Methods of Stopping &

Preventing Metal Corrosion

ARC - 4102
 Reviewing Corrosion
We have learned that three things are required for the
anodic and cathodic steps of corrosion to occur: an
electrolyte, an exposed metal surface, and an electron
acceptor. It follows, then, that we can prevent corrosion by
removing one of these essential conditions. The simplest
condition to remove is the exposed metal surface.
Corrosion can be prevented by removing one of these
conditions.
Coating a metal surface with paint or enamel provides a
barrier between the metal and the moisture in the
environment.
The process of coating a metal surface with another metal
that is more likely to be oxidized is referred to assacrificial
coating.
 Establishing a Physical Barrier

Coating a metal surface with paint or

enamel provides a barrier between
the metal and the moisture in the
environment, thus removing the
opportunity for bothoxygenand
moisture to come in contact with the
metal.
 Sacrificial Coatings

The process of coating a metal surface with another metal

that is more likely to be oxidized is referred to as sacrificial
coating.
Corrosion of the sacrificial zinc results in itsoxidation; the
iron is reduced, which renders it cathodic and inhibits its
corrosion.
When iron or an iron alloy is plated with a less active metal,
such as tin. As long as the tin coating remains intact,
corrosion is not possible.
The tin coating becomes degraded, exposing the underlying
metal, corrosion will occur. This is because the exposed iron
undergoes oxidation and is rendered anodic.
 Cathodic Protection
This method is referred to as cathodic protection.
Cathodic protection replicates the effects of a
sacrificial coating but with a more active metal.
The source of negative charge is usually an
external direct-current power supply. Cathodic
protection is used to protect underground fuel
tanks and pipelines, among other things.
 Passivation
Passivation is a process through
which a thin film of
corrosionproductsbuilds on a metal
surface to serve as a barrier against
oxidation. The formation of a
passivation layer is affected by
environmentalpH,temperature, and
chemical conditions.
 Anodization
Anodization is another surface treatment that
protects against corrosion. The metal to be
protected is bathed in a specificsubstance, and
electrochemical conditions are adjusted such that
uniform pores several nanometers wide appear in
the metal'soxidefilm. These pores allow an oxide
film, thicker than a passivation layer, to build up.
The resultant protective layer is very hard and
very resilient.
SacrificialAnodeProtection
a sacrificial anode, made of a metal
more active than the metal you want
to protect, can be used to prevent
corrosion on submerged or buried
metal structures. The sacrificial
anode will corrode before the metal it
is protecting does.
 Metal Corrosion
Metal corrosion occurs when metal is exposed to moisture and other
elements or chemicals. While it is generally a natural process it can lead
to a severe decrease in the functionality and esthetics of metal
products.
Ways to prevent corrosion of metals:

Turn to non-corrosive metals such as aluminum and stainless steel.

Keep the area around the metal surface dry.
Use drying agents and moisture barrier products.
Make sure underground piping is laid in a layer of backfill, such as
limestone.
Make sure any electrical components are cleaned regularly

Following these simple steps can add a lot of life to metal andstop the
corrosion of metalsin their tracks. Keep in mind that all metal
requires maintenance. Use these methods frequently toprevent
corrosion of metals.
 Additional Ways to Prevent
Metal Corrosion
Aside from the above suggestions, there are methods of treating
metal that canstop the corrosion of metalsbefore it starts; a
coating of grease or oil maintained on a metal surface, for
instance. Painting is another method of preventing metal
corrosion. Also consider usingcathodic protectionto prevent
corrosion on the primary metalpieces.

Carbon Fiber Coating to Prevent Corrosion in Metal

Carbon Fiber Coatingis another excellentmethod of preventing
the corrosion of metals. In this process, sheets of carbon fiber
are sealed around and often inside a metal pipe or on any metal
surface. This not only helps to prevent corrosion but strengthens
the metal, prevents cracks and stops leaks from forming.
.
 Common Metals and Their Corrosion Properties

Metal Metal's Corrosion Vulnerability(s) Common Preventative Techniques Galvanic Activity*

Uniform attack, galvanic, pitting, Cleaning, protective coating or Low (initial corrosion forms resistant
Stainless Steel (Passive)
crevice (all esp. in saltwater) sealant oxide layer)

Cleaning, protective coating or

Iron Uniform attack, galvanic, crevice sealant, galvanization, anti-rust High
solutions

Cleaning, protective coating or

Uniform attack, dezincification, sealant (usually oil or lacquer),
Brass Medium
stress adding tin, aluminum, or arsenic to
alloy

Cleaning, protective coating or

sealant, anodizing, galvanizing, High (initial corrosion forms resistant
Aluminum Galvanic, pitting, crevice
cathodic protection, electrical oxide layer)
insulation

Cleaning, protective coating or

Galvanic, pitting, aesthetic Low (initial corrosion forms resistant
Copper sealant, adding nickel to alloy (esp.
tarnishing patina)
for saltwater)
 Environmental Modification

Corrosion is caused through chemical interactions between metal and

gases in the surrounding environment. By removing the metal from, or
changing, the type of environment, metal deterioration can be
immediately reduced.

This may be as simple as limiting contact with rain or seawater by

storing metal materials indoors, or could be in the form of direct
manipulation of the environmental affecting the metal.

Methods to reduce the sulfur, chloride or oxygen content in the

surrounding environment can limit the speed of metal corrosion.

For example, feed water for water boilers can be treated with
softeners or other chemical media to adjust the hardness, alkalinity or
oxygen content in order to reduce corrosion on the interior of the unit.
Metal Selection and Surface
Conditions:
No metal is immune to corrosion in all environments, but through monitoring
and understanding the environmental conditions that are the cause ofcorrosion,
changes to the type of metal being used can also lead to significant reductions in
corrosion.

Metal corrosion resistance data can be used in combination with information on

the environmental conditions to make decisions regarding the suitability of each metal.

Monitoring of surface conditions is also critical in protecting against metal

deterioration from corrosion. Cracks, crevices or asperous surfaces, whether a result of
operational requirements, wear and tear or manufacturing flaws, all can result in
greater rates of corrosion.
Proper monitoring and the elimination of unnecessarily vulnerable surface
conditions, are designed to avoid reactive metal combinations and that corrosive
agents are not used in the cleaning or maintenance of metal parts are all also part of
effective corrosion reduction program.
 Cathodic Protection:
Cathodic protection works by converting unwanted
anodic (active) sites on a metal's surface to
cathodic (passive) sites through the application of
an opposing current.
This opposing current supplies free electrons and
forces local anodes to be polarized to the potential
of the local cathodes.

Cathodic protection can take two forms

Impressed current protection
The method of sacrificial system
 This method, known as asacrificial system, uses
metal anodes, introduced to the electrolytic
environment, to sacrifice themselves (corrode) in
order to protect the cathode.
While the metal needing protection can vary,
sacrificial anodes are generally made
ofzinc,aluminumormagnesium, metals that
have the most negative electro-potential.
The galvanic series provides a comparison of the
different electro-potential - or nobility - of metals
and alloys.
This method, which is often used to protect buried
pipelines and ship hulls, requires an alternative
source of direct electrical current to be supplied to
the electrolyte.
The negative terminal of the current source is
connected to the metal, while the positive terminal
is attached to an auxiliary anode, which is added to
complete the electrical circuit.
Unlike a galvanic (sacrificial) anode system, in an
impressed current protection system, the auxiliary
anode is not sacrificed.
 Corrosion Inhibitors:
Corrosion inhibitors are chemicals that react with the metal's surface
or the environmental gases causing corrosion, thereby, interrupting
the chemical reaction that causes corrosion.
Inhibitors can work by adsorbing themselves on the metal's surface
and forming a protective film. These chemicals can be applied as a
solution or as a protective coating via dispersion techniques.
The inhibitors process of slowing corrosion depends upon:
Changing the anodic or cathodic polarization behavior
Decreasing the diffusion of ions to the metal's surface
Increasing the electrical resistance of the metal's surface
Major end-use industries for corrosion inhibitors are petroleum
refining, oil and gas exploration, chemical production and water
treatment facilities.
The benefit of corrosion inhibitors is that they can be applied in-situ
to metals as a corrective action to counter unexpected corrosion.
 Coatings:
Paints and other organic coatings are used to protect
metals from the degradative effect of environmental gases.
Coatings are grouped by the type of polymer employed.
Common organic coatings include:
Alkyd and epoxy ester coatings that, when air dried,
promote cross-link oxidation
Two-part urethane coatings
Both acrylic and epoxy polymer radiation curable coatings
Vinyl, acrylic or styrene polymer combination latex coatings
Water soluble coatings
High-solid coatings
Powder coatings
 Plating:
Metallic coatings, or plating, can be applied to inhibit
corrosion as well as provide aesthetic, decorative finishes.

Four common types of metallic coatings

ELECTROPLATING
MECHANICAL PLATING
ELECTROLESS
HOT DIPPING
 OTHER TYPES
Corrosion can be prevented if the metal is coated with something which does not
allow moisture and oxygen to react with it.
Coating of metals with paint, oil, grease or varnish prevents the corrosion of metals.
Coating of corrosive metals with non-corrosive metals also prevents corrosion.
Some of the methods by which metals can be coated with non-corrosive metals are:
Galvanizing:It is process of giving a thin coating of zinc on iron or steel to protect
them from corrosion. Iron is galvanized by dipping it in molten zinc. It is then taken
out and allowed to cool. Galvanizing is an effective methods of protecting steel
because even if the surface is scratched, the zinc still protects the underlying layer.
Tinning:It is the process of giving a coating of tin, i.e., molten tin. Cooking vessels,
made of copper and brass get a greenish coating due to corrosion. This greenish
coating is poisonous. Therefore they are given a coating of tin to prevent corrosion.
Electroplating:In this method of a metal is covered with another metal using
electrolysis. Silver-plated spoons, gold-plated jewelry, etc, are electroplated.
Anodizing:In this method metals like copper and aluminum are electrically coated
with a thin strong film of their oxides. This film protects the metals from corrosion.
Alloying:Corrosion can be also prevented by alloying some metals with other
metals. The resultant metals called alloys do not corrode easily, e.g. stainless steel.
 MEMBERS:
DELA CRUZ, ALMIRA YASMIN
FIDER, KRISSE REILYN
BAY, LOUISE SHAYNE
DELA GENTE, APRIL JOY
LOPEZ, LEONA ANGELICA
HERNANDEZ, VANESSA
FAMATIGA, MARY ROSE
HERNANDEZ, EIRYLL BLAINE
SALUDO, JOHN PAOLO

ARC - 4102