TYPES OF CORROSION AND RATES

OF CORROSION
Prepared By:

SADAQAT ALI 13CH26

Chemical Engineering
(Mehran University of
Engineering And Technology,
Sind, Pakistan)

CORROSION

INTRODUCTION
Corrosion

is a process of formation of
the compound of pure metal by the
chemical reaction between metallic
surface and its environment.
It is an oxidation process. It causes
loss of metal.
Hence, disintegration of a metal by
its surrounding chemicals through a
chemical reaction on the surface of
the metal is called corrosion.
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 Corrosioncomes

in many different forms and

can be classified by the cause of the
chemical deterioration of a metal.

Example:

Formation of rust on the surface of

iron, formation of green film on the surface
of copper.

The

responsible factors for the corrosion of a

metal are the metal itself, the environmental
chemicals, temperature and the design.

TYEPS OF CORROSION
Listed

below are 10 common types of

corrosion:
I. General Attack Corrosion
II. Localized Corrosion
III. Galvanic corrosion
IV. Environmental Craking
V. Flow Assisted Corrosion
VI. Intergranular (Intercrystalline ) corrosion
VII. De-alloying
VIII.Fretting Corrosion
IX. High Temperature Corrosion
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1. General Attack Corrosion

Also

known

as
uniform
attack
corrosion,
general
attack corrosion is
the most common
type of corrosion and
is
caused
by
a
chemical
or
electrochemical
reaction that results
in the deterioration
of the entire exposed
surface of a metal.
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Ultimately, the metal deteriorates to

the point of failure.

General attack corrosion accounts for

the
greatest
amount
of
metal
destruction by corrosion, but is
considered as a safe form of corrosion,
due to the fact that it is predictable,
manageable and often preventable.

2. Localized Corrosion
Unlike

general attack corrosion,

localized corrosion specifically
targets one area of the metal
structure. Localized corrosion is
classified as one of three types:

a)
b)
c)

Pitting Corrosion
Crevice Corrosion
Filiform Corrosion

a) Pitting corrosion
Pitting

results when a
small hole, or cavity,
forms in the metal,
usually as a result of
de-passivationof
a
small area. This area
becomes
anodic,
while part of the
remaining
metal
becomes
cathodic,
producing a localized
galvanic reaction.
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The

deterioration of this small

area penetrates the metal and
can lead to failure.

This

form of corrosion is often

difficult to detect due to the fact
that it is usually relatively small
and may be covered and hidden
by corrosion-produced
compounds
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b) Crevice Corrosion
Similar

to pitting, crevice corrosion occurs

at a specific location. This type of corrosion
is often associated with a stagnant microenvironment, like those found under
gaskets and washers and clamps. Acidic
conditions, or a depletion of oxygen in a
crevice can lead to crevice corrosion.

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c) Filiform Corrosion
Occurring

under
painted or plated
surfaces when water
breaches the coating,
filiform corrosion
begins at small
defects in the coating
and spreads to cause
structural weakness

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3. Galvanic Corrosion
Galvanic

corrosion, or dissimiliar
metal corrosion, occurs when two
different metals are located together
in a corrosiveelectrolyte. A galvanic
couple forms between the two metals,
where one metal becomes theanode
and the other thecathode. The
anode, or sacrificial metal, corrodes
and deteriorates faster than it would
alone, while the cathode deteriorates
more slowly than it would otherwise.
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Three conditions must exist for

galvanic corrosion to occur:

Electrochemically

dissimilar metals

must be present
The

metals must be in electrical

contact
The

metals must be exposed to an

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4. Environmental Cracking
Environmental

cracking
is
a
corrosion process
that can result
from a
combination
of
environmental
conditions affecting the metal.
Chemical, temperature and stressrelated conditions can result in the
following types of environmental
corrosion:
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a)

Stress Corrosion Cracking (SCC)

b)

Corrosion fatigue

c)

Hydrogen-induced cracking

d)

Liquid metal embrittlement

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5. Flow-Assisted Corrosion
(FAC)
Flow-assisted

corrosion, or flowaccelerated corrosion, results when

a protective layer of oxide on a
metal surface is dissolved or
removed by wind or water,
exposing the underlying metal to
further corrode and deteriorate.

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6. Transgranular and
Intergranular Corrosion
Intergranular

corrosion is a
chemical
or
electrochemical attack on
the grain boundaries of a
metal. This often occurs
due to impurities in the
metal, which tend to be
present in higher contents
near
grain
boundaries.
These boundaries can be
more
vulnerable
to
corrosion than the bulk of
the metal.

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8. De-Alloying
De-alloying,

or selective leaching,
is the selective corrosion of a specific
element in an alloy. The most
common type of de-alloying is dezincification of unstabilized brass.
The result of corrosion in such cases
is a deteriorated and porouscopper.

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9. Fretting Corrosion:
Fretting

corrosion occurs as a result of

repeated wearing, weight and/or vibration on
an uneven, rough surface. Corrosion, resulting
in pits and grooves, occurs on the surface.
Fretting corrosion is often found in rotation
and impact machinery, bolted assemblies and
bearings, as well as to surfaces exposed to
vibration during transportation.

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Fuels

10. High-Temperature
Corrosion

used in gas turbines, diesel engines and

other machinery, which contain vanadium or
sulfates can, during combustion, form
compounds with a low melting point. These
compounds are very corrosive towards metal
alloys normally resistant to high temperatures
and corrosion, including stainlesssteel.
High temperature corrosion can also be caused
by high temperature oxidization, sulfidation and
carbonization.

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RATES OF
CORROSION
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The

rate ofcorrosionis the speed

at which a metal deteriorates in a
specific environment. The rate, or
speed, is dependent upon
environmental conditions as well as
the type, and condition, of the
metal.

In

order to calculate the rate of

corrosion, the following information
must be collected:
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a)

Weight loss (the decrease in

metal weight during the reference
time period)

b)

Density (density of the metal)

c)

Area (total initial surface area of

the metal piece)

d)

Time (the length of the reference

time period)
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Electrochemical

methods provide
an alternative to traditional
methods used to determine the
rate of corrosion. Direct and
quantitative determination of
corrosion rates can be
determined from simple
electrochemical measurement
like a
linear sweep voltammetry (LSV).
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The corrosion rate depends on

the kinetics of both anodic
(oxidation) and cathodic
(reduction) reactions. According
to Faraday's law, there is a
linear relationship between the
metal dissolution rate or
corrosion rate, RM, and the
corrosion current icorr

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where

M is the atomic weight of

the metal, is the density, n is the
charge number which indicates
the number of electrons
exchanged in the dissolution
reaction and F is the Faraday
constant, (96.485 C/mol). The
ratio M/n is also sometime
referred to as equivalent weight.
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Calculation

of corrosion rates
requires the determination of
corrosion currents. When reaction
mechanisms for the corrosion
reaction are known, the corrosion
currents can be calculated using
Tafel Slope Analysis.

The

NOVA
convenient
Tafel plots,
slopes and

software provides a
interface for making
calculating Tafel
corrosion rates
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Selecting the Corrosion Rate, Tafel

Slope analysis tool from the Analysis
menu, a Tafel plot is added as shown in
Figure.

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