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Written by Bobby
Created: 03 July 2009
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Galvanic Action
Corrosion within cooling systems can occur if the coolant, i.e. water, has not been properly
treated. The corrosion can take the form of acid attack with resultant loss of metal from a
large area of the exposed surface, or by Oxygen attack characterised by pitting. A primary
motive force for this corrosion is Galvanic action
Cathode
Gold and Platinum
Titanium
Silver
Silver solder
Chromium-Nickel-Iron (Passive)
Chromium-Iron (Passive)
Stainless Steel (Passive)
Copper
Monel
70/30 Cupro-Nickel
67-33 Nickel-Copper
Hydrogen
lead
Tin
2-1 Tin lead Solder
Bronzes
Brasses
Nickel
Stainless-Steel 18-8 (Active)
Stainless Steel 18-8-3 (Active)
Chromium Iron (Active)
Chromium-Nickel-Iron (Active)
Cadmium
Iron
Steel
Cast Iron
Chromium
Zinc
Aluminium
Aluminium Alloys
Magnesium
Anode
The metals closer to the anodic end of the list corrode with preference to the metals
towards the cathode end.
A galvanic cell can occur within an apparently Homogeneous material due to several
processes on of which is differential aeration where one area is exposed to more oxygen
than another. The area with less oxygen becomes anodic and will corrode.
Corrosion Inhibitors
* Corosion inhibitors are classified on how they affect the corrosion cell and are placed into
three catagories;
Anodic Inhibitors
Cathodic Inhibitors
Combination inhibitors/organic inhibitors
Common Corrosion Inhibitors
Chromate
Nitrite
Orthophosphtae
Bicarbonate
Silicate
Molybdate
Carbonate
Polyphosphate
Phosphonates
Zinc
Soluble Oils
Mercaptobenzothiazole (MBT)
Benzotriazole (BZT)
Tolytriazole (TTZ)
Anodic Inhibitors
Nitrite (NO2- )- These are the most commonly used form of treatment and operate by
oxidising mild steel surfaces with a thin, tenacious layer of corrosion product (magnetite
Fe3O4). Relatively high volumes of treatment chemical are required so this method is only
viable on closed systems
Sodium Nitrite- (sometimes with Borate added)-effective with low dosage, concentration
non-critical. It is non toxic, compatible with anti freezes and closed system cooling
materials. It does not polymerise or breakdown. However protection for non-ferrous
materials is low. An organic inhibitor is thus required. Although will not cause skin disease it
will harm eyes and skin. Approved for use with domestic fresh water systems.
Chromate's-the first passivator product was Sodium Chromate which was an excellent
inhibitor. Inexpensive, effective and concentration easily tested. Corrosion may increase by
incorrectly dosing, dangerous to handle, poisonous and can cause skin disease. Not
allowed where domestic water production is in use (Jacket water heated evaporators).
Unfortunately it was also highly toxic, a severe pollutant and staining agent, was
imcompatible with antifreeezes, nd will attack zinc and soft solder slightly. Due to its toxicity
is sometimes used as a biocide in such places as brine in large Reefer plants.
Silicates- react with dissolved metal ions at the anode. The resultant ion/silicate complex
forms a gel that deposits on anodic sites. This gel forms a thin, adherent layer that is
relaitvely unaffected by pH in comparsion to other inhibitors. The inhibiting properties
increase with temperature and pH, normal pH levels are 9.5 to 10.5.
Care should be taken with the use of silicates, which are often used for the protection of
systesm containing alumiinium. In the event of boiling increased concnetrations and lead to
aggressive corrosion due to the high pH.
Orthophosphate Forms an insoluble complex with dissolved ferric ions that deposit at the
anodic site. It is more adherent and less pH sensitive than other anodic inhibitors. The film
forms in pH of 6.5 to 7.0. Dosage is typically 10ppm in neutral water
Cathodic Inhibitors
Polyphosphate- Forms complexes with Calcium, Zinc and other divalent ions, this creates
positively charged colloidal particles. These will migrate to the cathodic site and precipitate
to form a corrosion inhibiting film. The prescence of calcium is required at a typical
minimum concentration of 50ppm.
Extreme variations in pH can upset the film and a reversion to orthophosphate will occur
with time and temperature.
Positively charged zinc ions migrate to the cathodic site and react with the free hydroxyl
ions to form a zinc hydroxide stable film at pH 7.4 to 8.2. If the water is too acidic the film
will dissolve and not reform. If it is too alkaline the zinc hydroxide will precipitate in bulk and
not at the cathodic site.
Benzotriazole and Triazole Specific corrosion inhibitor for copper. They break the
electrochemical cirsuit by absorbing into the copper surface.
They are generally added to standard treatments.
Sollble and dispersible oils.Petroleum industry recognised that emulsifying cutting oils
(erroneously called soluble oils) were able to reduce corrosion on metals by coating the
surface. There were disadvantages though, if the coating became too thick then it could
retard the heat transfer rate. Adherent deposits form as organic constituents polymerise or
form break down products which can accumulate and disrupt flow. MAN-B&W recommend
it not to be used.
It is effective in low dosages, safe to handle and safe with domestic water production.
Effectiveness is reduced by contamination with carbon, rust, scale etc. Difficult to check
concentration, overdosing can lead to overheating of parts
Oils are classed as a barrier layer type inhibitor. The surfaces being coated in a thin layer
of oil.
Modern treatment
Nitrite-Borate treatment is most effective with a high quality water base. This treatment has
no scale prevention properties and its effectiveness is reduced by high quantities of
dissolved solids.
A modern treatment will be a Nitrite -Borate base, with a complex blend of organic and
inorganic scale and corrosion inhibitors plus surfactants, alkali adjusters, dispersants and
foam suppressers. A high quality water supply is still strongly recommended.