CORROSION & ITS CONTROL

BY
SURENDRA SINGH Corrosion Control Cell

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Discussion Points
Corrosion Types Corrosion Control Methods Corrosion Testing Methods

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Corrosion C i
Corrosion is defined as the chemical or electrochemical reaction between a metal and its environment resulting in the loss of the mate ial and its p ope ties material properties.

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Ship Corrosion (Marine)

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Corrosion in Machinery (Industrial)

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Electrochemical cell
2+ Anode : 2Fe 2Fe2 + 4e Cathode : O2 + 2H2O + 4e- 4OH-

Net Reaction: 2Fe +02 + H2O Fe2O3 + H2 An electrical connection between anode and cathode A electrolyte An l t l t

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Corrosion Rate
Corrosion rate is defined in two form
Short Duration Test Mils Mil per year = K x W / A x T x D L Long D ti T t Duration Test mm/yr = Thickness loss / time

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Parameter influencing corrosion rate P t i fl i i t

Atmospheric exposure
Humidity Temperature Concentration of salts A Amount of air pollution, acid rain, di t d t etc t f i ll ti id i dirt, dust t pH

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Types of corrosion T f i
Uniform Corrosion Galvanic Corrosion Pitting Corrosion Crevice Corrosion Microbiological Corrosion Corrosion Fatigue Stress Corrosion Cracking Erosion Corrosion Hydrogen Induced g Cracking

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Uniform Corrosion
Uniform corrosion is a form of corrosion in which a metal is attacked at about the same rate over the entire exposed surface. Uniform thickness loss

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Steel ith ill Scale d Rust St l with mill S l and R t

Mill scale is yellow brownish color in nature and it is loosely adherance with the base metal. After further exposure mill scale leads to formation of rust.

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Assessment of Rust

Rust Grade A, as per ISO 8501-1 8501 1

Rust Grade B, as per ISO 8501-1 8501 1

Rust Grade C, as per ISO 8501-1

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Rust Grade D, as per ISO 8501-1 8501 1

Galvanic C G l i Corrosion i
Galvanic corrosion is an electrochemical action of two dissimilar metals in the presence of an electrolyte and an electron conductive path. It occurs when dissimilar metals are in contact with each other.

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Galvanic Series

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Severity of corrosion depends on conductivity of electrolyte and anode-cathode area ratio y

Cathode is more noble than anode and electrolyte with good conductivity Cathode i C th d is more noble than bl th anode and electrolyte with poor conductivity Unfavorable area ratio, Small anode area corrode very rapidly

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Pitting Corrosion
Pitti corrosion is a localized attack on a Pitting i i l li d tt k material. The passive film may be destroyed mechanically or by aggressive ions in an electrolyte y gg y

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 Pitting corrosion occur when the amount of corrosion at one or more points on metal is g g much greater then the average amount of corrosion. Susceptibility of metals to pitting corrosion can be detected by ASTM G48 Standard.

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Crevice Corrosion
It occurs mainly in the y crevices at the junction of two metals exposed in aggressive environment. environment Accelerated attack occurs because of a differential in oxygen concentration.

Susceptibility of matels to crevice corrosion can be detected by standard ASTM G48.

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Intergranular Corrosion
Alloys such as austenitic stainless steel & some alloys, when inadequately heat treated during heat-treated welding results chromium carbide p precipitation over grain boundaries. p g Chromium concentration variation between grain vicinity & grain boundary, which i i i b d hi h initiate corrosion i process.

ASTM No. 7

100X

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 Susceptibility of austenitic stainless steel can be detected by ASTM A262 Prevention

U l Use low carbon content i 304L 316L b i.e 304L, instead of SS304, 316. Use Ti or Nb grade SS such as 321, 347.

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Erosion Corrosion E i C i
The combined action involving corrosion and erosion of metals in the presence of a moving corrosive fluid or a material moving through the fluid, leading to accelerated loss of material The most significant effect of erosioncorrosion is the constant removal of protective film from the metal surface

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Sharp corners creates turbulence, leading to erosion corrosion This corrosion mainly occurs in bends, elbows, valves, pumps, blowers, impellers, nozzle etc.

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Stress Corrosion Cracking

The phenomenon of stress corrosion cracking is defined as the occurrence of microscopic brittle fracture in metal due to the combined action of tensile stress (residual or applied) some applied), specific environment.

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SCC causes premature cracking of metals in certain environments

Copper or Brass Stainless steel Carbon steel Nickel Alloy : Ammonia solutions water vapor solutions, : Seawater, Acid chloride, H2S : Nitrate solutions : Caustic soda or NaOH Solution

Susceptibility of metals to SCC can be detected by ASTM G36/NACE TM0177 y

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Transgranular and i t T l d intergranular SCC l

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Scanning Electron Microscopy Microscop

Transgranular SCC

Intergranular SCC I t l

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Corrosion F ti C i Fatigue
Corrosion fatigue can be defined as a materials failure mechanism which depends on the combined action of repeated cyclic stresses and chemically reactive environment.
Corrosion fatigue is a special case of stress corrosion caused by the combined effects of cyclic stress and corrosion.

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Hydrogen Embrittlement
Hydrogen Embrittlement (HE) causes ductility loss and result in brittle fracture of susceptible materials under applied and residual tensile stresses. Tensile stresses, susceptible T il ibl material, and the presence of hydrogen are necessary t h d to cause hydrogen embrittlement.
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Hydrogen Induced H drogen Ind ced Cracking

The four essential factors for cracking to occur S Susceptible grain tibl i structure: Martensite Hydrogen >15ml/100gm of weld Temperature less than 200oC Stress

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HIC Macrostructure

Prevention of HIC Use low hydrogen welding process Bake heat the welding electrode b f B k or h h ldi l d before welding ldi Preheat the metal to remove moisture Reduce stress by heat treatment

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Microbiological Corrosion Mi bi l i l C i
Microbial corrosion is caused by the presence and activities of microbes microbes. The microbes can be bacteria & fungi.

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Corrosion Control Methods

Better Material Selection Materials inherently resistant to corrosion in certain environments Corrosion Control by design Barrier Protection Li id Paints Liquid P i t Powder Coating Galvanizing (HDG) Cathodic Protection Impressed current Galvanic Sacrificial Anode Use of Inhibitors and Chemical Additives
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Better Material Selection

Use material which is not susceptible of corrosion or p use high chromium content such as Stainless Steel, Nickel alloy instead of carbon steel or mild steel. y Selection process depend on
Expected service life Reliability or safety Material cost Fabrication cost Maintenance and Inspection cost

Test the material prior to its usage as per ASTM / ASME Section II / NACE Standard
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Corrosion Control by design

Liquid trap

Concrete C t Bad Design Bad Design

Good Design

Bad Design

Concrete Good Design Good Design

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Paint Application
It acts as a barrier between the susceptible corrosive metal and the particular environment such as chemical, moisture, sunlight and rain. y y Not so costly method and easily applied on the substrate. Better Aesthetics. High degree of adhesion with the substrate. Sufficient thickness can be applied (greater the thickness better the corrosion resistance).
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Composition of P i t C iti f Paints

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Paint System
Selection of paint to be applied Surface Preparation Mixing and thinning of paint Application technique Primer layer Intermediate layer Top layer Thickness to be achieved

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Type of coating
Lacquers are solutions of natural or synthetic resins (Vinyl chloride, rubber and acrylic) W t emulsion (l t ) C ti Water l i (latex) Coating Oil based Coatings Epoxy Coatings Coal tar Epoxy Coatings Polyurethanes (isocynate and polyol) O Organic Zn rich coating i Z i h ti

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Paint/Coating Test
Sl No. 1 2 3 Abrasion/Erosion UV-Resistant Paint Properties Adhesion Paint Test Cross Cut or Cross Hetch Pull-Off Adhesion Taber Test UV-A (340nm) and UV B UV-B (313nm) Conical Bend Test 4 Flexibility Cylindrical Bend Test y Impact Test 5 Paint continuity Pinhole/Holiday Test Standard
ISO 2409 D 4541 D 4060 D 4587 ASTM D 522 ASTM D 522 D2794 ISO 5162

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Coating system in Enercon WEC components

Component Name Steel Tower Existing Paint System Interzinc 52 Intergard 400 g Interthane 990 (RAL 7038) Intergard 251 Intergard 400 I t d Interthane 990 (RAL 7035) F-93 varnish Resicoat R4-ES HLF 16R Congard200F & Congard 50F Pipcothane MT-300 DACRO-65 Maintenance Paint system Interplus 256 Interthane 990 Shade - RAL 7038 Interplus 256 Interthane 990 I t th Shade - RAL 7035 Interplus 256 Interthane 990 Shade - RAL 7035 Interplus 256 Interthane 990 Shade - RAL 7038

Cast Parts / Stator carrier Stator Ring St t Ri / Disc Rotor

Transformer

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Powder coating
Powder coating is a finishing g g technology where a decorative and highly p g y protective coating g can be applied to a wide range of products. p The process involves spraying finely ground electro-statically ground, electro statically charged particles of pigment and resin onto a surface to be coated.

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Thermoplastic Powder melts and flows to form a film. Continues to have the same chemical composition when it solidifies Will re-melt when heated. Thick coating surface E Examples l
:

Powder Types

Polyethylene PVC Thermosetting: Th tti

Powder melt flow and cross-link chemically to form film. Cured coatings have different chemical composition than the basic resins. i Will not re-melt when reheated Can produce thin paint like coating of 0.001 0.003 inch thick. Examples
Epoxy Acrylic Urethane

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Why powder coating

Superior Appearance p pp Corrosion Resistance Solvent Resistance Highly durable Coating does not drip or sag Ready to use and require no mixing solvents mixing, solvents, or hardners. Less wastage

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Galvanizing (HDG) G l i i
Iron metallurgically reacts with molten zinc and form a tightly bonded inorganic coating. Zinc coating forms an even and uniform thickness applied to edges and flat surfaces. C Corrosion protection mechanism i t ti h i Zn layer acts as barrier coating Zn is more active than steel and corrode first to protect the cathodic area of the p structure.

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Coating thickness of Gal anising Galvanising

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HDG Process

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HDG Coating Inspection

Coating Thickness magnetic gauges, optical microscopy (Micron) Coating Weight weigh-strip-weigh (g/m2, Oz/ft2) Finish and Appearance visual inspection Additional Tests Adherence stout knife Bending bend 180o, diameter = 4Thk

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Service Life of HDG

1mil = 25.4m = 0.56oz/ft2

Coutesy by AGA(USA)

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Cathodic Protection
A technique to control the corrosion of metal surface by making that surface cathode of an electrochemical cell cell. Corrosion Control can be achieved in two ways: 1) Sacrificial Anode 2) Impressed current Cathodic protection is commonly applied on pipelines, pipelines underground storage tanks ships and oil tanks, platforms.
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Sacrificial Anode
Type of sacrificial anodes Zinc, Al, Mg. Used on small structures Anodes welded or bolted to fixtures Need regular checks for wastage

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Impressed Current
Involves the use of an external power source metal to be protected is made cathodic to its surroundings Very costly to run mainly used in marine applications oil rigs large anodes placed approximately 100m away.

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Corrosion Testing Methods

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Crevice corrosion as per ASTM G48

Mainly used to determine resistance of Stainless Steels and related alloys Specimen Size 50mm x 25mm x T mm Test Solution : Ferrric Chloride Test Temperature: 22 2 or 50 2oC Test Duration: 72hrs Measure weight loss after cleaning

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Pitting corrosion as per G48

Mainly used to determine resistance of Stainless Steels and related alloys y Specimen Size 50mm x 25mm x T mm Test Solution : Ferrric Chloride Test Temperature: 22 2 or 50 2o C Test Duration: 72hrs Measure weight loss after cleaning
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Intergranular Corrosion as per ASTM A262

Mainly used to determine resistance of austenitic stainless steel to IGC Extra low carbon grades, and stabilized grades, such as 304L, 316L, 317L, 321, and 347, 347 are tested after sensitizing heat treatments at 650 to 675C for 1hr.

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Practice AOxalic Acid Etch Test A Oxalic

Cutting Polishing Etching Solution
10% Electrolytic oxalic Acid

The etched surface is examined on a metallurgical microscope at 250 X to 500 X X.

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Classification of Etch Structure

Step Structure

Dual Structure

Ditch Structure Dit h St t

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Practice BFerric Sulfate-Sulfuric Acid Test

Specimen Size 25mm x 15mm x T mm T t Solution : F Test S l ti Ferrric S lf t i SulfateSulfuric Acid Test Temperature: Boiling Solution Test Duration: 120hrs Measure weight loss W after cleaning and drying Corrosion rate:
Millimeter per month = 7290 x W / A x t x d

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Practice C Nit i Acid Test P ti CNitric A id T t

Specimen S e 25mm x 15mm x Spec e Size 5 5 T mm Test Solution : 65 0.2 % by y weight Nitric Acid Test Temperature: Boiling Solution Test Duration: 48 x 5 = 240 hrs Measure weight loss W after cleaning and drying Corrosion rate:
Millimeter per month = 7290 x W / A x t x d
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Practice E Copper Copper SulfateECopper-Copper Sulfate Sulfuric Acid Test

Specimen Size 100mm x 15mm x 10 mm Test Solution : Copper-Copper Sulfate-16 %Sulfuric Acid Test Temperature: Boiling Solution Test Duration: Min. 24 Hrs Bend test & Dia : 180O, 4T Observe the bend surface for cracks, fissure etc.
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SCC as per ASTM G36

This test method describes procedure for conducting stress-corrosion cracking tests in a boiling magnesium chloride solution i hl id l i This test method is applied on cast and welded stainless steel material Test Specimen Size: 100mm x 9mm x 3mm Test Solution: Magnesium Chloride Test Temperature: 155 1oC Test Duration: Min. 96hr Max. 500Hrs Periodically observe the specimen for crack initiation using 20X.

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SCC Test as per NACE TM0177

Used to detect suscept b ty o susceptibility of SS to H2S atmosphere. 75-85% UTS is applied to tensile pp specimen Test Duration 720 Hrs Purge H2S gas through inlet tube throughout the test duration Test temperature 90oC and pressure 16bar Report the failure of metal

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Hydrogen Induced Cracking Test as per NACE MR0284

Used to detect pipeline and pressure vessel steel for susceptibility to HIC 3 Specimen of each material of size 100mm x 25mm x T mm Immersed specimen in mixture of 5 wt% NaCl and 0 5% 0.5% CH3COOH. Initial pH 2.7 0.1. Purge H2S gas through inlet tube throughout the test duration g g g g Test duration: 96hrs each specimen ou part and observe o te a cracks Cut eac spec e in four pa t a d obse e for internal c ac s using microscope.

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Salt S S lt Spray Test as per ASTM B117 T t

Widely used corrosion test p yp Test specimen type, size, duration, evaluation method depends on client requirement Test Solution: 5% NaCl Test Chamber Temperature: 35 2oC If bare specimen: Calculate weight loss If Coated specimen: Observe for blistering, rusting.

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Thanks

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