CORROSION ASPECTS OF A

NUCLEAR POWER PLANT

CHEMICAL LAB

CORROSION
Definition The chemical or electrochemical reaction
between a material and its environment that
produces a deterioration of the material and
its properties
Unit It is expressed most commonly in the units
of mills per year(mpy)

CORROSION
Metal is in its meta stable state. Corrosion is
Anti-metallurgy. Here the metal going back to its original
form (i.e. ore form).

tal
lur
Me

Energy

gy

Metal

An
ti m
e ta
llu
rgy

Corrosion products
Ore

Time

Main types of corrosion are:

1. Uniform or general attack
2. Galvanic corrosion
3. Crevice corrosion
4. Pitting corrosion
5. Inter-granular corrosion
6. Selective leaching
7. Erosion corrosion
8. Stress corrosion cracking
9. Microbial induced corrosion

UNIFORM CORROSION
When the corrosion reaction proceeds
uniformly over the entire exposed surface,it
is termed as uniform or general corrosion
Ex. Rusting of iron
Implication- It is taken care in design stage
itself by proper material selection and
providing a corrosion allowance for the
designed service life of the material

Corrosion process occurring in metallic

surfaces
e

Zn+2
HCL+O2 solution

Zn+2
zinc

OXIDATION &
REDUCTION
REACTION OCCURS
ON THE SAME SURFACE
O2
OF THE METAL & IN
UNIFORM CORROSION
THESE ANODIC& CATHODIC
KEEP CHANGING WITH
RESPECT TO TIME.

Zn+2
2e
2e
2e

H+
H+
H+

H2O

GALVANIC CORROSION
When two metals/alloys are electrically
connected,one of the metal corrodes at a much
faster rate and other at a slower rate.Galvanic
series predicts the behavior of the materials.
Implication- GALVANIC CORROSION is used
for protection of materials also.
Ex- In CVC system the CS material is galvanized
with Zn.This is called Sacrificial Corrosion as Zn
will corrode in preference to steel.

Unprotected metal
. surface
Fe2+

Fe2+
e

Fe

Fe
Zn2+

Zn2+
Zn
e

Fe

Fe

Galvanic protection with Zn anode

Crevice corrosion
Identification:
Accelerated corrosion occurs if differential
aeration exists due crevice,metal joining or any
deposits
It occurs due to oxygen concentration cell
produced due to crevices
Prevention:
Avoid riveting, welding is preferred
Design for proper drainage
Remove the deposits
For SS high Mo content reduce the corrosion

Pitting corrosion
Identification:
Alloys in presence of certain ions (halides)
are prone to pitting
Local breakdown of passive film by
aggressive species in environment
( Halides) cause pitting
Pinholes grow in the direction of gravity

Pitting corrosion
Prevention:
Proper material selection
Eliminate ions responsible for pitting using
inhibitors
Ex- In IDCT system the CS system
primarily experiences pitting type of attack
in addition to general corrosion

Inter-granular corrosion
Identification:
Selective attack on grain boundaries with
negligible corrosion of the matrix
Attack of the alloy away from the weldment called
heat affected zone
Ex- Depletion of Cr in SS
Prevention:
Choose low carbon or extra low carbon SS
Controlling chromium and nickel content in SS

SELECTIVE LEACHING (DEZINCFICATON

Identification:
Selective removal of one element from a
solid alloy leaving and altered residual
structure
Change in density
X-ray diffraction reveals selective removal
of one element

SELECTIVE LEACHING (DEZINCFICATON)

Prevention:
Al addition reduces overall corrosion & to
extent dezincification
Ex- Selective removal of Zinc from brass
(Cu and Zn alloy)

Erosion corrosion
Identification:
Acceleration of the rate of attack on a metal
surface due to relative movement between a
corrosive fluid and the metal surface
Prevention:
Reduce the velocity of the medium
Choose hard materials
Controlling flow patterns

Stress corrosion cracking

Identification:
SCC occurs in a conjoint action of stress &
corrosiveenvironment
Alloy fails only when stress exceeds to a
threshold level
Ions promoting SCC of that particular alloy
must be present.(cl-,O2 for SS; ammonical
solution for Cu)

Stress corrosion cracking

Prevention:
Selection of the alloy
Control the ion promoting SCC
Reduction of residual stress

Microbiologically induced corrosion:

Micro bio fouling-settlement of sessile microbes
& their exo-polymeric secretions (EPS); formation
of heterogeneous surface deposits(bio-film)
a) It is an influential factor on corrosion
b) Charge transfer during respiratory,metabolic
activities of microbes
Macro bio-fouling:settlement & growth of sessile
macro organism possessive high adhesive
strength e.g. barnacles,mussels

Microbiologically induced corrosion:

a) Cause of increased fluid friction,decrease heat
transfer
b) Generate fine crevices & inflict crevice corrosion
damage on passive metal like Al,SS

Ex- In IDCT system, biocide is added to

counteract the biological growth and MIC