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    02.corrosion Mechanisms

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    Muhammad Shahzad
    This document discusses various corrosion mechanisms including: - Chemical vs electrochemical reactions and how corrosion processes are electrochemical - Examples of corrosion cells like galvanic, concentration, and differential aeration cells - Different forms of corrosion such as uniform, pitting, selective, intergranular, and cracking - Factors that influence corrosion rate and how metals are classified based on their corrosion resistance - Diagrams illustrating examples like pitting, erosion-corrosion, and galvanic corrosion cells

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    02.corrosion Mechanisms

    Uploaded by

    Muhammad Shahzad
    29 views31 pages
    This document discusses various corrosion mechanisms including: - Chemical vs electrochemical reactions and how corrosion processes are electrochemical - Examples of corrosion cells like galvanic, concentration, and differential aeration cells - Different forms of corrosion such as uniform, pitting, selective, intergranular, and cracking - Factors that influence corrosion rate and how metals are classified based on their corrosion resistance - Diagrams illustrating examples like pitting, erosion-corrosion, and galvanic corrosion cells

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    02.Corrosion Mechanisms

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    This document discusses various corrosion mechanisms including: - Chemical vs electrochemical reactions and how corrosion processes are electrochemical - Examples of corrosion cells like galvanic, concentration, and differential aeration cells - Different forms of corrosion such as uniform, pitting, selective, intergranular, and cracking - Factors that influence corrosion rate and how metals are classified based on their corrosion resistance - Diagrams illustrating examples like pitting, erosion-corrosion, and galvanic corrosion cells

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
    29 views31 pages

    02.corrosion Mechanisms

    Uploaded by

    Muhammad Shahzad
    This document discusses various corrosion mechanisms including: - Chemical vs electrochemical reactions and how corrosion processes are electrochemical - Examples of corrosion cells like galvanic, concentration, and differential aeration cells - Different forms of corrosion such as uniform, pitting, selective, intergranular, and cracking - Factors that influence corrosion rate and how metals are classified based on their corrosion resistance - Diagrams illustrating examples like pitting, erosion-corrosion, and galvanic corrosion cells

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    Corrosion Mechanisms

    Lecture#02

    Chemical vs. Electrochemical Reactions

    Chemical reactions are those in which elements are added or removed from a chemical species Electrochemical reactions are chemical reactions in which not only may elements may be added or removed from a chemical species but at least one of the species undergoes a change in the number of valance electron Corrosion processes are electrochemical in nature

    Simplest Example: Dry Cell Battery

    Faradays Law

    The mass of an element discharged at an electrode is directly proportional to the amount of electrical charge passed through the electrode weight of metal reacting = kIt

    What Happens if the Battery is Not in Use?

    There will be some local action current generated by local action cells because of other metallic impurities in zinc

    Shelf life of an ordinary zinc-carbon rod battery is limited

    Local Action Cell

    Anode & Cathode

    Anode

    Loss of electron in oxidation Oxidation always occurs at the anode

    Cathode

    Gain of electron in reduction Reduction always occurs at the cathode

    Corrosion Cells

    Galvanic cell (Dissimilar electrode cell) dissimilar metals Salt concentration cell difference in composition of aqueous environment Differential aeration cell difference in oxygen concentration

    Differential temperature cell difference in temperature distribution over the body of the metallic material

    Dissimilar Electrode Cell

    When a cell is produced due to two dissimilar metals it is called dissimilar electrode cell

    Dry cell Local action cell A brass fitting connected to a steel pipe A bronze propeller in contact with the steel hull of a ship

    Zn anode
    HCl Solution

    Cu cathode

    Salt Concentration Cell

    Differential Aeration Cell

    Corrosion at the bottom of the electrical poles

    Differential Temperature Cell

    This is the type of cell when two identical electrodes are immersed in same electrolyte, but the electrodes are immersed into solution of two different temperatures This type of cell formation takes place in the heat exchanger equipment where temperature difference exists at the same metal component exposed to same environment For example for CuSO4 electrolyte & Cu electrode the electrode in contact with hot solution acts as cathode.

    Cells responsible for corrosion may be a combination of these three types

    Forms of Corrosion
    1. 2. General corrosion or uniform attack Pitting
    i. Impingement attack or erosion-corrosion ii. Fretting corrosion iii. Cavitation erosion

    3. 4. 5.
    i. ii.

    Selective Corrosion Intergranular Corrosion Cracking


    Corrosion fatigue Stress corrosion cracking (SCC)

    Uniform Corrosion

    Corrosion Rate and Classification of Metals

    mm/y millimeters penetration per year gmd grams per square meter per day ipy inches penetration per year mpy mils penetration per year (1000 mil = 1 inch) mdd milligrams per square decimeter per day

    Corrosion Rate and Classification of Metals

    Mils per year (mpy) = 534W/DAT mm/y =87.6W/DAT


    W = weight loss in mg D = density of specimen material in g/cm3 A = area in cm2 T= exposure time in hours

    Classification of metallic materials according to their rate of uniform attack


    A. <0.005 ipy (<0.15 mm/y) Metals in this category have good corrosion resistance and can be used for critical parts B. 0.005 to 0.05 ipy (0.15 mm/y to 1.5 mm/y) Metals in this group are satisfactory if a higher rate of corrosion can be tolerated C. >0.05 ipy (>1.5 mm/y) Usually not satisfactory

    Pitting

    Erosion-Corrosion

    Fretting Corrosion

    Cavitation Erosion

    Selective Corrosion

    Intergranular Corrosion

    Corrosion Fatigue

    SCC

    Galvanic Corrosion

    Crevice Corrosion

    Hydrogen Damage

    Failure Statistics in Germany (a) & USA (b)

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