Degradation of Materials

Corrosion Prevention and Control

Primary and Secondary Mechanisms

Primary Corrosion Mechanism

Primary and Secondary Mechanisms

Secondary Corrosion Mechanism Contributions from people, designers, manufacturers Influence of a remote subsystem: effect of ac/dc Unpredictability in the environment

Corrosion Prevention
Materials Selection

Design Factors
Life Prediction Analysis

Materials Selection
Cost
Raw materials Quantity Production costs Labor requirements Anticipated service

Availability
Made to order Bought from

life

manufacturer Available off the shelf Tooling required

Materials Selection
Material Properties
Mechanical: hardness,

creep, fatigue, stiffness, compression, shear, impact, tensile, wear Physical Electrical Magnetic Thermal Chemical Corrosion resistance

Design-Related Causes
Use of dissimilar metal

Poor drainage
Presence of crevices Relative motion between two interacting parts or

between a metal and the environment Selective leaching of a metal in an alloy Inability to clean the surface thoroughly

Design Considerations
Environment

Stress
Shape Compatibility Movement Temperature

Environment
Natural
Air Waters Soils

Chemical
Urban and industrial

atmospheres Environmental pollutants Chemical plant

Environment

Stress
Static
Stress Corrosion

Fluctuating
Corrosion Fatigue

Cracking

Stress

Shape

Compatibility
Within the metal

Within the environment

Contact with other materials Welds

Compatibility

Movement
Flowing fluids

Parts moving in the fluid

Two-phase and multi-phase fluids

Temperature
Environmental factors

Sources of heat
Condensation

Corrosion Protection
Choice of Materials

Addition of Inhibitors
Use of Protective Coatings Cathodic and Anodic Protection

Addition of Inhibitors
Purpose:
Suppress the corrosion reaction Produce a competent corrosion product

Example Chemicals:

Zinc/polyphosphates Chromates Phosphonates Polymers Nitrates Vanadates Arsenates

Addition of Inhibitors
Cathodic Inhibitors
Inhibit the hydrogen

Anodic Inhibitors
Effective in the pH

evolution in acidic solution or reduction of oxygen in neutral or alkaline solution

range 6.5-10.5 Increase in potential to reach passivation region; dependent on concentration of inhibitor

Protective Coatings
Application of PAINTS as protective barriers PAINTS
Source of insulation of the metal from the corrosive

environment
HOW TO ACHIEVE CORROSION CONTROL BY

COATING?
Barrier coating mitigates current transfer between

anode and cathode Cathodic protection as in the case of Zn-containing pigments Inhibitive primer which forms passive films or layers

Composition of Paints
Vehicle: liquid that gives the paint its fluidity and

dries or evaporates to form a solid film Pigment: suspended in the vehicle, the pigment controls the corrosion rate or the rate of diffusion of the reactants through the dry film Additives or Fillers: these accelerate the drying process or better enable the dry coating to withstand the working environment

Protective Coatings
Barrier coatings must be:
Impermeable to ionic species Impermeable to oxygen Able to maintain adhesion under wet conditions

Metallic Coatings
provide enhanced corrosion resistance of metals

as either barrier coatings or sacrificial coatings Durable, usually easy to form but sometimes porous Examples: Nickel, lead, zinc, copper, cadmium, tin, chromium

Inorganic Coatings
inorganic, nonmetallic coatings that act as a

barrier between the corrosive environment and the base material being protected Oxide film Useful for providing high temperature corrosion protection Examples: chromate films, phosphate coatings

Cathodic Protection
Two Types:
Impressed Current Sacrificial Anode

Cathodic Protection
Impressed Current

Cathodic Protection
Impressed Current

Cathodic Protection
Sacrificial Anode

Cathodic Protection
Sacrificial Anode

Anodic Protection
Make metal an anode and drive it into its passive

region Applicable only to metals which exhibit an activepassive behavior such as Cr, N, Fe, Ti, Al and alloys containing these elements

Cathodic vs. Anodic Protection