1-1 UNIT 1

Corrosion and Corrosion Control

1-2 UNIT 1 OBJECTIVES
An Understanding of:
• Mechanism of metal corrosion
• Common types of corrosion
• Methods of corrosion control
1-3 MECHANISM OF MEDAL
CORROSION
• The corrosion process
• The corrosion cell
• Relative corrosion tendencies of medal
1-4 Corrosion
• Corrosion: The chemical or electrochemical
reaction between a material and it’s
environment that results in the loss of
the material and it’s properties
1-4A TYPICAL CORROSION
COST ITEMS
• Replacement of deteriorated items
• Maintenance of facilities
• Shut-down of facilities
• Product loss or environmental contamination
• Damage/injuries from accidents
1-5 FIGURE:
NATURAL CYCLE OF CORROSION
1-6 FOUR CONDITIONS NECESSARY
FOR CORROSION
• Anode
• Cathode
• Metallic Path
• Electrolyte
1-7 FIGURE: FOUR BASIC PARTS OF A
CORROSION CELL
1-8 Figure 1: CORROSION CELL
1-9 FIGURE: DRY CELL BATTERY
(CORROSION CELL ANALOGY)
1-9A FIGURE: THE CORROSION
CELL ON A METAL SURFACE
1-10 TABLE 1: GALVANIC SERIES
Active
Magnesi
um
Zinc
Galvaniz
ed Steel
Aluminiu
m
Mild
Steel
Wrought
Iron
Cast Iron
Chromiu
m Stainless Steel Type 410
(Active)
Stainless
Steel Type 304 (active)
Naval
Brass
Yellow
Brass
Nickel
(active)
Cooper
Silver
Solder
Chromiu
m Stainless Steel Type 410
 1-11 POTENTIAL DIFFERENCES ON A
SINGLE PIECE OF METAL
• Chemical differences (e.g., contaminants in the
metal)
• Physical difference (e.g., cuts, hammering, etc.)
 1-12 Common Corrosion Cell Chemistry
• Anode Loses Metal
• Cathode protected, become, becomes alkaline,
may produce hydrogen
• Oxygen cathode affects corrosion rate
 1-13 FIGURE: CORROSION REACTION
Anode: M
Cathode: 2H2O + 2e- 2OH- + H2
Water Electrons Hydroxide Hydrogen Gas
(alkalinity)

Or depending on localized conditions:

2H2O + O2 +4e- 4OH-
 1-14 COMMON TYPES OF CORROSION
• Uniform
• Dissimilar metal (galvanic)
• Concentration cell
• Stray current
• Dealloying
• Erosion-corrosion
• Exfoliation
 1-15 UNIFORM CORROSION
• Anodes and cathodes reverse
• Not usually
1-16 UNIFORM CORROSION
 1-16A Pitting Corrosion
• Localized Accelerated corrosion
• Caused by metal ion non-uniformity
• Caused by localized breakdown of passive
layer
1-16B DIVER USING A GAUGE TO
MEASURE PIT DEPTH
1-17 DISSIMILAR METAL CORROSION
1-18 CORROSION CAUSED BY
DISSIMILAR SURFACE CONDITION
1-19 STEEL PIPE IN ALUMINUM DECK
1-20 PIPE WITH VALVE OF A
DIFFERENT MATERIAL
1-21 AVOID DISSIMILAR METAL
CORROSION BY:
• Choosing compatible metals
• Using rubber or plastic insulators
• Avoiding electrolyte
1-22 FIGURE: THE EFFECTS OF RELATIVE ANODE
AND CATHODE AREAS ON CORROSION
1-23 ALUMINUM TRUSS (ANODE) AND
STAILESS STEEL BOLTS (CATHODE)
1-24 COMMON TYPES OF CONCENTRATION
CELL CORROSION
• Difference in oxygen concentration
• Difference in metal ion concentration
1-24A FIGURE: OXYGEN CONCENTRATION CELL
1-24B FIGURE: METAL ION
CONCENTRATION CELL
 1-12 Common Corrosion Cell Chemistry
• Skip weld
• Back-to-back angles
• Areas under bolt heads
1-25A SKIP WELD
1-26 CREVISE CORROSION
1-27 SOURCE OF STRAY CURRENT
CORROSION
• Electric railways
• Electric cranes
• Welding generators
• Adjacent CP system
1-27A FIGURE: EXAMPLE OF STRAY
CURRENT CORROSION
1-27B METHOD OF REDUCING STRAY
CURRENT CORROSION
• Reducing Current flow by modifying source
• Modifying electrical flow by bonding
• Applying counterbalancing CP
1-28 DEALLOYING
• Selective metal loss
• Dezincification of brass
• Graphitization of cast iron
1-29 DEZINCIFICATION OF BRASS
 1-30 EROSION-CORROSION
• Abrasive removes corrosion products
• Metal surfaces actively corrodes
1-30A ROLLING OF ALUMINUM PLATE
1-30B EXFOLIATION OF ALUMINUM
 1-31 METHOD OF CORROSION CONTROL
• Design
• Resistant metals
• Non-metallics
• Inhibitors
• Altering the environment
• Cathodic protection
• Coatings
1-32
• Avoid contact of dissimilar metals
• Incopatible environments
• Water traps
• Crevices
• Rough surfaces and sharp edges
• Limited access to work
1-33 DISSIMILAR METAL CORROSION -
STEEL NUT ON COOPER FITTING
1-34 ALUMINUM POLE IN CONCRETE
1-35 WATER TRAP
 1-36 AVOID WATER TRAPS BY:
• Inverting configuration
• Drilling weep holes
1-38 TWO WELDS, ONE GROUND AND
ONE UNGROUND
1-39 SPRAYING PAINT WHERE THERE IS
LIMITED ACCESS TO WORK
1-40 CORROSION-RESISTANT
METALS AND ALLOYS
• Titanium
• Aluminum alloys
• Stailess steels
• Zinc (galvaniszing)
• Weathering steel
1-41 WEATHERING (LOW-ALLOY)
STEEL (ADVANTAGES)
• Forms protective oxide
• Coating my not be necessary
• Reduced Corrosion rate
1-342 A588 BRIDGE IN GOOD CONDITION
 1-43 WEARING STEEL
(LIMITATIONS)
• Protective layer destroyed by chlorides
• needs open, dry exposure
• May not be aesthetically pleasing
1-44 CORRODED A588 BRIDGE
 1-45 HOT-DIP GALVANIZING OF STEEL
• Barrier coating of zinc
• Cathodic protection
• Painted for added protection
1-45A GALVANIZING BATH
1-45B GALVANIZING LAYERS
1-46 GALVANIZED GUARDRAIL
 1-46A WAYS OF COATING STEEL WITH ZINC
• Hot-dip galvanizing
• Electrogalvanizing
• Tumbling with powdered zinc
• Metallizing
• Zinc-rich coatings
1-47 CORROSION-RESISTANT NON-
METALLICS
• Plastic
• Elastomers
• Composites
• Ceramics
 1-47A THERMOPLASTICS
• Fluorocarbons
• Polythylenes
• Polypropylenes
• Polyvinyl chlorides
 1-47B THERMOSETS
• Epoxies
• Phenolics
• Polyesters
 1-47C ELASTOMERIC LININGS
• Natural and synthetic rubbers
• Polyurethanes
1-47D COMPOSITES
• FRP and FGRP materials
• Used in Piping, Process Vessels, tanks, etc.
 1-47E CERAMICS
• Chemical resistant
• Temperature resistant
• Electrical resistant
 1-48 INHIBITORS
• Thin, Protective films
• Passive layer on metal
• Remove aggressive constituents
1-49 CORROSION CONTROL BY ALTERING
ENVIRONMENT
• Dehumidification
• Purification
 1-50 CATHODIC PROTECTION
• External anode
• Entire structure becomes cathode
• Immersed or buried conductive media
(electrolyte)
 1-50A USES OF CATHODIC PROTECTION
• Ships
• Waterfront Structures
• Underground piping and tanks
• Water tanks interiors
1-52 SYNERGISM OF COATINGS AND CATHODIC
PROTECTION
• CP protects at holidays
• Coating reduce CP current requirements
1-53 TWO BASIC TYPES OF CATHODIC
PROTECTION
• Sacrificial Anode (Galvanic)
• Impressed current (external power source)
1-54 Figure: GALVANIC SYSTEM OF
CATHODIC PROTECTION
1-55 SECRIFICIAL ANODE METALS
• Magnesium
• Zinc
• Aluminum
1-56 FIGURE: IMPRESSED CURRENT SYSTEM
OF CATHODIC PROTECTION
1-56A FIGURE: A CATHODICALLY
PROTECTED WATER TANK
FIGURE 1-56 IMPRESSED CURRENT CP
SYSTEM FOR SHIP HULLS
1-57 IMPRESSED CURRENT ANODE
MATERIALS
• High-silicon cast iron
• Graphite
• Aluminum
• Scrap iron
• Pure, alloyed, or planted platinum
1-58 TABLE 3: SACRIFICIAL ANODE VS.
IMPRESSED CURRENT CATHODIC PROTECTION
Sacrificial Anode Impressed Current
No external power supply External power supply
Limited current output Variable voltage
Adjustable medium output Variable current
OK for low resistivity OK fo high resistivity medium
Requires electrolytes Requires electrolytes
Lower installation cost Higher installation cost
Few interference problems Can cause interference
Low maintenance cost Monthly power bills
Localized protection Protects larger structures
1-58A POSSIBLE ADVERSE EFFECTS OF
CATHODIC PROTECTION
• Deterioration of coatings not resistant to alkali
• Disbonding of coating by hydrogen gas from
excessive current
• Electroendosmosis
 1-59 CORROSION CONTROL BY COATING
• Barrier
• Inhibitors
• Cathodic protection
 1-59A ADVANTAGES OF COATINGS
• Ease of Application
• Ease of storage and handling
• Range of Acceptable ambient conditions
• Economics
• Easy repair
• Selection of color, gloss, and texture
 1-59B LIMITATIONS OF COATINGS
• Surface preparation requirements
• Application requirements
• Drying/curing requirements
• Health/safety/environmental concerns
 1-60A CORROSION CONTROL PROGRAMS
• A successful corrosion control program utilizes
as many corrosion control systems as
appropriate and practical.
 1-61 UNIT 1 Summary
• Mechanisms of metal corrosion
• Common types of corrosion
• Methods of corrosion control