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Uniform Corrosion
Uniform Corrosion
This one is common in steel that is unprotected by any
surface coating. Most noticeable. Surface effect,
leaving rust on the surface.
The good thing about this, if there is one, is that the
corrosion is widely spread around.
Uniform Corrosion
Corrosion over the entire
exposed surface at a
uniform rate. e.g..
Atmospheric corrosion.
Maximum metal loss by
this form.
Not dangerous, rate can be
measured in the laboratory.
Uniform Corrosion
EXAMPLES:
1.rusting of iron 2.tarnishing
of silver 3.Fogging of nickel
4.high - temperature
oxidation of metals
C.
:Galvanic Corrosion
Possibility when two dissimilar metals are electrically
connected in an electrolyte*
Results from a difference in oxidation potentials of metallic
ions between two or more metals. The greater the
difference in oxidation potential, the greater the galvanic
corrosion.
Refer to Galvanic Series
The less noble metal will corrode (i.e. will act as the anode)
and the more noble metal will not corrode (acts as cathode).
Perhaps the best known of all corrosion types is galvanic
corrosion, which occurs at the contact point of two metals
or alloys with different electrode potentials.
Galvanic Corrosion
When two dissimilar metals are
joined together and exposed, the
more active of the two metals
corrode faster and the nobler
metal is protected. This excess
corrosion is due to the galvanic
current generated at the junction
Fig. Al sheets covering
underground Cu cables
Galvanic Series:
Questions:
1. Worst combination?
2. Aluminum and steel?
3. Titanium and Zinc?
4. Stainless Steel and
Copper?
GALVANIC SERIES
Mercury
Platinum
Gold
Zirconium Graphite
Titanium
Hastelloy C Monel
Stainless Steel (316-passive)
Stainless Steel (304-passive)
Stainless Steel (400-passive)
Nickel (passive oxide)
Silver
Hastelloy 62Ni, 17Cr
Silver solder
Inconel 61Ni, 17Cr
Aluminum (passive AI203)
70/30 copper-nickel
90/10 copper-nickel
Bronze (copper/tin)
Copper
Brass (copper/zinc)
Alum Bronze Admiralty Brass
Nickel
Naval Brass Tin
Lead-tin
Lead
Hastelloy A
Stainless Steel (active)
316 404 430 410
Lead Tin Solder
Cast iron
Low-carbon steel (mild steel)
Manganese Uranium
Aluminum Alloys
Cadmium
Aluminum Zinc
Beryllium
Magnesium
ACTIVE: will
corrode act as
anode. These
elements most likely
to give up electrons!
Note, positions of
SS and Al
Galvanic Corrosion
Galvanic Corosion
Dissimilar metals are physically
joined in the presence of an
electrolyte.
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Galvanic Corrosion
Steel screw in Mg
Dissimilar metals, the damage occurs
.at the anode
Eliminate electrolyte
Galvanic of anodic protection
Pitting
It is based on low oxygen concentration at the bottom of the pit.
This is very common in materials that protect themselves with a
passive layer, i.e. stainless steel and aluminum.
Pitting
A form of extremely localized
attack causing holes in the
metal
Most destructive form
Autocatalytic nature
Difficult to detect and measure
Mechanism
Pitting
Pitting is a localized form of corrosive
attack. Pitting corrosion is typified by the
formation of holes or pits on the metal
surface. Pitting can cause failure, yet the
total corrosion, as measured by weight loss,
may be minimal.
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Pitting
Intergranular Corrosion
Again, stainless steel is the ideal victim here. The
problem is triggered by improper heating, and often
this comes with welding. Carbides of chromium form
in the grain boundary regions.
The chromium is tied up in the carbides. It cant
protect by forming the passive layer.
PLUS, there is a dissimilarity in metals producing a
small but definite galvanic corrosion.
Intergranular Corrosion
Corrosion which occurs preferentially at grain
boundries.
Why at grain boundries?
Higher energy areas which may be more anodic
than the grains.
Intergranular Corrosion
The grain boundaries in
metals are more active than
the grains because of
segregation of impurities
and depletion of protective
elements. So preferential
attack along grain
boundaries occurs. e.g.
weld decay in stainless
steels
Intergranular Corrosion
How to recognize it?
Near surface
Corrosion only at grain boundries
Corrosion normally at uniform depth for all grains.
Intergranular corrosion
Corrosion along
grain boundaries,
often where precipitate
particles form.
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Intergranular Corrosion
Example2:Intergranular Corrosion
Exfoliation corrosion in Aluminum that has been
heavily worked, such as in extrusion.
Corrosion products start to build up in between the
long elongated grains, separating them and lead in to
increased corrosion propagation through the metal.
Intergranular Corrosion
CREVICE CORROSION
Intensive localized
corrosion within
crevices & shielded
areas on metal surfaces
Small volumes of
stagnant corrosive
caused by holes,
gaskets, surface
deposits, lap joints
Crevice Corrosion
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Crevice Corrosion
Crevice Corrosion
Erosion Corrosion
This is caused by the impingement of a high velocity turbulent
flow on a surface.
The flow is often multi-phase. This means there can be entrained
solid particles, or even gas bubbles, as in cavitation of a propeller.
The flow will carry away any protective layer that was intended to
protect the material, and even abrade the flow surface.
Erosion-corrosion
Combined chemical attack and
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mechanical wear
(e.g., pipe elbows)
Cavitation Damage
Cavitation is a special case of
Erosion-corrosion.
In high velocity systems, local
pressure reductions create
water vapour bubbles which
get attached to the metal
surface and burst at increased
pressure, causing metal
damage.
Cavitation Erosion
Impingement Attack
:Dealloying
When one element in an alloy is anodic to the other
element.
Example: Removal of zinc from brass (called
dezincification) leaves spongy, weak brass.
Brass alloy of zinc and copper, and zinc is anodic to
copper (see galvanic series).
Dealloying
Two common types:
Dezincification: preferential removal of zinc in brass
Try to limit Zinc to 15% or less and add 1% tin.
Cathodic protection
Dealloying
Dealloying
Preferred corrosion of
one element/constituent
[e.g., Zn from brass (Cu-Zn)].
Dezincification.
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Dealloying
Alloys exposed to
corrosives experience
selective leaching out of
the more active
constituent. e.g.
Dezincification of
brass.
Loss of structural
stability and
mechanical strength
:Dealloying
Danger!
The alloy may not appear damaged
May be no dimensional variations
Material generally becomes weak hidden to inspection!
Fretting Corrosion