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ISSUES TO ADDRESS...
• Why does corrosion occur?
• What metals are most likely to corrode?
• How do temperature and environment affect
corrosion rate?
• How do we suppress corrosion?
1
THE COST OF CORROSION
• Corrosion:
--the destructive electrochemical attack of a material.
--Al Capone's
ship, Sapona,
off the coast
of Bimini.
• Cost:
--4 to 5% of the Gross National Product (GNP)*
--this amounts to just over $400 billion/yr**
2
CORROSION OF ZINC IN ACID
• Two reactions are necessary:
-- oxidation reaction: Zn Zn2 2e
-- reduction reaction: 2H 2e H2 (gas )
reduction 2e - oxidation
2H 2e H2 (gas )
H+
O2 4H 4e 2H2O H+
Acid H+
H+ H+
6
EFFECT OF SOLUTION
CONCENTRATION
• Ex: Cd-Ni cell with • Ex: Cd-Ni cell with
standard 1M solutions non-standard solutions
o o RT X
VNi VCd 0.153 o o
VNi VCd VNi VCd ln
- nF Y
+
n = #e-
per unit
oxid/red
Cd T Ni reaction
(=2 here)
F=
XM YM Faraday's
Cd2+ solution Ni2+ solution constant
• Reduce VNi - VCd by =96,500
C/mol.
--increasing X
--decreasing Y
7
GALVANIC SERIES
• Ranks the reactivity of metals/alloys in seawater
Platinum
Gold
Graphite
Titanium
Silver
316 Stainless Steel
Nickel (passive)
Copper
Nickel (active)
Tin
Lead
316 Stainless Steel
Iron/Steel
Aluminum Alloys
Cadmium
Zinc
Magnesium
8
FORMS OF CORROSION
• Stress corrosion
Stress & corrosion
• Uniform Attack work together • Erosion-corrosion
Oxidation & reduction at crack tips. Break down of passivating
occur uniformly over layer by erosion (pipe
surface. elbows).
• Selective Leaching • Pitting
Preferred corrosion of Downward propagation
one element/constituent of small pits & holes.
(e.g., Zn from brass (Cu-Zn)).
• Intergranular
Corrosion along
grain boundaries, • Galvanic
often where special Dissimilar metals are
• Crevice Between two
phases exist. pieces of the same metal.
physically joined. The
Rivet holes
more anodic one
corrodes.(see Table
17.2) Zn & Mg
very anodic.
9
DETERIORATIVE
• Stress & Saltwater... • Heat treatment: slows
--causes cracks! crack speed in salt water!
4mm
--material:
7150-T651 Al "alloy"
(Zn,Cu,Mg,Zr)
10
Uniform Corrosion: Rust!
Prevention:
• Paint
• Plate
• Sacrificial anode
Galvanic Corrosion
Causes:
Dissimilar metals
Electrolyte
Current Path
Solutions:
Choose metals close in galvanic
series
Have large anode/cathode ratios
Insulate dissimilar metals
Use “Cathodic protection”
Pitting and Creviced
Corrosion
Solutions:
•Change design to minimize or eliminate fluid
turbulence and impingement effects.
•Use other materials that resist erosion
•Remove particulates from fluids
Selective Leaching
• Occurs in alloys in which one
element is preferentially removed –
e.g., in Brass, Zinc is electrically
active and is removed, leaving
behind porous Copper
• Occurs in other metals, such as Al,
Fe, Co, Cr
Solutions:
• Use protective coating to protect surfaces
• Use alternative materials
Stress Corrosion
Adapted
from Fig.
17.14,
Callister
6e.
11
Corrosion prevention
Sacrificial Anode Applied Voltage
Surface coatings & Passivation
12