CORROSION of Materials

SCIMATP
August 6, 2011

CORROSION
reduction in performance of component during lifetime the deterioration of materials by chemical interaction with their environment. Also refers to degradation of plastics, concrete and wood, but generally refers to metals.

CORROSION

CORROSION
With focus on upgrading the quality and safety of national roads, DPWH has been provided with budget of P29.7-billion for the rehabilitation and maintenance of national roads and bridges. The amount is 11.8 percent higher than this years P26.5 billion.
Message of His Excellency Benigno S. Aquino III President of the Philippines to The Fifteenth Congress of the Philippines On The National Budget for 2012 [July 26, 2011]

Why do metals corrode?

They are more stable in an ionic state than as metals Essentially, all metals occur in nature as compounds oxides, carbides, carbonates, silicates, sulfides, and sulfates

Chemical Corrosion
Direct dissolution A material dissolves in a corrosive liquid Liquid metal attack Selective leaching Selective dissolution of one particular element in an alloy Dezincification Graphitic Corrosion

Chemical Corrosion
Dezincification
The zinc component of the metal is leached out to leave copper. Deep pitting is initiated and the pipe becomes porous prior to producing an actual leak

http://t2.gstatic.com/images?q=tbn:YFRGRV0xQhQ4 NM:http://www.corrview.com/images/corr_07d.jpg

Graphitic Corrosion Occurs when iron (in gray cast iron) is selectively dissolved in water or soil leaving behind interconnected graphitic flakes and a corrosion product
http://www.andersonmaterials.com/images/metal3.jpg

Electrochemical Corrosion
Occurs when metal atoms lose electrons and become ions Most common form of attack of metals Occurs most frequently in an aqueous medium

Electrochemical Corrosion
Basic principles: Metals in aqueous solutions tend to form ions

OXIDATION (Anodic Reaction)

Electrochemical Corrosion

H+ H2 H+

REDUCTION (Cathodic Reaction)

Electrochemical Corrosion

Electrochemical Corrosion
What happens to the metal ions?
They can simply remain in solution They can react with the electrolyte to form a solid product
This may take the form of a film, which may protect the underlying metal

PASSIVATION

Galvanic Corrosion
Occurs when dissimilar metals are in contact

GALVANIC CELL

+
cathode half-cell Cu+2 + 2e- Cu

1.1 volts

anode half-cell Zn Zn+2 + 2e-

Cu

Zn

1.0 M CuSO4

1.0 M ZnSO4

STANDARD EMF SERIES

metal Au Cu Pb Sn Ni Co Cd Fe Cr Zn Al Mg Na K Vo metal +1.420 V +0.340 - 0.126 - 0.136 - 0.250 - 0.277 - 0.403 - 0.440 - 0.744 - 0.763 - 1.662 - 2.262 - 2.714 - 2.924

Data based on Table 17.1, Callister 6e.

GALVANIC SERIES
Ranks the reactivity of metals/alloys in seawater
Platinum Gold Graphite Titanium Silver 316 Stainless Steel Nickel (passive) Copper Nickel (active) Tin Lead 316 Stainless Steel Iron/Steel Aluminum Alloys Cadmium Zinc Magnesium

Based on Table 17.2, Callister 6e. (Source of Table 17.2 is M.G. Fontana, Corrosion Engineering, 3rd ed., McGraw-Hill Book Company, 1986.)

Corrosion types
Uniform corrosion Oxidation and reduction reactions occur randomly across whole surface Localised corrosion Oxidation reaction concentrated at one area of surface

Crevice Corrosion
Occurs in water when oxygen content varies across component

Crevice Corrosion

Pitting Corrosion
Similar to crevice corrosion Arises from local breakdown in protective oxide film

Protecting Against Corrosion

Isolate metal surface from electrolyte Passivation Paint Inhibit anodic reaction Cathodic protection or Sacrificial protection

Protecting Against Corrosion

Inhibit cathodic reaction Minimize dissolved oxygen Reduce conductivity of electrolyte

Polymer Degradation

 www.nace.org/nace/content/ publicaffairs/images_cocorr/ccsupp.pdf http://www.cmse.ed.ac.uk/MSE3/Topics/MSE206/Lecture%20corrosion.pdf Askeland, Donald (2010) Materials Science and

Engineering http://academic.pgcc.edu/~ssinex/E_cells.ppt http://en.wikipedia.org/wiki/Silver_Bridge