Corrosion

Paint School
1

Definition of Corrosion
Corrosion is a reaction between Material and Surrounding environment under formation of corrosion products

Paint School
2

Production and degradation of steel

Reaction between the material and the surrounding environment takes place

Plates, pipes, profiles, etc.

Raw material Iron ore

Rust

The presence of water / humidity and Oxygen is a pre-requisite for corrosion of steel
Paint School
3

Manufacturing / Refining Brings the Material to a Higher Energy Level

Oxidation of metals is a natural process

The resistance to the oxidation (corrosion) varies for different materials When brought in contact with an electrolyte (aqueous solution that conducts electricity) some metals easily dissolve into ions. These are called Base metals Noble metals have a very strong resistance to corrosion and do not react to form ions unless exposed to very aggressive chemicals

Paint School
4

Galvanic potentials in seawater

Paint School
5

Pre-requisites for corrosion

A galvanic cell consists of:

A Cathode: The noble metal / alloy (or part of metal) An Anode: The less noble metal / alloy An electrical connection between the two metals. Conducting electrical current (by electrons) An electrolyte: Conducting electrical current (by ions)

Paint School
6

A galvanic cell
2e-

Cathode: Steel
O2

Zn = Zn + 2 e

2+

Anode: Zinc

- 2OH O2 + H2 O + 2e - =

In seawater, a calcareous deposit is formed on the steel surface

Paint School
7

How fast will a metal corrode ?

The speed of a corrosion process depends on:

The properties of the material The surrounding environment

Paint School
8

Some environments are more aggressive than others.

Steel will corrode at different

rates when exposed to dissimilar environments, such as seawater and fresh water Seawater is more aggressive than fresh water and will give a higher corrosion velocity

CP and corrosion: Corrosivity_liquid1

Paint School
9

Corrosion speed differ when exposed to the same environment

In a strong alcaline environment Aluminium and Zinc will corrode rapidly, while steel will be passive
Aluminium Zink Steel

Protective Iron oxide

pH > 10

Paint School
10

What kind of information can be obtained from the galvanic series ?

The difference in Galvanic Potential will tell which of the two materials that will corrode when connected

The metal with the more negative potential will corrode The metal with the more positive potential will be protected
Corrosion speed depends on the difference in potential between the metals

The greater the potential difference, the greater the corrosion.

Rule of thumb: A potential difference less than
50 mV will cause no additional corrosion
Paint School
11

Steel in Seawater
Potential versus Zinc & Ag/Ag Cl ref. electrodes
Ag / Ag Cl

Potentials in volt
Rapid corrosion

Zinc

Cu / CuSO4

- 0.55

+ 0.50

- 0.60

General corrosion
- 0.80

Some corrosion
100% Cathodic protection

+ 0.25

- 0.85

-1.05

Increasing polarisation

+ 0.0

-1.10

- 1.30

Overprotection
Possible coating damage

- 0.25

- 1.35

Paint School
12

How to measure the corrosion potential of a structure

Volt meter Structure

Sea water
Paint School
13

Reference electrode

How to measure the corrosion potential of a structure

+

Paint School
14

Elements influencing the corrosion speed of metals

Submerged materials

Temperature Salinity Oxygen content Water velocity Acidity (See below) Type of electrolyte ( e.g. cargo or chemicals) Content of contaminants / pollution that
promotes corrosion Micro-organisms.
Paint School
15

The pH of the solution will affect the corrosion speed

Steel Corrosion increases at lower pH. (Acidic solutions, pH 6 lower) Strong alcaline solutions prevent corrosion (pH 10 higher) Zinc and Aluminium Slow corrosion at close to neutral solutions Heavy corrosion in acidic and alcaline solutions

Paint School
16

pH-scale
Acidic

Neutral

Alcaline

Paint School
17

Parametres influencing the corrosion speed. Atmospheric corrosion

Humidity Temperature Concentration of salts Amount of air pollution,
including acid rain, soot and dust particles

Paint School
18

Atmospheric corrosion corrosion rate depends on humidity

Corrosion rate

0
Paint School
19

20

40

60

80

100

Relative Humidity, %

General corrosion
General corrosion is uniform by nature Still, deep pits or uneven areas are found

CD 0026-001

CD 4911-0004

Paint School
20

Uniform corrosion
A steel surface consists of noble and less noble areas This can be looked upon as small galvanic cells The anodic parts will corrode
Rust
-

+ + -

+ -

+
+

+ + +

Paint School
21

Types of corrosion
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.
Paint School
22

Uniform corrosion Galvanic corrosion Selective (preferential) corrosion Pitting corrosion Crevice corrosion Micro biological corrosion (bacteria) Corrosion fatigue Stress corrosion cracking Erosion corrosion Cavitation Stray current corrosion

Apart from using paint and CP: How to protect against corrosion ?
Corrosion protection can be achieved in many ways

Good design Avoid corrosion traps Improved accessibility - maintenance Proper materials selection Insulate between dissimilar materials Change the surrounding environment Remove water / humidity Apply metallic coatings Use corrosion inhibitors (closed systems)
Paint School
23