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    03-Corrosion Mechanisms

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    03-Corrosion Mechanisms

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    3 views31 pages

    03-Corrosion Mechanisms

    Uploaded by

    engr.adlakh

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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
    Faraday’s 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 Zn
    anode
    HCl Solution
    Cu cathode

     A brass fitting connected to a


    steel pipe
     A bronze propeller in contact
    with the steel hull of a ship
    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. General corrosion or uniform attack


    2. Pitting
    i. Impingement attack or erosion-corrosion
    ii. Fretting corrosion
    iii. Cavitation erosion
    3. Selective Corrosion
    4. Intergranular Corrosion
    5. Cracking
    i. Corrosion fatigue
    ii. 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/cm 3
     A = area in cm2
     T= exposure time in hours
    Classification of metallic
    materials according to their rate
    of uniform
    A. <0.005 attack
    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)

    a b

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