FACULTY OF CHEMICAL AND METALLURGICAL ENGINEERING

METALLURGICAL CHEMISTRY (MCI201T)

NATIONAL DIPLOMA: METALLURGICAL ENGINNERING (S3)

NAME & SURNAME: MOAKI S.MOAKI

STUDENT NUMBER: 209324610
ASSIGNMENT TITLE: CORROSION
SUBMISSION DATE: 17th May 2014
SUPERVISOR: DR.D.J.DELPORT

INTRODUCTION
WHAT IS CORROSION?
Corrosion is defined as the chemical deterioration of a material as a result
of a reaction with its environment.
The material can be metal, ceramic, polymer or composite. The reaction
can be chemical, physical, or electrochemical. As a result of corrosion the
outcome is weight loss of a material but could also be weakening of a
material strength without weight loss. Corrosion of metals happens in a
water-base media and is normally electrochemical.
There are various problems that corrosion can cause in any metallurgical
operations and briefed as follows

Maintenance and operating cost

Plant shutdowns
Contamination of products
Loss of valuable products
Product liability
And effects of safety and reliability

In corrosion principles the cost and corrosion resistance of a material are

usually the most important properties in the Engineering applications
requiring high chemical resistance. Fabricability ease of forming and other
mechanical properties are considered in the principles.
Physical and chemical, electrochemical, thermodynamics and
metallurgical are some of the
factors that affect the corrosion
resistance of any metal.
There are factors that affect the choice of an engineering metal such as
cost, fabricability, corrosion resistant, availability, strength and
appearance.

MECHANISM OF CORROSION
Electro-chemical reactions: water-based media which normally consist of
loaded and neutral specimen which are cations, anions, and dissolved
gases. When a metal is put into contact with an electrolyte a potential
difference exists between the surface of the metal and the electrolyte.
This reaction causes electrons to be removed from the metal and then
ionised.
The are some environmental effects that facilitate corrosion such as
1. Effects of oxygen and oxidizers

2.
3.
4.
5.

Effects of velocity
Effects of temperature
Effects of Corrosive concentration
And of Galvanic coupling.

THERE ARE 8 FORMS OF CORROSION BUT OF INTEREST PITTING CORROSION IS

DISCUSSED.
Pitting Corrosion: it is an example of a non-uniform corrosion resulting from inhomogeneity
in metal due to inclusions, coring, and distorted zones. These inhomogeneities set up
differences of potential at localised spots to cause isolated holes. The pitting ranges from
average large to very micro holes, small holes grow progressively to form cavities into deep
penetration of the surface.
Pits are described in terms of diameter: depth ratio-for a wide pit the ratio > 1and for anarrow
pit the ratio < 1. Pitting is very destructive and causes equipment to fail because of
perforation.
Pitting is an autocatalytic process-that is corrosion process within the pit produce conditions
which are stimulating and necessary for the continuing activity of the pit. The sample below
illustrates a steel bolt that was found at an automotive mechanics work-shop.

FIGURE.1

In most cases the metal can pitted by aerated sodium chloride solution. Some dissolution
occurs in the pit, while oxygen reduction takes place on the adjacent surfaces. The process is
self propagating and self stimulating. The rapid dissolution in the metal tends to produce

excess of positive charge in the affected area, resulting in the migration of chloride ions to
maintain electro neutrality. Both hydrogen and chloride ions stimulate the dissolution of most
metals and alloys and in the process accelerates with time. Oxygen is virtually zero in
concentrated solutions no oxygen reduction occurs in the pit. The cathodic oxygen reduction
on the surfaces adjacent to the pit tends to suppress corrosion. Pits cathodically protect the
rest of the metal surface.

PREVENTETIVE MEASURES OF PITTING

Pitting can be stopped by adding molybdenum in the corroded area.
Application of sol-gel coatings.
Design vessels for complete drainage; avoid sharp corners and stagnant areas.
Inspect equipment and remove deposits frequently.
Weld instead of rolling in tubes in tube sheets.
Use welded butt joint instead of riveted or bolted joints in new equipment.
Coating with zinc.