Professional Documents
Culture Documents
Prevention
and Control
Monteclaro, Richard B.
Nave, John Christian R.
Obias, Cherry Mae V.
What is Corrosion ?
How can Corrosion be prevented?
How can Corrosion be controlled?
Introduction :
Corrosion is the slow but continuous eating away of
metallic components by chemical or electrochemical
attack.
Three factors govern corrosion.
1. The metal from which the component is made.
2. The protective treatment the component surface
receives.
3. The environment in which the component is kept.
All metals corrode to a greater or lesser degree;
even precious metals like gold and silver tarnish in
time, and this is a form of corrosion.
1. Dry Corrosion
2. Wet Corrosion
3. Galvanic Corrosion
1. Dry corrosion
This is the direct oxidation of metals which occurs
when a freshly cut surface reacts with the oxygen
of the atmosphere.
Stress Corrosion
Corrosion takes place in these regions of high energy
and the locked-up stresses give rise to the formation
of cracks which grow progressively with the
continuance of corrosion. A similar process may take
place in components in which unequal heating or
cooling has given rise to the presence of locked-up
stresses, as, for example, near to welded joints.
Corrosion Fatigue. As might be expected, any
component which is subjected to alternating
stresses and is working in conditions which
promote corrosion may fail at a stress well
below the normal fatigue limit (3.72). The
action of the corrosive medium will tend to be
concentrated at any surface flaw and behave
as a focal point for the initiation of a fatigue
crack.
Fretting Corrosion is allied to corrosion
fatigue and occurs particularly where closely
fitting machine parts are subjected to
vibrational stresses. In steel this form of
corrosion appears as patches of finely divided
ferric oxide (Fe203).
Impingement Corrosion refers to the
combined effects of mechanical abrasion and
chemical corrosion on a metallic surface.
Mechanical wear can be caused by the
impingement of entrained air bubbles or
abrasive particles suspended in the liquid.
Surface morphology
Example of crack propagation during
transgranular stress corrosion cracking (TGSCC)
brass
Example of crack
propagation during
intergranular stress
corrosion cracking
(IGSCC) ASTM A245
carbon steel
Fracture surface of
intergranular SCC on
carbon steel in hot nitric
solution
Fracture surface of
transgranular SCC on
austenitic stainless steel in
hot chloride solution
Fracture surface due Fracture surface due to
to intergranular SCC local stress has reached
its tensile strength value
on the remaining section
Factors affecting
Corrosion
1. Structural Design
2. Environment
3. Applied or internal stresses
4. Composition and structure
5. Temperature
1. Structural Design
The design should avoid crevices and corners where
moisture may become trapped, and adequate
ventilation and drainage should be provided.
The design should allow for easy washing down and
cleaning.
Joints which are not continuously welded should be
sealed, for example, by the use of mastic
compounds or impregnated tapes.
Where dissimilar metals have to be joined, high-
strength epoxy adhesives should be considered
since they insulate the metals from each other and
prevent galvanic corrosion.
1. Chromium
Minimum concentration of Cr in a stainless steel is 12-14wt.%
Structure : BCC (ferrite forming element)
Molybdenum
Ferritic forming element. Added to increase pitting corrosion
resistance of stainless steel (2-4%).
Molybdenum addition has to be followed by decreasing chromium
concentration (i.e. in 18-8SS has to be decreased down to 16-18%) and
increasing nickel concentration (i.e. has to be increased up to 10-14%).
Improves mechanical properties of stainless steel at high
temperature. Increase aqueous corrosion resistance of material
exposed in reducing acid.
Tungsten
Is added to increase the strength and toughness of
martensitic stainless steel.
Nitrogen (up to 0.25%)
Stabilize austenitic structure. Increases strength and
corrosion resistance. Increases weld ability of duplex SS.
Titanium, Niobium and Tantalum
To stabilize stainless steel by reducing susceptibility of
the material to intergranular corrosion. Ti addition > 5x
%C. Ta+Nb addition > 10x%C.
Copper
Is added to increase corrosion resistance of stainless steel
exposed in environment containing sulfuric acid.
Silicon
Reduce susceptibility of SS to pitting and crevice corrosion
as well as SCC.
Five basic types of stainless steels :
Austenitic - Susceptible to SCC. Can be hardened by only by cold
working. Good toughness and formability, easily to be welded and
high corrosion resistance. Nonmagnetic except after excess cold
working due to martensitic formation.