Corrosion Types and Rust-Preventive Coatings

Preparing by Efekan BakIR

Contents
Definition of Corrosion Types of Corrosion Definition of Rust Prevention of Rust Rust-Preventive Coatings Conclusion References

What is the Corrosion ?

Corrosion is the gradual destruction of material, usually metals, by chemical reaction with its environment. In the most common use of the word, this means electrochemical oxidation of metals in reaction with an oxidant such as oxygen. Rusting, the formation of iron oxides, is a well-known example of electrochemical corrosion.

This type of damage typically produces oxide or salt of the original metal. Corrosion can also occur in materials other than metals, such as ceramics or polymers, although in this context, the term degradation is more common. any types and causes of corrosion and depending on a particular scientist's or corrosion engineer's tendencies to look upon the subject more broadly or narrowly there is no clear and exact total for the number of corrosion types. Most corrosion experts however can agree on the basic varieties of corrosion listed and described.

As a result, methods to reduce the activity of the exposed surface, such as passivation and chromate conversion, can increase a material's corrosion resistance. However, some corrosion mechanisms are less visible and less predictable.

Example of Corrosion

Types of Corrosion
Corrosion comes in many different forms and can be classified by the cause of the chemical deterioration of a metal. Listed below are 8 common types of corrosion: Galvanic Corrosion, Environmental Cracking, Erosion Corrosion , Intergranular corrosion, De-Alloying, Fretting corrosion, Pitting Corrosion,High-Temperature Corrosion.

Fretting corrosion
Fretting corrosion refers to corrosion damage at the asperities of contact surfaces. This damage is induced under load and in the presence of repeated relative surface motion, as induced for example by vibration. Pits or grooves and oxide debris characterize this damage, typically found in machinery, bolted assemblies and ball or roller bearings. Contact surfaces exposed to vibration during transportation are exposed to the risk of fretting corrosion.

Galvanic Corrosion
When dissimilar metals are connected in the presence of an electrolyte a galvanic corrosion reaction occurs. Both the presence of an electrolyte solution and a bi-metallic coupling is required for this type of corrosion to occur.

Example of Galvanic Corrosion

Environmental Cracking
Environmental cracking is a corrosion process that can result from a combination of environmental conditions affecting the metal. Chemical, temperature and stress-related conditions can result in the following types of environmental corrosion: Stress Corrosion Cracking (SCC) Corrosion fatigue Hydrogen-induced cracking Liquid metal embrittlement

Erosion 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. The increased turbulence caused by pitting on the internal surfaces of a tube can result in rapidly increasing erosion rates and eventually a leak. Erosion corrosion can also be aggravated by faulty workmanship. For example, burrs left at cut tube ends can upset smooth water flow, cause localized turbulence and high flow velocities, resulting in erosion corrosion. A combination of erosion and corrosion can lead to extremely high pitting rates.

Intergranular corrosion
The microstructure of metals and alloys is made up of grains, separated by grain boundaries. Intergranular corrosion is localized attack along the grain boundaries, or immediately adjacent to grain boundaries, while the bulk of the grains remain largely unaffected. 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.

De-Alloying
Dealloying or selective leaching refers to the selective removal of one element from an alloy by corrosion processes. A common example is the dezincification of unstabilized brass, whereby a weakened, porous copper structure is produced.

High-Temperature Corrosion
Under very high temperature metals need only the presence of oxygen or other oxidizing gases to corrode. This type of corrosion is referred to as high temperature oxidation, scaling or tarnishing and requires neither moisture nor dissolved electrolytes (salts, acids) to proceed.

Definition of Rust
Rust is another name for iron oxide, which occurs when iron or an alloy that contains iron, like steel, is exposed to oxygen and moisture for a long period of time. Over time, the oxygen combines with the metal at an atomic level, forming a new compound called an oxide and weakening the bonds of the metal itself. Although some people refer to rust generally as "oxidation," that term is much more general; although rust forms when iron undergoes oxidation, not all oxidation forms rust. Only iron or alloys that contain iron can rust, but other metals can corrode in similar ways.

Prevention of Rust
Because of the widespread use and importance of iron and steel products, the prevention or slowing of rust is the basis of major economic activities in a number of specialized technologies. A brief overview of methods is presented here; for detailed coverage, see the cross-referenced articles. Rust is permeable to air and water, therefore the interior metallic iron beneath a rust layer continues to corrode. Rust prevention thus requires coatings that preclude rust formation.

There are kinds 7 of prevention of rust : Rust-resistant alloys, Galvanization, Cathodic protection, Coatings and painting, Bluing, Inhibitors, Humidity control

Rust-Preventive Coatings
Stop rust before it starts with water based rust preventive dip coating. In just one coat, corrosion control is achieved by using water based rust proofing that contains a balanced rust inhibitor system. This rust prevention product is a cream colored liquid when applied but upon drying turns to a translucent light brown dry to the touch wax coating. Dyes can be added if color coding is desired.

This corrosion resistant coatings will not transfer, abrade or run under normal handling. Therefore neither the floor of your packaging area, storage bins or the packages you send to your customers will be oil stained and messy. Some materials active rust inhibitor system neutralizes metal corrosion normally attributed to fingerprints from parts handling. This protective coating and its rust inhibitor system are compatible with lube oil so they do not need to be removed from internal parts before assembly.

Rust formation can be controlled with coatings, such as paint, lacquer, or varnish that isolate the iron from the environment. Large structures with enclosed box sections, such as ships and modern automobiles, often have a wax-based product (technically a slushing oil) injected into these sections. Such treatments usually also contain rust inhibitors. Covering steel with concrete can provide some protection to steel because of the alkaline pH environment at the steel-concrete interface. However rusting of steel in concrete can still be a problem, since expanding rust can fracture or slowly "explode" concrete from within.

Conclusion
Corrosion comes in many different forms and can be classified by the cause of the chemical deterioration of a metal. However, some corrosion mechanisms are less visible and less predictable. Rusting, the formation of iron oxides, is an example of electrochemical corrosion. Rust-Preventive Coatings is a well-known method for preventing the rust.

References
http://www.corrosion-doctors.org/pict-type.htm http://www.counteractrust.com/types%20of%20corrosion.htm http://metals.about.com/od/metallurgy/a/Types-Of-Corrosion.htm http://www.corrosionist.com/Corrosion_Types_Uniform_Corrosion. htm http://en.wikipedia.org/wiki/Corrosion http://www.tis-gdv.de/tis_e/misc/korro.htm http://www.authorstream.com/Presentation/hitiboy-410714corrosion-hiti-science-technology-ppt-powerpoint/ http://www.sanchem.com/safegard_uses.html http://en.wikipedia.org/wiki/Rust#Prevention http://www.metaltreaters.net/rust-preventives.html