Corrosion and its prevention

Successful completion of this corrosion course helps participants prepare for their NACE certification examinations at the Corrosion Technician, Corrosion Technologist and Senior Corrosion Technologist levels.

Corrosion and its prevention

Galvanic corrosion Galvanic corrosion of aluminium.

Corrosion Of Metals And Its Prevention | Resistant To Corrosion

A 5-mm-thick aluminium alloy plate is physically and hence, electrically connected to a mm-thick mild steel structural support. Galvanic corrosion occurred on the aluminium plate along the joint with the steel. Perforation of aluminium plate occurred within 2 years.

In a galvanic couplethe more active metal the anode corrodes at an accelerated rate and the more noble metal the cathode corrodes at a slower rate.

Corrosion and its prevention

When immersed separately, each metal corrodes at its own rate. What type of metal s to use is readily determined by following the galvanic series.

For example, zinc is often used as a sacrificial anode for steel structures. Galvanic corrosion is of major interest to the marine industry and also anywhere water containing salts contacts pipes or metal structures. Factors such as relative size of anodetypes of metal, and operating conditions temperaturehumiditysalinityetc.

The surface area ratio of the anode and cathode directly affects the corrosion rates of the materials.

Galvanic Corrosion

Galvanic corrosion is often prevented by the use of sacrificial anodes. Galvanic series In any given environment one standard medium is aerated, room-temperature seawaterone metal will be either more noble or more active than others, based on how strongly its ions are bound to the surface.

Two metals in electrical contact share the same electrons, so that the "tug-of-war" at each surface is analogous to competition for free electrons between the two materials.

Using the electrolyte as a host for the flow of ions in the same direction, the noble metal will take electrons from the active one. The resulting in mass flow or electric current can be measured to establish a hierarchy of materials in the medium of interest.

This hierarchy is called a galvanic series and is useful in predicting and understanding corrosion. Rust removal Often it is possible to chemically remove the products of corrosion.

For example, phosphoric acid in the form of naval jelly is often applied to ferrous tools or surfaces to remove rust.

Corrosion removal should not be confused with electropolishingwhich removes some layers of the underlying metal to make a smooth surface.

Corrosion - Wikipedia

For example, phosphoric acid may also be used to electropolish copper but it does this by removing copper, not the products of copper corrosion.

Resistance to corrosion[ edit ] Some metals are more intrinsically resistant to corrosion than others for some examples, see galvanic series. There are various ways of protecting metals from corrosion oxidation including painting, hot dip galvanizingand combinations of these.

The materials most resistant to corrosion are those for which corrosion is thermodynamically unfavorable. Any corrosion products of gold or platinum tend to decompose spontaneously into pure metal, which is why these elements can be found in metallic form on Earth and have long been valued.

More common "base" metals can only be protected by more temporary means. Some metals have naturally slow reaction kineticseven though their corrosion is thermodynamically favorable.

These include such metals as zincmagnesiumand cadmium. While corrosion of these metals is continuous and ongoing, it happens at an acceptably slow rate. An extreme example is graphitewhich releases large amounts of energy upon oxidationbut has such slow kinetics that it is effectively immune to electrochemical corrosion under normal conditions.

The chemical composition and microstructure of a passive film are different from the underlying metal.

Corrosion and its prevention

Typical passive film thickness on aluminium, stainless steels, and alloys is within 10 nanometers. The passive film is different from oxide layers that are formed upon heating and are in the micrometer thickness range — the passive film recovers if removed or damaged whereas the oxide layer does not.

Passivation in natural environments such as air, water and soil at moderate pH is seen in such materials as aluminiumstainless steeltitaniumand silicon. Passivation is primarily determined by metallurgical and environmental factors.

The effect of pH is summarized using Pourbaix diagramsbut many other factors are influential. Some conditions that inhibit passivation include high pH for aluminium and zinc, low pH or the presence of chloride ions for stainless steel, high temperature for titanium in which case the oxide dissolves into the metal, rather than the electrolyte and fluoride ions for silicon.

On the other hand, unusual conditions may result in passivation of materials that are normally unprotected, as the alkaline environment of concrete does for steel rebar. Exposure to a liquid metal such as mercury or hot solder can often circumvent passivation mechanisms.

Corrosion in passivated materials[ edit ] Passivation is extremely useful in mitigating corrosion damage, however even a high-quality alloy will corrode if its ability to form a passivating film is hindered. Proper selection of the right grade of material for the specific environment is important for the long-lasting performance of this group of Corrosion Prevention by Protective Coatings (2nd Edition) (): C.

What is Corrosion?

G. Munger: Books. The following is a brief summary of corrosion prevention tactics for metal boats. Primarily these strategies are aimed at the boat building process, at which time one has the very best opportunity to create a hassle free, low lifetime maintenance situation for any metal vessel.

Vigilance and good. Comprehensive Corrosion Test: 46 Products Compared. By: DIY_guy. We all want to use goods quality products on our guns, bows, fishing gear, knives, autos, hunting and lake front gear and like you I’m not a fan of letting things get rust on them nor am I a fan of items wearing out prematurely.

Course Overview. This 5-day basic corrosion course covers fundamental aspects of corrosion control and its prevention.

The course will enable beginners to establish a solid foundation in corrosion before moving on to advanced topics. 5. Intergranular Corrosion - all austentic stainless steels contain a small amount of carbon. At extremely high temperature, such as welding, the carbon forces local chrome to form chromium carbide around it, thus starving adjacent areas of the chrome it needs for its own corrosion welding, it is recommended you consider low .


Corrosion is a galvanic process by which metals deteriorate through oxidation—usually but not always to their oxides. For example, when exposed to air, iron rusts, silver tarnishes, and copper and brass acquire a bluish-green surface called a patina.

Of the various metals subject to corrosion, iron is by far the most important commercially.

Corrosion Prevention - Kasten Marine Design