CORROSION CONTROL

It is impractical to eliminate corrosion but corrosion can be controlled and minimized by

several methods. The rate of corrosion can be controlled by either modifying the base
metal/alloy or the environment.
I.

Control of corrosion by modifying metal:

a) Modifying the composition of metal/alloy
b) Proper designing.
c) Modifying the surface.

II.

Control of corrosion by modifying the environment

a) Removal of harmful constituents
b) Use of inhibitors

CONTROL OF CORROSION BY MODIFYING THE BASE METAL

a) Modifying the composition of the metal:
1. Selecting pure metal to avoid impurities, which cause heterogeneity and
leads to electrochemical corrosion.

Impurities cause heterogeneity and leads to electrochemical

corrosion.

Corrosion resistance of pure metal depends on the nature of

environment.

Al in the pure form gives coherent, impervious, protective film. But

in alkaline medium, the oxide film is destroyed.

In many cases it is not practical to produce pure metal because of

high cost and inadequate mechanical properties like softness and
low strength.

2. By alloying with passive metals.

Alloy should be completely homogeneous.
Ex.: Stainless steel: steel alloy with a minimum of 10.5 or 11% chromium content by mass.
Cr enhances the corrosive resistance of stainless steel by forming stable CrO3 layer.
Because of the self healing effect of Cr, it enhances the corrosive resistance of
stainless steel.

3. keeping the metal surface clean with out dust deposits

b) Proper Designing:
1. Avoiding the contact of dissimilar metals.

Avoid the contact of dissimilar metals.

Choose high anode area than cathodic area. When the ratio of anodic to
cathodic area increases, the rate of corrosion decreases.

Choose the metals which are close in the emf series.

Insulate the fitting of different metals.

2. By providing proper design in fabrication of metallic tools:

3. Avoiding sharp corners, stressed parts and crevices to avoid stress corrosion.

4. Anodic metal should not be painted.

5. Storage tanks should be supported at the bottoms.

6) Cathodic Protection: The metallic structure can be protected by forcing it to behave

as cathode thereby corrosion does not occur.
a. Sacrificial anodic protection method: The metallic structure to be protected is
connected by a wire to a more anodic metal like Zn, so that all corrosion is concentrated
at this more active metal.

The more active metal itself corroded slowly while the metallic structure
is protected.

The more active metal is called sacrificial anode or galvanic anodes

and it is replaced by fresh one, when consumed completely.

Galvanic or sacrificial anodes are made in various shapes and sizes using
alloys of zinc, magnesium and aluminium. ASTM International
publishes standards on the composition and manufacturing of galvanic
anodes

Buried pipelines, underground cables, marine structures, ship-hulls,

water-tanks, piers, etc.

b. Impressed current cathodic protection:

An impressed current is applied to in opposite direction to nullify the

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

Impressed current is derived from DC source (battery) with an

insoluble anode (graphite).

A sufficient d.c current is applied to insoluble anode, buried in the soil

or immersed in the corroding medium and connected to the metallic
structures to be protected.

Anodes for ICCP systems are available in a variety of shapes and

sizes. Common anodes are tubular and solid rod shapes or continuous
ribbons of various materials. These include high silicon cast iron,
graphite, mixed metal oxide, platinum and niobium coated wire and
others.

The positive DC output terminal would be connected via cables to the

anode array, while another cable would connect the negative terminal
of the rectifier to the pipeline, preferably through junction boxes to
allow measurements to be taken.

It is useful for large structures for long-term operations. eg. Buried

water or oil pipes, water tanks.

CONTROL OF CORROSION BY MODIFYING THE SURFACE

Modifying the surface by application of protective coatings.
1. The coated surface isolates the underlying metal from the corroding
environment.
2. The coating applied must be chemically inert to the environment under
particular condition of temp. and press.
Protective coatings are
Metallic coatings, Non- metallic coatings and Organic coatings
A. By metal plating (Metallic Coatings):
a. Anodic metal Coatings:
i. Produced from coating-metal which are anodic to the base metal.
ii. If any break or discontinuities occur in such anodic coatings, a
galvanic cell is formed the coating-metal and the exposed part of
the metal.
iii. The coating metal (being anodic) is attacked leaving behind the
underlying base metal unattacked.
Eg. Galvanization (coating of Zn on iron or steel).
Galvanized steel.

b. Cathodic metal Coatings:

Obtained by coating of noble metal on the base metal.

They protect the base metal because they have higher resistance
than the base metal.

They provide effective protection t o the base metal only when

they are completely continuous and free from pores, breaks and
discontinuities.

If such coatings are punctured, much more corrosion damages can

be done to the base metal.

The exposed base metal acts as anode and intense localized attack
occurs at the small exposure.

Eg. Tin-coating on steel.

C. Electroplating

D. Electroless plating (without

electricity)

Electroless plating will give more smooth coatings than electroplating.

2. Non-metallic coatings:

Inorganic

surface

barriers

produced

by

chemical

or

electrochemical reactions, brought at the surface of the metal.

They are particularly used as an excellent base for organic

coatings.

3. Organic coatings: By painting:

Inert organic-barriers (like paints, varnishes, lacquers and enamels)

applied on metallic surfaces for both corrosion protection and
decoration.

II.CORROSION CONTROL BY MODIFYING THE ENVIRONMENT

a) By Removal of harmful constituents:
i) Deaeration:

In oxygen concentration corrosion, exclusion of oxygen from the aqueous

environment reduces metal corrosion.

Expulsion of dissolved oxygen is done by the adjustment of temperature,

together with mechanical agitation.

The method also reduces CO2-content of water, thereby decreasing the

corrosion rate of steel pipelines carrying steam condensates from the boiler.

Involves addition of chemicals, capable of combining rapidly with the oxygen

in aqueous solution.

Eg. Sodium sulphite ( Na2SO3)

2 Na2SO3+ O2------------- 2 Na2SO4

Hydrazine hydrate
N2H4+ O2--------------- N2+ 2H2O
Hydrazine hydrate is advantageous over the sodium sulphite because the reaction
products are N2 gas and water.
iii) Dehumidification;

Reduces the moisture content of air to such an extent that the amount of water
condensed on the metal is too small to cause corrosion.

Alumina gel or silica gel used in closed area like air-conditioning shop.

iv) Alkaline Neutralisation:

Prevention of corrosion by neutralizing the acidity of corrosive environment

(H2S, HCl, CO2, SO2, etc).

Alkaline neutralizers (NH3, NaOH etc) are injected either in vapour or liquid
form.

Used in controlling the corrosion of refinery equipments.

b) Use of Inhibitors:
A substance which when added in small quantities to the aqueous environment
effectively decreases the corrosion of metal.
i) Anodic Inhibitors:

They control the corrosion reaction occurring at the anode by forming a sparingly
soluble compound with the newly produced metal ion.

The compounds are adsorbed on the metal surface forming protective film or
barrier thereby reducing the corrosion rate.

Although this type of control is effective, it may be dangerous, since severe local
attack can occur, if certain areas are left unprotected by the depletion of the
inhibitor.

Eg. Chromates, phosphates, tungstates or other ions of transition elements with

high oxygen content.]

ii) Cathodic Inhibitors:

In acidic solution: Corrosion may be reduced either by slowing down the

diffusion of hydrated H+ ions to the cathode, and/or by increasing the
overvoltage of hydrogen evolution.

The diffusion of H+ ions is considerably decreased by organic inhibitors

like amines, hetrocyclic compounds and urea which are capable of being
adsorbed at the metal surface.

Antimony and arsenic oxides deposit adherent film of metallic arsenic or

antimony at the cathodic areas, (so the hydrogen evolution hindered)
thereby increasing considerably the hydrogen overvoltage.

In neutral solutions: Corrosion can be controlled by eliminating oxygen

from the corroding medium or by retarding its diffusion to the cathodic
areas.

Adding deaerating agent the oxygen can be eliminated.

The inhibitors like Zn, Ni salts react with hydroxyl ions at the cathode
forming corresponding insoluble hydroxide which act as impermeable
self-barriers.