Materials Under Stress

Materials Under Stress
5MEC342 – LECTURE 10
Corrosion & Associated
Degradation
 Corrosion process
 Environmental factors
 Common forms of corrosion
 Methods of corrosion control and prevention
Metal Corrosion
 “the destruction of a material by chemical or electrochemical

reaction to its environment”
 typically, a transfer of electrons from one metal to another
through an Oxidation-Reduction Reaction.
Oxidation - Reduction Reduction
 Anodic metal gives up electrons

+2 −
(oxidation) Fe → Fe + 2 e
Al → Al +3 + 3e −
 Cathodic metal accepts

electrons (reduction)
Cu 2 + + 2e − → Cu
 Or gases accept electrons

(reduction) 2 H + + 2e − → H2 ( gas)
Corrosion Mechanism
 Cathodic cell
 discussion of emf
 galvanic series
 intergranular corrosion
 oxidation-reduction of iron
 salt effects
Slides on Impact of Corrosion
 Aluminum corrosion
 Pitting
 Crevice corrosion
 Contaminants
 Environments
Basics of Corrosion
 EMF series is a numeric rating of potential under ideal conditions

 Galvanic Series is a practical listing
 Galvanic Protection
Steel Corrosion
Initial Oxidation Reaction
2 Fe + O2 + 2 H2 O → 2 Fe ( OH ) 2
Secondary Oxidation Reaction
1
2 Fe(OH ) 2 + O2 + H2 O → 2 Fe(OH ) 3
2
Rust
Corrosion potential calculation
 Reduction Reaction must have higher potential than the oxidation

reaction or they will not form a cathodic cell
Fe +2 + 2e − → Fe -0.440 V
Zn +2 + 2e − → Zn -0.763 V
V = −.440 − ( −.763) = +0.323V

Relative measure of
corrosion
Acceleration of Corrosion
 Physical Characteristics
 exposed area (less, increases corrosion rate)
 time of exposure (more time, more corrosion)
 Environmental Characteristics
 acidic environment
 sulfur gas environment
 temperature (high temps, more corrosion)
 moisture (oxygenated moisture)
Passivation
 A protective film in oxidizing atmospheres

 chromium,nickel, titanium, aluminum
 Metal oxide layer adheres to parent metal
 barrieragainst further damage
 self-healing if scratched
 Sensitive to environmental conditions

 passivated metal may have high corrosion rates
Forms of Corrosion
 Uniform corrosion of a single metal

 usually an electrochemical reaction at granular level
 relatively slow and predictable
 rusting of exposed steel, tarnished silver
 easily corrected with coatings and regular maintenance
Forms of Corrosion
 Galvanic Corrosion
 2 dissimilar metals, electrolyte, electrical connection and oxygen
 Pitting Corrosion
 Localized corrosion forming holes or indentations
 Difficult to initially detect
Forms of Corrosion
 Crevice Corrosion
 narrow crevice filled with ionized solution
 Oxygen-rich on the outside, oxygen-poor on the inside
 metals oxidize with salt anions FeCl2 and pH rises in cathodic zone
 H+ may destroy passivity
Forms of Corrosion
 Intergranular Corrosion
 corrosion along grain boundaries at microscopic level
 stainless steels and heat treated high-strength steels
 carbides precipitate along grain boundaries leaving these areas with no alloyed
Chromium
 Welds can have this same depletion effect
Forms of Corrosion
 Cavitation and Erosion in Pipe

 particulate matter
 turbulent flow
 abrades away the corrosion product
 abrasion of zinc coatings
Forms of Corrosion
 Stress Corrosion Cracking

 tensile stress and corrosive environments
 cracks are initiated at corrosion areas
 tensile stresses propagate the crack
 corrosion further deteriorate crack
 etc.....
Reinforcement Corrosion
Corrosion Products
 Fe + 2OH = Fe(OH)2  Passivity barrier

breaks down
 Oxidation of Fe(OH)2  Presence of
Oxygen
 Fe(OH)3 (rust)
 Moisture
Corrosion of Metals in Concrete
Reinforcing Steel & Prestressing Steel
 Concrete is Normally Highly Alkaline

 Protects Steel from Rusting if Properly Embedded
 If Corrosion Occurs, the Reaction Products are
Greater in Volume Than the Original Steel
 Corrosion Initiation and Rate Depends On
 Amount of Concrete Cover, Quality of Concrete
 Details of Construction, & Exposure to Chlorides
Avoiding Corrosive Situations
 Choose couple metals close on the galvanic

series
 Use large anode, and small cathode areas
 Electrically insulate dissimilar metals
 Connect a more anodic metal to the system
 Avoid turbulent flow and impingements in pipe
systems
Examples of Corrosion in CE
 Steel strapping or
iron nails with
copper pipe is ok,
but they may rust
with time.
 Never use Copper
strapping or
attachments with
condensation on the bottom steel pipe, steel
of cold-water pipe pipe will corrode
Corrosion Prevention
 Coatings  Active Cathodic

 Barrier films Protection
 Inhibitive Pigments
 Sacrificial treatments
 Paint

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 “the destruction of a material by chemical or electrochemical

 Anodic metal gives up electrons

 Cathodic metal accepts

 Or gases accept electrons

 EMF series is a numeric rating of potential under ideal conditions

 Reduction Reaction must have higher potential than the oxidation

V = −.440 − ( −.763) = +0.323V

 A protective film in oxidizing atmospheres

 Sensitive to environmental conditions

 Uniform corrosion of a single metal

 Cavitation and Erosion in Pipe

 Stress Corrosion Cracking

 Fe + 2OH = Fe(OH)2  Passivity barrier

 Concrete is Normally Highly Alkaline

 Choose couple metals close on the galvanic

 Coatings  Active Cathodic

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