UNIT-I Corr

UNIT-I
INTRODUCTION AND CORROSION PRINCIPLES
Definition of Corrosion
 Corrosion can be viewed as a universal phenomenon, omnipresent and omnipotent. It is there

everywhere, air, water, soil and in every environment, we encounter
 Corrosion is the deterioration or destruction of metals and alloys in the presence of an environment
by chemical or electrochemical means.
 In simple terminology, corrosion processes involve reaction of metals with environmental species.
 As per IUPAC, “Corrosion is an irreversible interfacial reaction of a material (metal, ceramic, polymer)
with its environment which results in its consumption or dissolution into the material of a
component of the environment.
 With the knowledge of the role of various microorganisms present in soil and water bodies, the
definition for corrosion need be further widened to include microbiallyinfluenced factors.
Industry and corrosion.
1 2
IUPAC defines corrosion as follows "An irreversible interfacial This process is often considered as inevitable with materials
reaction of a material (metal, ceramic, polymer) with its especially in regard to metals and alloys.
environment which results in consumption of the material or in
dissolution into the material of a component of the
environment."
Pictorial representation of corrosion
Most common form of metal corrosion

Activity of surface: When a metal
surface is polished, it becomes Activity of electrolyte: When two
activated or in other word , surface dissimilar metals are made to
contact in presence of The former is termed as Dry
atoms get excited .These excited
electrolyte(may also be an specific corrosion while the later is called as
atoms loves to combine with the
environment), due to difference in wet corrosion.
atmospheric electrophiles to form a
stable octet. electrode potential between to
metals, a cell reaction is induced
causing deterioration of anodic
surface.
IMPORTANCE OF CORROSION
 The three main reasons for the importance of corrosion are: economics, safety,
and conservation.
 To reduce the economic impact of corrosion, corrosion engineers,

with the support of corrosion scientists, aim to reduce material losses, as
well as the accompanying economic losses, that result from the corrosion of
piping, tanks, metal components of machines, ships, bridges, marine structures,
and so on.
 Corrosion can compromise the safety of operating equipment by

causing failure (with catastrophic consequences) of, for example, pressure vessels,
boilers, metallic containers for toxic chemicals, turbine blades and rotors, bridges,
airplane components, and automotive steering mechanism
 Safety is a critical consideration in the design of equipment for nuclear power plants and for
disposal of nuclear wastes. Loss of metal by corrosion is a waste not only of the
metal, but also of the energy, the water, and the human effort
 In addition, rebuilding corroded equipment requires further investment of all these resources —
metal, energy, water, and human.
 Economic losses are divided into (1) direct losses and (2) indirect losses
 Direct losses include the costs of replacing corroded structures and machinery
or their components, such as condenser tubes, mufflers, pipelines, and metal
roofing, including necessary labour.
 Other examples are (a) repainting structures where prevention of rusting is the prime objective and (b) the capital
costs plus maintenance of cathodic protection systems for underground pipelines.
Sizable direct losses are illustrated by the necessity to replace several million domestic
replacement of millions of corroded automobile mufflers.
 Direct losses include the extra cost of using corrosion - resistant metals and alloys instead of carbon
steel where the latter has adequate mechanical properties but not sufficient corrosion
resistance; there are also the costs of galvanizing or nickel plating of steel,
of adding corrosion inhibitors to water, and of dehumidifying storage rooms for
metal equipment.
 The economic factor is a very important motivation for much of the current
research in corrosion. Losses sustained by industry and by governments amount
to many billions of dollars annually
Scope of Corrosion Engineering
 Engineering metallurgy
 Electrochemistry
 Corrosion Science / Principles of Corrosion
 Environmental corrosion : atmospheric, fresh water, brackish water, sea water,
soils, industrial environments, boiler water corrosion, electronic contacts, museum conservation, monuments,
microbiologically induced corrosion
 Organic coatings and linings
 Concrete weight coatings
 Intumescent coatings
 Phosphating
 Paint chemistry & formulation
 Environmental and planning law.
 Tort
 Marketing.
 Behavioural sciences &:Team Building
 Corporate finance & Tax
 Specialised corrosion : localised corrosion, fretting, flow induced corrosion.
 Corrosion monitoring & Standards
 Materials selection
 Corrosion of non-metallics : concrete, ceramics, glass, polymers, natural building stones
 High temperature corrosion
 Metallic coatings
 Cathodic protection
 Anodic protection
 Corrosion in the process industries : oil and gas, pulp & paper, power industry, chemical industry.
 Corrosion in shipping, aircraft, bridges, buildings, automobiles, masts & towers
What to do with industry
• Almost all industries deal with metals as their primary raw material in product
manufacturing Which leaves corrosion and its control in evitable.
• An automobile intended for dynamic loads and exposure to drastic environment
leaves the metal in it in a homicidal situation.
• In an civil construction of SRC , Steel is made into contact with slurry of aqueous
cemeteries material as binder, where corrosion is inevitable.
• In an Nuclear reactor coolant pipes , even the modern one using liquid sodium as
coolant, is made to flow via pipes of alloys only. In such a situation where both
radioactive environment along with strong alkaline media (flowing through it) and
sub zero temperature, Corrosion brings the hell out of one.
• Similarly almost all industry operating in world faces corrosion.
Cost of corrosion
 Losses sustained by industry and by governments amount

to many billions of dollars annually, approximately $ 276 billion in the United
States, or 3.1% of the Gross Domestic Product (GDP), according to a recent
study .
 It has been estimated that about 25 – 30% of this total could be avoided
if currently available corrosion technology were effectively applied .
 Studies of the cost of corrosion to Australia, Great Britain, Japan, and other
countries have also been carried out. In each country studied, the cost of corrosion
is approximately 3 – 4 % of the Gross National Product
 Indirect losses are more difficult to assess, but a brief survey of typical losses
of this kind compels the conclusion that they add several billion dollars to the
direct losses already outlined
 There is no single figure for loss to the nation due to corrosion. It can be a minimum of 3.5% of the nation‟s GDP.
 Losses due to corrosion could be around Rs. 2.0 lakh crores per annum in India.
 Corrosion costs manifest in the form of premature deterioration or failure necessitating maintenance,
repairs and replacement of damaged parts.
 In the US, total direct cost of corrosion is estimated at about 300 billion dollars per year;
which is about 3.2% of domestic product.
 The replacement of a corroded tube in an oil refi nery may cost

a few hundred dollars, but shutdown of the unit while repairs are underway
may cost $ 50,000 or more per hour in lost production
 Corrosion processes can impose limits on the effi ciencies of energy

conversion systems, representing losses that may amount to billions of
dollars.
 Contamination of Product. A small amount of copper picked up by slight

corrosion of copper piping or of brass equipment that is otherwise durable may damage an entire batch
 Corrosion can be classified in different ways, such as
 Chemical and electrochemical

 High temperature and low temperature
 Wet corrosion and dry corrosion.
The most important types are
 Uniform corrosion.
 Galvanic corrosion,
 concentration cells, water line attack Pitting.
 Dezincification, Dealloying (selective leaching)
 Atmospheric corrosion.
 Erosion corrosion
 Fretting
 Crevice corrosion;
 cavitation,
 Stress corrosion, intergranular and transgranular corrosion,
hydrogen cracking and embrittlement
 Corrosion fatigue.

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UNIT-I

INTRODUCTION AND CORROSION PRINCIPLES

 Corrosion can be viewed as a universal phenomenon, omnipresent and omnipotent. It is there

Most common form of metal corrosion

 To reduce the economic impact of corrosion, corrosion engineers,

 Corrosion can compromise the safety of operating equipment by

 Losses sustained by industry and by governments amount

 The replacement of a corroded tube in an oil refi nery may cost

 Corrosion processes can impose limits on the effi ciencies of energy

 Contamination of Product. A small amount of copper picked up by slight

 Chemical and electrochemical

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