Basics of Corrosion

Recommended study References:

M.G. Fontana and N.D. Greene, Corrosion

Engineering,

ASM Handbook Volume 13 - Corrosion

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 Gain

By completion of this module…..you will

1. Fundamental idea of Corrosion mechanism

2. Know the various forms of corrosion
3. Know the application of Corrosion tests
4. Be able to Plan corrosion monitoring or test

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 Information sources

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 Definition

The chemical or electrochemical reaction

between a material, usually a metal, and its
environment that produces a deterioration of
the material and its properties

THE DRIVING FORCE of corrosion is the

lowering of energy associated with the
oxidation of a metal.

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 Metal – unstable state!

Reduction process

Stable Form
Unstable Form

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 Environments

Aqueous
Solutions

Metal
Molten
Salts and
Gaseous
Liquid
Metals

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 Over view

Corrosion

Theory Forms Testing Evaluation design

Specific

Metal or
Protection Industry
Alloy

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 Focus to specific case

Whether stainless steel compatible with sulfuric acid ?

Which alloy of stainless steel, with which microstructure,

with which design detail, is compatible with which sulfuric
acid. What is the acid's temperature, concentration, pH,
impurity level, types of trace species, degree of aeration,
flow velocity, etc.? !!!

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 Prevention Sequence

Recognize
• Forms of Corrosion

Parameters
• Controlling

Mitigate
• Actions

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 Basic Sequence

Metal Vs Environment Reactions

theory of corrosion through

thermodynamic and kinetic points

forms of corrosion & influencing

parameters

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 Study Flow

Thermodynamic Effect of Major

Mechanism Various Forms
conditions Variables

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 Oxidation & Reduction

ELECTRONS TRANSFER
VALENCY CHANGE

Oxidation is the Removal of

electrons from atoms, resulting in
an Increase in valence

Reduction is the Addition of

electrons to an atom s, resulting in
the Decrease in valence

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 Anode - Cathode

Anode
The electrode of an electrolyte cell at which Oxidation occurs. Electrons
flow away from the anode in the external circuit. It is usually at the
electrode that corrosion occurs and metal ions enter solution.

Cathode
The electrode of an electrolytic cell at which Reduction is the principal
reaction. Typical cathodic processes are cations taking up electrons and being
discharged, oxygen being reduced, and the reduction of an element from a
higher to a lower valence state.

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 Variables

Free Energy

Cell Potentials

pH Level

(Gibbs free Energy): ΔG = ΔH (Enthalpy) –TΔS (Entropy)

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 Environmental Variables on
Aqueous Corrosion

pH (acidity)

Concentration Oxidizing
(solution power
constituents) (potential)

Temperature
Velocity (fluid
(heat
flow)
transfer)

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 Metallurgical Variables on
Aqueous Corrosion

Structure

Heat
Composition
Treatment

Phase
Alloying
Diagrams

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 Forms
General corrosion
Atmospheric corrosion
Galvanic corrosion
Stray-current corrosion
General biological corrosion
Molten salt corrosion
Corrosion in liquid metals
High-temperature corrosion
Oxidation
Sulfidation
Carburization
Localized corrosion
Filiform corrosion
Crevice corrosion
Pitting corrosion
Localized biological corrosion
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Mechanically assisted degradation
Erosion corrosion
Fretting corrosion
Cavitation and water drop impingement
Corrosion fatigue
Metallurgically influenced corrosion
Intergranular corrosion
Dealloying corrosion
Environmentally induced cracking
Stress-corrosion cracking
Hydrogen damage
Liquid metal embrittlement
Solid metal induced embrittlement
Other forms include hydrogen effects and
hot corrosion
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 Testing & Evaluation

Planning

Evaluation In-Service
Criteria Monitor

Simulated
Lab Test
Service Test

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 Planning and Preparation of Corrosion
Tests (Objective)
The first and most important part of test planning is to define clear
objectives and significant criteria for interpreting the test results.

 Determining the best material to fill a need (material selection)

 Predicting the probable service life of a product or structure
 Evaluating the new commercial alloys and processes
 Assisting with development of materials with improved resistance to
corrosion
 Conducting lot-release and acceptance tests to determine whether material
meets specifications (QC)
 Evaluating environmental variations and controls (inhibitors)
 Determining the most economical means of reducing corrosion
 Studying corrosion mechanisms

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 In-Service Monitoring

In-Service

Electrical Ultrasonic Polarization

Direct
Resistance Thickness Resistance
Coupons
Probes Measurements Measurement

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 Simulated Service Testing

Simulated
Service
Testing

Atmospheric-
Testing in Testing in
Corrosion
Water Soil
Tests

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 Lab Tests

Lab Tests

Conversion of
Electrochemical
Electrochemical Reaction
Polarization
Current Data to diagrams
Experiment
Corrosion Rates

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 Evaluation Standards (Typical)…
Uniform Corrosion ASTM G 31

Pitting Corrosion ASTM G 46

Galvanic Corrosion ASTM G 82

Intergranular Corrosion ASTM G 46

Stress-Corrosion Cracking ASTM G 35

Hydrogen Embrittlement ASTM F 326

Crevice Corrosion ASTM G 48

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 Corrosion of Weldments

• Micro segregation
• Precipitation of secondary phases
• Formation of unmixed zones
• Recrystallization and grain growth
in the weld heat-affected zone
(HAZ)
• Volatilization of alloying elements
from the molten weld pool
• Contamination of the solidifying
weld pool

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 EMF Series

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 Wet Sour

Sour service environments are defined by NACE MR0175

"fluids containing water and hydrogen sulphide (H2S) that is at

a total pressure of 0.4MPa (4 Bar) (65psia) or greater,

and

if the partial pressure of (H2S) in the gas is greater than

0.0003MPa (0.003 Bar) (0.05psia)"

The acidity of the environment is below pH 3.5, and carbon

dioxide, and chlorides are also normally present

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 Common Corrosion Tests

Corrosion
Tests

HIC SCC-SSC
IGC
(NACE TM (NACE TM
(ASTM A 262)
0284) 0177)

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