Types of Corrosion PDF

ChE430 (530)
Metallic corrosion
Forms of corrosion
Introduction
Significance and
cost of corrosion
Definitions and
underlying
mechanisms
Forms of corrosion
Corrosion rate
measurements
Electrochemical
thermodynamics
Electrochemical
kinetics
Corrosion rate
measurements
Various forms of
corrosion
Corrosion mitigation
image source:
Institute for
Energy Technology
Uniform corrosion
(continued)
Significance and
cost of corrosion
Definitions and
underlying
mechanisms
Forms of corrosion
Corrosion rate
measurements
Electrochemical
thermodynamics
Electrochemical
kinetics
Corrosion rate
measurements
Various forms of
corrosion
Uniform corrosion
Pitting
Crevice corrosion
Galvanic corrosion
Erosion corrosion
Cavitation
Fretting corrosion
Forms of corrosion
Introduction
Intergranular corrosion
Exfoliation
Dealloying (selective leaching)
Environmental cracking Stress
Corrosion Cracking (SCC)
Corrosion fatigue
Hydrogen embrittlement
Introduction
Significance and
cost of corrosion
Definitions and
underlying
mechanisms
Forms of corrosion
Corrosion rate
measurements
Electrochemical
thermodynamics
Electrochemical
kinetics
Corrosion rate
measurements
Various forms of
corrosion
Uniform corrosion is characterized by

corrosive attack proceeding evenly over
the entire surface area, or a large
fraction of the total area. On the basis of
tonnage wasted, this is the most
important form of corrosion.
image source: Corrosion Doctors , www.corrosion-doctors.org
Pitting
Introduction
Significance and
cost of corrosion
Definitions and
underlying
mechanisms
Forms of corrosion
Corrosion rate
measurements
Electrochemical
thermodynamics
Electrochemical
kinetics
Corrosion rate
measurements
Various forms of
corrosion
A pit
Pitting corrosion is a localized form of

corrosion by which cavities or "holes" are
produced in the material. Pitting is
considered to be more dangerous than
uniform corrosion damage because it is
more difficult to detect, predict and
design against.
Introduction
Significance and
cost of corrosion
Definitions and
underlying
mechanisms
Forms of corrosion
Corrosion rate
measurements
Electrochemical
thermodynamics
Electrochemical
kinetics
Corrosion rate
measurements
Various forms of
corrosion
Significance and
cost of corrosion
Definitions and
underlying
mechanisms
Forms of corrosion
Corrosion rate
measurements
Electrochemical
thermodynamics
Electrochemical
kinetics
Corrosion rate
measurements
Various forms of
corrosion
deep pit
(anode)
An aluminum
A92519 specimen
exposed to a 3,5%
NaCl solution for
seven days. The
width of the
picture is
approximately 1
mm.
intact
(cathode)
Causes of pitting
Introduction
general attack
(small pits)
Passive metals pit
Localized chemical or mechanical

damage to the protective oxide film.
Low dissolved oxygen concentrations
and high concentrations of chloride (as
in seawater)
Localized damage to, or poor
application of, a protective coating
The presence of non-uniformities in
the metal structure of the component,
e.g. inclusions.
Introduction
Significance and
cost of corrosion
Definitions and
underlying
mechanisms
Forms of corrosion
Corrosion rate
measurements
Pitting corrosion on a stainless steel bar

exposed to an alkaline solution loaded
with chlorides.
Electrochemical
thermodynamics
Electrochemical
kinetics
Corrosion rate
measurements
Various forms of
corrosion
image source: Prof. Dr. H. Bhni, www.ibwk.baum.ethz.ch
Morphology of pitting
Morphology of pitting
Introduction
(continued)
Significance and
cost of corrosion
Definitions and
underlying
mechanisms
Forms of corrosion
Corrosion rate
measurements
elliptical pits
Electrochemical
thermodynamics
Electrochemical
kinetics
Corrosion rate
measurements
Various forms of
corrosion
subsurface
pits
Introduction
narrow/deep
pits
Significance and
cost of corrosion
Definitions and
underlying
mechanisms
Forms of corrosion
Corrosion rate
measurements
undercutting
pits
Electrochemical
thermodynamics
Electrochemical
kinetics
Corrosion rate
measurements
Various forms of
corrosion
shallow pits
vertical grain
attack
horizontal
grain attack
mesa attack
A pitting-related accident
Introduction
Significance and
cost of corrosion
Definitions and
underlying
mechanisms
Forms of corrosion
Corrosion rate
measurements
Crevice corrosion
The sewer explosion that killed 215

people in Guadalajara, Mexico, in 1992.
Besides the fatalities, the series of blasts
damaged 1,600 buildings and injured
1,500 people. Damage costs were
estimated at 75 million U.S. dollars.
Introduction
Significance and
cost of corrosion
Definitions and
underlying
mechanisms
Forms of corrosion
Corrosion rate
measurements
Electrochemical
thermodynamics
Electrochemical
kinetics
Corrosion rate
measurements
Various forms of
corrosion
Electrochemical
thermodynamics
Electrochemical
kinetics
Corrosion rate
measurements
Various forms of
corrosion
10
11
Crevice corrosion is a localized form of

corrosion usually associated with
stagnant solutions in shielded areas such
as those formed under gaskets, washers,
insulation material, fastener heads,
surface deposits, disbonded coatings,
threads, lap joints, clamps, etc.
image source: Corrosion Doctors, www.corrosion-doctors.org
12
Another example of crevice

corrosion
Example of crevice corrosion

Introduction
Significance and
cost of corrosion
Definitions and
underlying
mechanisms
Forms of corrosion
Corrosion rate
measurements
Introduction
Crevices corrosion of a S30400 stainless

steel washer after 30 days in 0.5 FeCl3 +
0.05 M NaCl solution
Significance and
cost of corrosion
Definitions and
underlying
mechanisms
Forms of corrosion
Corrosion rate
measurements
Electrochemical
thermodynamics
Electrochemical
kinetics
Corrosion rate
measurements
Various forms of
corrosion
Electrochemical
thermodynamics
Electrochemical
kinetics
Corrosion rate
measurements
Various forms of
corrosion
Stainless steel bolt used in seawater after 5 years

of exposure.
image source: George Dinwiddie,
www.alberg30.org
13
14
Analysis of a crevice-corrosion
related problem (popped rivets)
Initiation of crevice corrosion

Introduction
Significance and
cost of corrosion
Definitions and
underlying
mechanisms
Forms of corrosion
Corrosion rate
measurements
Electrochemical
thermodynamics
Electrochemical
kinetics
Corrosion rate
measurements
Various forms of
corrosion
Crevice corrosion is initiated by changes

in local chemistry within the crevice:
Introduction
Significance and
cost of corrosion
Definitions and
underlying
mechanisms
Forms of corrosion
Corrosion rate
measurements
Depletion of inhibitor in the crevice

Depletion of oxygen in the crevice
A shift to acid conditions in the crevice
Build-up of aggressive ion species (e.g.
chloride) in the crevice
Popped rivets found
on an external
section of a
maritime patrol
aircraft fuselage.
image source: Corrosion Doctors
www.corrosion-doctors.org
15
Electrochemical
thermodynamics
Electrochemical
kinetics
Corrosion rate
measurements
Various forms of
corrosion
Subsequent inspection revealed corrosion in

the bonded area of the skin plates.
The cause was believed to be water ingress
from a global positioning system (GPS) antenna.
It was believed that water penetrated through
cracks in the seal surrounding the GPS antenna.
Once the water was in, crevice corrosion began
and it ultimately led to the loss of the bond
between the two portions of the structure.
The loss of this bond allowed more water to
seep in the structure and generalized the
corrosion problem.
16
related problem (continued)
related problem (continued)
Introduction
Introduction
Significance and
cost of corrosion
Definitions and
underlying
mechanisms
Forms of corrosion
Corrosion rate
measurements
Electrochemical
thermodynamics
Electrochemical
kinetics
Corrosion rate
measurements
Various forms of
corrosion
Significance and
cost of corrosion
Definitions and
underlying
mechanisms
Forms of corrosion
Corrosion rate
measurements
Electrochemical
thermodynamics
Electrochemical
kinetics
Corrosion rate
measurements
Various forms of
corrosion
Underside of panel where severe

corrosion was found
Close-up picture showing the severity

of corrosion
17
18
Advanced crevice corrosion

pillowing
Stage 0 of crevice corrosion
Introduction
Introduction
Significance and
cost of corrosion
Definitions and
underlying
mechanisms
Forms of corrosion
Corrosion rate
measurements
Electrochemical
thermodynamics
Electrochemical
kinetics
Corrosion rate
measurements
Various forms of
corrosion
Significance and
cost of corrosion
Definitions and
underlying
mechanisms
Forms of corrosion
Corrosion rate
measurements
Electrochemical
thermodynamics
Electrochemical
kinetics
Corrosion rate
measurements
Various forms of
corrosion
Notice how the rivet heads appear to be

lower than the surrounding skin surface.
Consider the case of a

passive metal corroding
Assume that the main
cathodic species is
dissolved oxygen
Crevice shown is not
drawn to scale (it is much
narrower and longer in
reality)
Initially, the dissolved oxygen content in the crevice is

equal to the one outside. The corrosion rate is uniform.
image source: Mike Dahlager, www.corrosion-control.com

19
20

Introduction
Significance and
cost of corrosion
Definitions and
underlying
mechanisms
Forms of corrosion
Corrosion rate
measurements
Electrochemical
thermodynamics
Electrochemical
kinetics
Corrosion rate
measurements
Various forms of
corrosion
Due to the difficult

access caused by the
crevice geometry, oxygen
is rapidly depleted in the
crevice by uniform
corrosion.
The corrosion reactions
now separate, i.e.
metal dissolves more in
the crevice (anode) and
oxygen is reduced more
on the outside metal
surface (cathode).
The large cathodic surface (Sc) vs. anodic surface (Sa)
ratio (Sc/Sa) leads to an acceleration of the anodic
(corrosion) reaction in the crevice.
Introduction
Significance and
cost of corrosion
Definitions and
underlying
mechanisms
Forms of corrosion
Corrosion rate
measurements
Electrochemical
thermodynamics
Electrochemical
kinetics
Corrosion rate
measurements
Various forms of
corrosion
Significance and
cost of corrosion
Definitions and
underlying
mechanisms
Forms of corrosion
Corrosion rate
measurements
Electrochemical
thermodynamics
Electrochemical
kinetics
Corrosion rate
measurements
Various forms of
corrosion
22
Example of galvanic
corrosion
The driving force for corrosion is a

potential difference between the
different materials. In a bimetallic
couple, the less noble material will
become the anode of this corrosion cell
and tend to corrode more compared with
the uncoupled condition. The more noble
material will act as the cathode in the
corrosion cell and corrode less.
The acidification of the local environment produces a

serious increase in the corrosion rate of most metals.
The corrosion products seal even further the crevice
environment and the problem gets worse.
21
Galvanic corrosion
Introduction
The metal ions produced

by the anodic corrosion
reaction form corrosion
products (hydrolyze)
giving off protons (acid)
and.
The pH in a crevice can
reach very acidic values,
sometimes equivalent to
pure acids.
Introduction
Significance and
cost of corrosion
Definitions and
underlying
mechanisms
Forms of corrosion
Corrosion rate
measurements
Stainless screw in contact with a

cadmium plated steel washer
Electrochemical
thermodynamics
Electrochemical
kinetics
Corrosion rate
measurements
Various forms of
corrosion
23
image source: Mike Dahlager, http://www.corrosion-doctors.org/Aircraft/dahlager.htm
24
Nobility and galvanic

corrosion
Introduction
Significance and
cost of corrosion
Definitions and
underlying
mechanisms
Forms of corrosion
Corrosion rate
measurements
Electrochemical
thermodynamics
Electrochemical
kinetics
Corrosion rate
measurements
Various forms of
corrosion
Galvanic series in seawater

Introduction
The relative nobility of a material can

be predicted by measuring its corrosion
potential.
The well known galvanic series lists the
relative nobility of certain materials in a
given environment (e.g. seawater).
A small anode/cathode area ratio is
highly undesirable. In this case, the
galvanic current is concentrated onto a
small anodic area leading to a very high
corrosion rate.
Significance and
cost of corrosion
Definitions and
underlying
mechanisms
Forms of corrosion
Corrosion rate
measurements
Electrochemical
thermodynamics
Electrochemical
kinetics
Corrosion rate
measurements
Various forms of
corrosion
Platinum
Gold
Graphite
Titanium
Silver
Chlorimet 3
Hastelloy C
18-8 Mo stainless steel (passive)
18-8 stainless steel (passive)
Chromium steel >11 % Cr (passive)
Inconel (passive)
Nickel (passive)
25
(continued)
(continued)
Introduction
Significance and
cost of corrosion
Definitions and
underlying
mechanisms
Forms of corrosion
Corrosion rate
measurements
Electrochemical
thermodynamics
Electrochemical
kinetics
Corrosion rate
measurements
Various forms of
corrosion
26
Introduction
Significance and
cost of corrosion
Definitions and
underlying
mechanisms
Forms of corrosion
Corrosion rate
measurements
Silver solder
Monel
Bronzes
Copper
Brasses
Chlorimet 2
Hastelloy B
Inconel (active)
Nickel (active)
Tin
Lead
Electrochemical
thermodynamics
Electrochemical
kinetics
Corrosion rate
measurements
Various forms of
corrosion
27
Lead-tin solders
18-8 Mo stainless steel (active)
18-8 stainless steel (active)
Ni-resist
Chromium steel >11 % Cr (active)
Cast iron
Steel or iron
2024 aluminum
Cadmium
Commercially pure aluminium
Zinc
Magnesium and its alloys
28
Example of erosion
corrosion
Erosion corrosion
Introduction
Significance and
cost of corrosion
Definitions and
underlying
mechanisms
Forms of corrosion
Corrosion rate
measurements
Electrochemical
thermodynamics
Electrochemical
kinetics
Corrosion rate
measurements
Various forms of
corrosion
Erosion corrosion is an acceleration

in the rate of corrosion attack in
metal due to the relative motion of
a corrosive fluid and a metal
surface.
Introduction
Significance and
cost of corrosion
Definitions and
underlying
mechanisms
Forms of corrosion
Corrosion rate
measurements
Electrochemical
thermodynamics
Electrochemical
kinetics
Corrosion rate
measurements
Various forms of
corrosion
Aggravating
factors:
high flow velocity
flow disturbances
presence of solids
multiphase flow
29
Example of erosion
corrosion
30
Cavitation
Introduction
Significance and
cost of corrosion
Definitions and
underlying
mechanisms
Forms of corrosion
Corrosion rate
measurements
pump rotor destroyed by erosion

corrosion
Introduction
Inside of the stainless steel pump

column spools pumping seawater serving
in the Arabian gulf.
Significance and
cost of corrosion
Definitions and
underlying
mechanisms
Forms of corrosion
Corrosion rate
measurements
Electrochemical
thermodynamics
Electrochemical
kinetics
Corrosion rate
measurements
Various forms of
corrosion
Cavitation occurs when a fluid's

operational pressure drops below
the vapor pressure causing bubbles
to form and then increases causing
them to violently collapse.
Electrochemical
thermodynamics
Electrochemical
kinetics
Corrosion rate
measurements
Various forms of
corrosion
image source: Bud Ross and Paul Dillon, http://www.nidi.org/
31
32
Cavitation usually
happens
Introduction
Significance and
cost of corrosion
Definitions and
underlying
mechanisms
Forms of corrosion
Corrosion rate
measurements
Electrochemical
thermodynamics
Electrochemical
kinetics
Corrosion rate
measurements
Various forms of
corrosion
Fretting
Introduction
at the suction side of a pump, especially

if operating near the net positive suction
head
at the discharge of a valve or regulator,
especially when operating in a nearclosed position
at flow expansions
in other processes incurring sudden
pressure drops and increases
Significance and
cost of corrosion
Definitions and
underlying
mechanisms
Forms of corrosion
Corrosion rate
measurements
Electrochemical
thermodynamics
Electrochemical
kinetics
Corrosion rate
measurements
Various forms of
corrosion
33
Significance and
cost of corrosion
Definitions and
underlying
mechanisms
Forms of corrosion
Corrosion rate
measurements
Intergranular corrosion is localized

attack along the grain boundaries, or
immediately adjacent to grain
boundaries, while the bulk of the grains
remain largely unaffected.
Introduction
Significance and
cost of corrosion
Definitions and
underlying
mechanisms
Forms of corrosion
Corrosion rate
measurements
Electrochemical
thermodynamics
Electrochemical
kinetics
Corrosion rate
measurements
Various forms of
corrosion
Electrochemical
thermodynamics
Electrochemical
kinetics
Corrosion rate
measurements
Various forms of
corrosion
34
Causes of intergranular
corrosion
Intergranular corrosion
Introduction
Fretting corrosion is damage at

contact surfaces rubbing against
each other (under load and in
repeated relative surface motion, as
induced for example by vibration).
35
This form of corrosion is usually

associated with chemical segregation
effects (impurities have a tendency to
be enriched at grain boundaries) or
specific phases precipitated on the
grain boundaries.
Such precipitation can produce zones
of reduced corrosion resistance in the
immediate vicinity.
36
Example of intergranular
corrosion
Introduction
Significance and
cost of corrosion
Definitions and
underlying
mechanisms
Forms of corrosion
Corrosion rate
measurements
Electrochemical
thermodynamics
Electrochemical
kinetics
Corrosion rate
measurements
Various forms of
corrosion
Exfoliation
Sensitization of stainless steels:

Chromium-rich grain boundary
precipitates lead to a local depletion
of Cr immediately adjacent to these
precipitates, leaving these areas
vulnerable to corrosive attack in
certain electrolytes.
Reheating a welded component
during multi-pass welding is a
common cause of this problem.
Introduction
Significance and
cost of corrosion
Definitions and
underlying
mechanisms
Forms of corrosion
Corrosion rate
measurements
Electrochemical
thermodynamics
Electrochemical
kinetics
Corrosion rate
measurements
Various forms of
corrosion
Anisotropic grain structure

Significance and
cost of corrosion
Definitions and
underlying
mechanisms
Forms of corrosion
Corrosion rate
measurements
failed aircraft component

made of 7075-T6 aluminum
(picture width = 400 m)
37
Introduction
Exfoliation is a form of intergranular

corrosion associated with high strength
aluminum alloys that have been extruded
or otherwise worked heavily, with a
microstructure of elongated, flattened
grains.
38
Example of exfoliation
in wrought aluminum alloys
Introduction
Significance and
cost of corrosion
Definitions and
underlying
mechanisms
Forms of corrosion
Corrosion rate
measurements
Electrochemical
thermodynamics
Electrochemical
kinetics
Corrosion rate
measurements
Various forms of
corrosion
exfoliation of an aircraft component
Electrochemical
thermodynamics
Electrochemical
kinetics
Corrosion rate
measurements
Various forms of
corrosion
39
image source: Mike Dahlager, http://www.corrosion-doctors.org/Aircraft/dahlager.htm
40
10
Dealloying
(selective leaching)
Introduction
Significance and
cost of corrosion
Definitions and
underlying
mechanisms
Forms of corrosion
Corrosion rate
measurements
Electrochemical
thermodynamics
Electrochemical
kinetics
Corrosion rate
measurements
Various forms of
corrosion
Environmental cracking
Introduction
Dealloying or selective leaching is a

selective removal of one or more
elements from an alloy by the corrosion
processes.
Significance and
cost of corrosion
Definitions and
underlying
mechanisms
Forms of corrosion
Corrosion rate
measurements
Examples:
dezincification of unstabilized brass
graphitization of gray cast iron
Electrochemical
thermodynamics
Electrochemical
kinetics
Corrosion rate
measurements
Various forms of
corrosion
41
42
Types of environmental
cracking
Introduction
Significance and
cost of corrosion
Definitions and
underlying
mechanisms
Forms of corrosion
Corrosion rate
measurements
Electrochemical
thermodynamics
Electrochemical
kinetics
Corrosion rate
measurements
Various forms of
corrosion
Cracks
Introduction
Stress Corrosion Cracking (SCC)
Stresses that cause environmental

cracking arise from:
residual cold work
welding
grinding
thermal treatment
service conditions
To be effective the stresses must be
tensile.
Significance and
cost of corrosion
Definitions and
underlying
mechanisms
Forms of corrosion
Corrosion rate
measurements
Sulfide stress cracking

Chloride induced SCC
Caustic induced SCC
Electrochemical
thermodynamics
Electrochemical
kinetics
Corrosion rate
measurements
Various forms of
corrosion
Corrosion fatigue
43
The cracks form and propagate

approximately at right angles to the
direction of the tensile stresses at stress
levels much lower than those required
to fracture the material in the absence
of the corrosive environment.
As cracking penetrates further into the
material, it eventually reduces the
supporting cross section of the material
to the point of structural failure from
overload.
44
11
Stress Corrosion Cracking

Introduction
Significance and
cost of corrosion
Definitions and
underlying
mechanisms
Forms of corrosion
Corrosion rate
measurements
Electrochemical
thermodynamics
Electrochemical
kinetics
Corrosion rate
measurements
Various forms of
corrosion
Stress corrosion cracking (SCC) is the

cracking induced from the combined
influence of tensile stress and a
corrosive environment.
Introduction
Significance and
cost of corrosion
Definitions and
underlying
mechanisms
Forms of corrosion
Corrosion rate
measurements
Electrochemical
thermodynamics
Electrochemical
kinetics
Corrosion rate
measurements
Various forms of
corrosion
intergranular SCC of
an Inconel heat
exchanger tube
image source: Corrosion Doctors,
Stress Corrosion Cracking
image source: MTi,

http://www.met-tech.com/metal.html 45
46
Example of SCC
Introduction
Significance and
cost of corrosion
Definitions and
underlying
mechanisms
Forms of corrosion
Corrosion rate
measurements
Electrochemical
thermodynamics
Electrochemical
kinetics
Corrosion rate
measurements
Various forms of
corrosion
SCC in a 316 stainless steel

chemical processing piping system
containing chlorides.
Chloride stress
corrosion cracking
in austenitic
stainless steel is
characterized by
the multi-branched
"lightning bolt"
transgranular
crack pattern.
image source: MTi,
http://www.met-tech.com/metal.html 47
Usually, most of the surface remains

unattacked, with fine cracks penetrating
into the metal.
In the microstructure, these cracks can
have an intergranular or a transgranular
morphology.
Macroscopically, SCC fractures have a
brittle appearance.
SCC is classified as a catastrophic form
of corrosion, as the detection of such
fine cracks can be very difficult and the
failure not easily predicted.
A catastrophic case history

Introduction
Significance and
cost of corrosion
Definitions and
underlying
mechanisms
Forms of corrosion
Corrosion rate
measurements
Electrochemical
thermodynamics
Electrochemical
kinetics
Corrosion rate
measurements
Various forms of
corrosion
On October 4, 1992 an EL AL Boeing 747 freighter crashed

in Amsterdam, killing all four people on board and over 50
people on the ground.
The cause of the crash was the number 3 and 4 engines
separated from the wing, causing a loss of control.
The reason for the
number 3 engine
separation was a
breakage of the fuse pin
weakened by a crack.
The pin was designed
to break when an
engine seizes in flight,
producing a large
amount of torque.
48
12
Introduction
Significance and
cost of corrosion
Definitions and
underlying
mechanisms
Forms of corrosion
Corrosion rate
measurements
Electrochemical
thermodynamics
Electrochemical
kinetics
Corrosion rate
measurements
Various forms of
corrosion
Sources of hydrogen
also called: hydrogen induced cracking

involves the ingress of hydrogen into
the metal causing:
Introduction
Significance and
cost of corrosion
Definitions and
underlying
mechanisms
Forms of corrosion
Corrosion rate
measurements
reduced ductility and load-bearing

capacity,
subsequent cracking and
catastrophic brittle failures at stresses
below the yield stress of susceptible
materials
Electrochemical
thermodynamics
Electrochemical
kinetics
Corrosion rate
measurements
Various forms of
corrosion
most vulnerable are high-strength

steels, titanium alloys and aluminum
alloys
in the metal making process

in meatl processing (phosphating,
pickling)
from welding
in storage or containment of hydrogen gas
as a by-product of general corrosion
from cathodic protection
in electroplating
49
50
Hydrogen embrittlement of
stainless steel
Introduction
Significance and
cost of corrosion
Definitions and
underlying
mechanisms
Forms of corrosion
Corrosion rate
measurements
Electrochemical
thermodynamics
Electrochemical
kinetics
Corrosion rate
measurements
Various forms of
corrosion
Corrosion Fatigue
hydrogen (atoms) present at the surface

enters the steel
hydrogen diffuses along the grain
boundaries and combines with the
carbon, which is alloyed with the iron, to
form methane gas
methane gas is not mobile and collects in
small voids along the grain boundaries
and reduces ductility
the gas can build up enormous pressures
that can initiate cracks
Introduction
Significance and
cost of corrosion
Definitions and
underlying
mechanisms
Forms of corrosion
Corrosion rate
measurements
Electrochemical
thermodynamics
Electrochemical
kinetics
Corrosion rate
measurements
Various forms of
corrosion
51
Corrosion-fatigue is the result of the combined

action of an alternating stress and a corrosive
environment.
The fatigue process is thought to cause rupture
of the protective passive film, upon which
corrosion is accelerated.
The introduction of a corrosive environment
often eliminates the normal fatigue limit of a
ferrous alloy, thereby
creating a finite life
regardless of stress
level.
52
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Types of Corrosion PDF

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ChE430 (530)

Uniform corrosion is characterized by

image source: Corrosion Doctors , www.corrosion-doctors.org

Pitting corrosion is a localized form of

image source: Corrosion Doctors , www.corrosion-doctors.org

Passive metals pit

Localized chemical or mechanical

Pitting corrosion on a stainless steel bar

image source: Prof. Dr. H. Bhni, www.ibwk.baum.ethz.ch

image source: Corrosion Doctors , www.corrosion-doctors.org

The sewer explosion that killed 215

image source: Corrosion Doctors , www.corrosion-doctors.org

Crevice corrosion is a localized form of

image source: Corrosion Doctors, www.corrosion-doctors.org

Another example of crevice

Example of crevice corrosion

Crevices corrosion of a S30400 stainless

Stainless steel bolt used in seawater after 5 years

image source: Corrosion Doctors, www.corrosion-doctors.org

Initiation of crevice corrosion

Crevice corrosion is initiated by changes

Depletion of inhibitor in the crevice

Subsequent inspection revealed corrosion in

Underside of panel where severe

Close-up picture showing the severity

Advanced crevice corrosion

Stage 0 of crevice corrosion

Notice how the rivet heads appear to be

Consider the case of a

Initially, the dissolved oxygen content in the crevice is

image source: Mike Dahlager, www.corrosion-control.com

Stage 1 of crevice corrosion

Stage 2 of crevice corrosion

Due to the difficult

The driving force for corrosion is a

image source: Corrosion Doctors, www.corrosion-doctors.org

The acidification of the local environment produces a

The metal ions produced

Stainless screw in contact with a

image source: Mike Dahlager, http://www.corrosion-doctors.org/Aircraft/dahlager.htm

Nobility and galvanic

Galvanic series in seawater

The relative nobility of a material can

Galvanic series in seawater

Galvanic series in seawater

Erosion corrosion is an acceleration

image source: Corrosion Doctors, www.corrosion-doctors.org

image source: Corrosion Doctors, www.corrosion-doctors.org

pump rotor destroyed by erosion

Inside of the stainless steel pump

Cavitation occurs when a fluid's

image source: Bud Ross and Paul Dillon, http://www.nidi.org/

image source: Corrosion Doctors, www.corrosion-doctors.org

at the suction side of a pump, especially

image source: Corrosion Doctors, www.corrosion-doctors.org

Intergranular corrosion is localized

image source: Corrosion Doctors , www.corrosion-doctors.org

Fretting corrosion is damage at

This form of corrosion is usually

Sensitization of stainless steels:

Anisotropic grain structure

failed aircraft component

Exfoliation is a form of intergranular