Department of Chemical Engineering

University of Engineering & Technology, Lahore

Muhammad Sulaiman
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Muhammad Sulaiman
Most materials experience some type of interaction with a
large number of diverse environments.
This interaction results in the deterioration of their material
properties including:

1. Mechanical Properties (ductility, strength)

2. Material Appearance

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Defined as the destructive and unintentional attack of a metal
resulting in a slow or continuous eating away of metallic and
non-metallic components by chemical or electrochemical
attack”.
Metals: In metals, there is actual material loss either by
dissolution (corrosion).
Ceramics: Ceramic materials are relatively resistant to
deterioration, which usually occurs at elevated temperatures
or in rather extreme environments; the process is frequently
also called corrosion.
Polymers: For polymers, mechanisms and consequences
differ from those for metals and ceramics, and the term
degradation is most frequently used.
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For metallic materials, the corrosion process is normally
electrochemical, that is, A chemical reaction in which
there is transfer of electrons from one chemical species
to another.
Metal atoms characteristically lose or give up electrons
in what is called an oxidation reaction.
For example, the hypothetical metal M that has a valence of
n (or n valence electrons) may experience oxidation
according to the following reaction:

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The site at which oxidation takes place is called the anode;
oxidation is sometimes called an anodic reaction.

The electrons generated from each metal atom that is

oxidized must be transferred to and become a part of another
chemical species in what is termed a reduction reaction. For
example, some metals undergo corrosion in acid solutions,
which have a high concentration of hydrogen (H) ions; the H
ions are reduced as follows and hydrogen gas (H2) is
evolved.

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The location at which reduction occurs is called the cathode.
An overall electrochemical reaction must consist of at least
one oxidation and one reduction reaction, and will be the sum
of them; often the individual oxidation and reduction
reactions are termed half-reactions.

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1. Dry corrosion

2. Wet corrosion

3. Galvanic corrosion

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 Dry Corrosion

Direct oxidation of metals OR Corrosion due to atmospheric

gases.
Freshly cut surface reacts with the oxygen(no moisture or
water to aid the corrosion.
Wet Corrosion
Oxidation in the presence of air and moisture.
Rusting of ferrous metals
Involving oxidation and reduction process.

Galvanic Corrosion

Occurs when two metals or alloys having different compositions

are electrically coupled while exposed to an electrolyte. Here
one metal acts as Anode and the other one acts as Cathode. The
Anode metal will be active in a particular series and the Cathode
metal will be acting as a noble metal.
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 Passive
Active Component
Component (Cathodic)
(Anodic)

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The less noble or more reactive metal in the particular
environment will experience corrosion;
The more inert metal, the cathode, will be protected from
corrosion.
When galvanic couple is formed, one of the metal in the
couple becomes anode and corrodes faster than it would
alone, while other become cathode and corrodes slower
than it would alone.
The electrolyte is provided in the form of rain, dew, humidity,
or chemicals.

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GALVANIC CORROSION
Galvanizing
In the case of galvanized iron (zinc-coated mild steel),
steel base acts as cathode and zinc coating as anode.
The zinc corrodes away whilst protecting the steel.
This is termed as “SACRIFICIAL CORROSION”.

Galvanic Corrosion-Prevention
 If coupling of dissimilar metals is necessary, choose two that
are close together in the galvanic series.
 Avoid an unfavorable anode-to-cathode surface area ratio;
use an anode area as large as possible.
 Electrically insulate dissimilar metals from each other.
 Electrically connect a third, anodic metal to the other two;
this is a form of cathodic protection, discussed presently.
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Hydrogen Embrittlement
Loss in ductility of a material in the presence of hydrogen is known as
hydrogen embrittlement.
 This type of corrosion occurs when a metal is exposed to hydrogen
environment. Iron liberates atomic hydrogen with hydrogen sulphide in
the following way.
Fe + H2S → FeS + 2H
 Hydrogen diffuses into the metal matrix in this atomic form and gets
collected in the voids present inside the metal. Further, diffusion of
atomic hydrogen makes them combine with each other and forms
hydrogen gas.
H + H → H2↑
 Collection of these gases in the voids develops very high pressure,
causing cracking or blistering of metal.
 Hydrogen embrittlement is similar to stress corrosion.

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It arises from the combined action of chemical attack and
mechanical abrasion/wear as a consequence of fluid
motion.
The nature of the fluid can have influence on the corrosion
behavior. Increasing fluid velocity normally enhances the rate
of corrosion. Also, a solution is more erosive when bubbles
and suspended particulate solids are present.
Erosion–corrosion is commonly found in piping, especially at
bends, elbows, and abrupt changes in pipe diameter-
positions where the fluid changes direction or flow suddenly
becomes turbulent.
Propellers, turbine blades, valves, and pumps are also
susceptible
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Elbow fitting that was part of a steam condensate line
under Erosion Corrosion.

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Change the design to eliminate fluid turbulence.
Other materials/coatings may also be utilized that
inherently resist erosion.
Removal of particulates and bubbles from the solution will
less its ability to erode.

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It results from the combined action of an applied tensile
stress and a corrosive environment.
Small cracks form and then propagate in a direction
perpendicular to the stress, with the result that failure may
eventually occur.
Most alloys are susceptible to stress corrosion in specific
environments, especially at moderate stress levels.
Probably the best measure to take in reducing or totally
eliminating stress corrosion is to lower the magnitude of the
stress.
For example, most stainless steels stress corrode in solutions
containing chloride ions, whereas brasses are especially
vulnerable when exposed to ammonia.

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Corrosion promoted by microorganisms.

It can apply to both metals and non-metallic materials, in

both the presence and lack of oxygen.
Sulfate-reducing bacteria are common in lack of oxygen;
they produce hydrogen sulfide, causing sulfide stress
cracking.
In presence of oxygen, some bacteria directly oxidize iron
to iron oxides and hydroxides.

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CORROSION FURTHER TYPES
Uniform Corrosion
 Corrosion that occur at the same rate over the exposed metal
surface.
Pitting corrosion
 Corrosion by which cavities are produced in the material.
 Chloride ions(liquid) are damaging to the passive films and can
make pit formation auto-catalytic.
 The area covered by the drop of salt solution acts as anode.
Crevice Corrosion
 Corrosion occurred in the crevice between two joining surface.
 Accumulation of liquid(chlorides) inside crevice will aggravate
damage.
 The crevice becomes anodic region and undergoes corrosion
 Bolts, nuts, rivets, joints are examples for this type of corrosion.

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