELECTRICAL CONTACT BETWEEN DISIMILAR MATERIALS TO PREVENT GALVANIC CORROSION.
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- AVOID SHARP BEND IN PIPING SYSTEM.

- AVOID HOT SPOT DURING HEAT TRANSFER SYSTEM.

- DESIGN TO EXCLUDE AIR.

-AVOID HETEROGENETY, DISIMILAR METALS, VAPOUR SPACES, UNEVEN HEAT, & STRESS DISTRIBUTION.

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CATHODIC PROTECTION OF AN UNDERGROUND TANK USING IMPRESED CURRENT.

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PROTECTION OF AN UNDERGROUND PIPELINE WITH A MAGNESIUM ANODE.

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CATHODIC PROTECTION OF A DOMESTIC HOT-WATER TANK USING A SACRIFICIAL ANODE.

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THANK U
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Corrosion Cell

OBJECTIVES.
y BECOME FAMILIAR WITH THE PHENOMENON OF CORROSION. y APPRECIATE DIFFERENT TYPES OF CORROSION. y KNOW THE MECHANISM OF CORROSION. y UNDERSTAND THE MANIFESTATION (FORMS) OF CORROSION. y KNOW DIFFERENT CORROSION. METHODS TO CONTROL

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STRUCTURE.
1.1 1.2 1.3 INTRODUCTION. DEFINATION OF CORROSION. CLASSIFICATION OF CORROSION.

1.3.1 DRY OR DIRECT CHEMICAL CORROSION 1.3.2 WET OR ELECTROCHEMICAL CORROSION. 1.3.2 (A) EVOLUTION OF HYDROGEN. (B) ABSORPTION OF OXYGEN 1.4 CELL TYPES OF CORROSION.
contd 71

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