Uniform Corrosion.
The corrosion rate will be dependent on the
If a metal is not immune to attack
and corrosion cannot be completely eliminated,
uniform corrosion is considered the form of
corrosion that can be tolerated in marine
structures and equipment. It is also relatively
easy to control uniform corrosion to acceptable
levels through judicious selection of materials,
the application of corrosion control measures,
and to allow for any corrosion which does occur.
Definition.
Uniform corrosion is the attack of a metal at
essentially the same at all exposed areas of its
surface. At no point is the penetration of the
metal by corrosion twice as great as the average
rate.
Mechanism.
Uniform corrosion occurs when there are local
anodic and cathodic sites on the surface of the
metal (see Galvanic Corrosion). Due to
polarization effects, these locations shift from
time to time and a given area on a metal will be
act as both an anode and as a cathode over any
extended period of time. The averaging effect of
these shifting local action cells results in a rather
uniform attack and general loss of material and
roughening of the surface.
Examples.
Rusting steel in the atmosphere and
the corrosion of copper alloys in seawater are
common examples where uniform corrosion is
usually encountered. Steel submerged in
seawater also suffer uniform corrosion but can
also suffer from non-uniform attack under some
circumstances
What can be considered as an acceptable rate of
attack will depend on the cost of the material;
the duty, particularly as regards to safety; and
the economic life of the plant.
For the more commonly used inexpensive
materials, such as the carbon and low alloy
steels.
For the more expensive alloys, such as the high
alloy steels, the brasses and aluminium.
temperature and concentration of the corrosive
fluid. An increase in temperature usually results
in an increased rate of corrosion; though not
always. The rate will depend on other factors
that are affected by temperature, such as oxygen
solubility.
The effect of concentration can also be complex.
For example, the corrosion of mild steel in
sulphuric acid, where the rate is unacceptably
high in dilute acid and at concentrations above
70 per cent, but is acceptable at intermediate
concentrations.
Galvanic Corrosion
If dissimilar metals are placed in contact, in an
electrolyte, the corrosion rate of the anodic
metal will be increased, as the metal lower in the
electrochemical series will readily act as a
cathode.
Table 7.4; active indicates the absence of the
protective film.
Galvanic corrosion tends to occur when
dissimilar conducting materials are connected
electrically and exposed to an electrolyte. The
following fundamental requirements therefore
have to be met for galvanic corrosion:
1. Dissimilar metals (or other conductors,
such a graphite).
2. Electrical contact between the dissimilar
conducting materials
(can be direct contact or a secondary
connection such as a common grounding
path).
3. Electrolyte (the corrosive medium) in
contact with the dissimilar conducting
materials.
If metals which are widely separated in the
galvanic series have to be used together,
they should be insulated from each other,
breaking the conducting circuit.
Alternatively, if sacrificial loss of the anodic
material can be accepted, the thickness of
this material can be increased to allow for
 the increased rate of corrosion. The
corrosion rate will depend on the relative
areas of the anodic and cathodic metals. A
high cathode to anode area should be
avoided. Sacrificial anodes are used to
protect underground steel pipes.
a 5-mm thick aluminum alloy plate is physically
(and hence, electrically) connected to a 10-mm
thick mild steel structural support.
Galvanic corrosion occurred on the aluminium
plate along the joint with the mild steel.
Perforation of aluminum plate occurred within 2
years due to the huge acceleration factor in
galvanic corrosion.
Pitting
Pitting is the term given to very localised
corrosion that forms pits in the metal surface.
If a material is liable to pitting penetration can
occur prematurely and corrosion rate data are
not a reliable guide to the equipment life.
Pitting can be caused by a variety of
circumstances; any situation that causes a
localised increase in corrosion rate may result in
the formation of a pit. In an aerated medium the
oxygen concentration will be lower at the
bottom of a pit, and the bottom will be anodic to
the surrounding metal, causing increased
corrosion and deepening of the pit. A good
surface finish will reduce this type of attack.
Pitting can also occur if the composition of the
metal is not uniform; for example, the presence
of slag inclusions in welds. The impingement of
bubbles can also cause pitting, the effect of
cavitation in pumps, which is an example of
erosion-corrosion.
Intergranular corrosion
Intergranular corrosion is the preferential
corrosion of material at the grain (crystal)
boundaries.
Though the loss of material will be small,
intergranular corrosion can cause the
catastrophic failure of equipment. Intergranular
corrosion is a common form of attack on alloys
but occurs rarely with pure metals. The attack is
usually caused by a differential couple being set
up between impurities existing at the grain
boundary. Impurities will tend to accumulate at
the grain boundaries after heat treatment. The
classic example of intergranular corrosion in
chemical plant is the weld decay of
unestablished stainless steel. This is caused by
the precipitation of chromium carbides at the
grain boundaries in a zone adjacent to the weld,
where the temperature has been between 500
800C during welding. Weld decay can be
avoided by annealing after welding, if practical;
or by using low carbon grades (<0.3 per cent C);
or grades stabilised by the addition of titanium
or niobium.