What is Corrosion?

What does it look like?

How do you know when you have it?

What is Corrosion?
Metals made by smelting ( reduction of ore) Metals in air want to return to their oxidized state

Corrosion is a natural process!

Is Corrosion Important?
National issue? International issue?

What industries are affected?

Does it affect us personally?

Importance to USA
CC Technologies study March 2002 In 2000 about 3.1% of GDP spent on corrosion repair and control Total cost $276Billion! Of industries analyzed, the cost was $137.9 Billion

Examples of Corrosion Damage

Automotive problems - body rust Home examples-

- Plumbing fixtures - Mail box - Exterior fixtures and fasteners Concrete cracking

Corrosion Affects Our Safety!

Unexpected failures of equipment and devices Need to replace damaged items

Corrosion weakens structures

- Need to evaluate fitness for service when corrosion occurs

What Does Corrosion Look Like?

Rust and tarnish, red blue or gray scale 8 types of damage Fontana

Several others also.

Most Common Forms of Corrosion

General attack (uniform wastage) Pitting/ Crevice attack

Cracking (embrittlement)
Galvanic corrosion

Corrosion is Electrochemical
Two different reactions occur - oxidation and reduction

Electron transfer occurs

Potential (voltage) driving force required Oxidation occurs at anode

Reduction occurs at cathode

Corrosion Reactions
Oxidation - e.g.

Fe Fe++ + 2e Reduction e.g. O2 + 2H2O 4OH- - 4e Secondary - e.g. 4 Fe++ + O2 Fe2O3 + 8H+

Conclusions
Corrosion rate depends upon the corrosion products that form

Solubility of corrosion products determines the rate

If solubility is high, the rate is high! If solubility is low, the rate is low

Potential/pH (Pourbaix) Diagram

Very useful way to present data Developed by Marcel Pourbaix (1966)

Available for all metals and many other elements

Shows solubility and potential effects If solubility is < 10-6 M/l, no corrosion is assumed

Characteristics of Corrosion Products

Very thin and dense: protective,e.g., Cr, Al, Ti, 10 to 100 nm thick Thin: protective but some corrosion occurs, e.g.,Cu, Zn, Pb 1 to 10 m Thick and porous, e.g., Fe, >100 m Corrosion is a problem. Soluble, e.g., Na, K Not able to be used.

There are many ways to prevent or minimize corrosion damage

Alloying to Resist Corrosion - Steel

Add >13% Cr (stainless steel) Add >2% Mo to stainless (to resist pitting)

Add Si, P, Cu, Cr ( and others) to obtain weathering steel

Alloying to Resist Corrosion Copper

Add Ni and Fe (cupronickel) sea water Add As, Sb, or P to prevent dealloying of brass (Cu + 10 to 35% Zn) Add Al or Si to resist erosion

Metallic Coatings
Widely used to protect steel and to make other metals more attractive

Zn and Zn alloys on steel Galvanizing

Ni + Cr on steel, brass or zinc to give a bright finish Cu + Ni + Cr also used for bright finish

Organic Coatings - Paint

Barrier layer to keep water away Adhesion is key to success

Susceptible to thermal damage

Susceptible to UV damage

Electrochemical Protection
Cathodic protection reduce the potential and also corrosion rate - widely used underground and in sea water Anodic protection increase potential to produce a less soluble corrosion product used in some chemical plants

Corrosion Inhibitors
Used in water systems:

- Automotive cooling systems - Cooling towers - Boilers, especially high pressure steam Temporary preservatives for metals - Volatile corrosion inhibitors Paints and primers

Quiz Time!
What is the most corrosive substance we can think of? Corrosion damage only causes metals to become thinner True or False? How does corrosion affect me?

Answers!
Water!!! False! Corrosion also causes cracking, pitting, staining, wedging in crevices, loss of electrical conductivity, and failure of components What is your answer?

Break Time

Careers in Corrosion Technician - Education

High school diploma + interest in chemistry or technology

Associates degree possible night school - not required at entry level

- Chemistry - Electrical technology - Materials science

Careers in Corrosion Technician-Work

Lab technician

- Chemistry laboratory - Materials laboratory - Materials or chemical company Field technician civil engineering - Pipeline monitoring - Bridges, tunnels etc.

Careers in Corrosion Civil Engineer - Education

Civil, mechanical or electrical SB MBA or MS (not required but often helpful)

PE license
NACE Certification

Careers in Corrosion Civil Engineer - Work

Engineering firm or consultant

- Cathodic protection design - System monitoring and evaluation State or local government - Specify protection systems for bridges, tunnels, other facilities - Inspection and monitoring

Mat., Chem., Chem. Eng. Education

High School Diploma College SB, Major: Mat. Eng., Chem., Chem. Eng., or Mech.Eng. Grad school optional, MBA, MS or PhD Certification NACE (optional)

PE License (optional)

Mat.,Chem.,Chem. Eng. Work

Chemical, materials, petroleum, auto firm

- Engineering - Safety - Research (PhD) - Plant Maintenance Engineering or consultant firm

NACE International
Short courses, some with certification Annual meeting and show

Standards development
Local sections Symposia

Books, videos and computer products

NACE International The Corrosion Society

Address: P.O.Box218340, Houston,TX77218-8340 Phone: 281-228-6200

Website: www.nace.org

ASTM International
Standards development, Vol.03.02 Training courses

Symposia
Address:100 Barr Harbor Drive, PA 19428-2959

West Conshocken,

Website: www.astm.org Corrosion committee: G-1

Corrosion Testing
Used for a variety of purposes Standard test methods available

Some tests are simple and easy to run

ASTM corrosion tests are in Volume 03.02 of the Annual Book of ASTM Standards

Corrosion Testing-Purposes
Accelerated tests to demonstrate products durability Acceptance tests to show that a material meets standard Monitoring tests to show changes in a system corrosivity Research tests to determine mechanism of corrosion

Standard Tests
Usually corrosion tests have many parameters Corrosion tests often give results that are difficult to reproduce Standardization helps reproducibility Consensus standard tests: ASTM and NACE

Accelerated Test Example

ASTM G48 Pitting and Crevice Corrosion Resistance Ferric chloride, 6%solution

72Hrs at 22oC (room temperature)

Report pitting or crevice corrosion Simulates sea water attack of stainless steels

Acceptance Test - Al Alloys

ASTM G 69, Test of metallurgical condition of Al alloys

Measure potential,E, in salt solution

Cu increases E, Zn reduces E Heat treatment determines condition

Condition affects strength and corrosion tendencies

ASTM G 69 Continued
Solution: 1M Na Cl + 2.7%H2O2, 22oC Surface preparation: 00 steel wool rub

1 Hour immersion
Measure potential every 5 minutes after 30 minutes against SCE electrode

Average result: -750+/-10mV for pure Al Al foil is pure Al

Monitoring Test

ASTM C 876

Corrosion of steel rebar in concrete Potential indicates when corrosion of steel is occurring

Copper/copper sulfate reference cell

Chloride causes steel to corrode Deicing salt usually reason for problem

Sea water also causes problems

Procedure ASTM C876

Place electrode on concrete surface Measure potential with volt-meter

If potential varies with time prewet surface with 25ml/l detergent solution
Record potential at several points on the surface

Analyze Data
Arrange values in ascending order and number the values sequentially

Determine plotting position,f

f = r/(n +1) where r is the measurement number, and n is the total number of values Plot on probability paper

ASTM C876 Report

Potential > -0.20 V, rebar is not corroding Potential <-0.35V, rebar is corroding

Potential in between then the rebar may be corroding

Demonstration of Corrosion
A simple test to show local cathodes and anodes with a corroding specimen

Uses indicators to show where reactions occur

Phenolphthalein turns red at cathode generated there)

(OH ion

K3Fe(CN)6 turns blue at anode

Demonstration Test Materials

Agar agar Salt (NaCl)

5%K3Fe(CN)6 solution
1% Phenolphthalein solution (in alcohol) 2 steel nails, bright finish (e.g.: 10d)

1 steel nail, galvanized (e.g.:10d) Copper wires

Demonstration test Procedure

Prepare 250 ml of 3%salt (7.5g) and 2% agar agar solution Boil to dissolve agar agar Add 5ml K3Fe(CN)6 solution and 1ml of phenolphthalein solution Pour into 2 dishes, one with bright nail, one with bright nail wired to galvanized nail

Demonstration Test Procedure Continued

Allow the solutions to cool and watch colors develop Where do are the red areas? (cathodes)

Blue areas? (anodes)

What does it mean when no blue areas develop on the bright nail wired to the galvanized nail?

Follow-up NACE Foundation

NACE Foundation wants to help high schools with programs and information NACE local sections can provide technical people to run field trips or lead experimental demonstrations Contact Teri Elliott, phone 281-228-6210 Website: www.nace.foundation.org

Summary
Corrosion is an important issue Corrosion technology shows where chemistry can be used to prevent problems Corrosion tests can provide good hands-on experience for students Many opportunities for careers in corrosion prevention

Thank You!
Questions please?