Case study 1: corrosion and surface coating

Corrosion and surface coating Outline

1) Corrosion
y y y y y Definition Corrosion conditions Causes Various forms Methods of corrosion protection

2) Surface coatings 3) Various surface coatings or treatments and their benefits. 4) Case study : corrosion in the underground pipelines and its prevention by surface coating
y Effects of corrosion in underlying pipelines y Corrosion detection in underlying pipe y Prevention of the pipe from corrosion by surface coating

5) Conclusion 6) References

Corrosion
Corrosion of a metal is a chemical or an electrochemical process in which surface atoms of a solid metal react with a substance in contact with the exposed surface. Usually the corroding medium is a liquid substance, but gases and even solids can also act as corroding media. All structural metals corrode in natural environment such as the atmosphere, soil , waters.

 Corrosive conditions y water: water can readily dissolve a high amount of oxygen from the atmosphere thus becomes corrosive. When the free oxygen from the water is removed the water becomes noncorrosive unless it becomes acidic or anaerobic incited corrosion. If oxygen free water is maintained at neutral PH with slight alkalinity, it is noncorrosive to structural steel.

y Soils: if an electrolyte is present and the soil has a negative charge in relation to the metal, an electrical path from the metal to the soil will occur, resulting in corrosion. differences in the conditions of the soil such as moisture content, resistivity are commonly responsible for creating the cathodic and anodic areas. y Chemicals: in an acidic environment, even without the presence of oxygen, the metal at the anode is attacked at the rapid rate. At the cathode atomic hydrogen is released continuously, to become hydrogen gas y Atmospheric corrosion: differs from the corrosion action that occurs in water or underground, because sufficient oxygen is always present. The formation of insoluble films and the presence of moisture and deposits from the atmosphere control the rate of corrosion.

Corrosion causes:
Pits that induce microcracking Microcracks at pits invite hydraulic split during impact Roughens surface, reducing energy needed to abrade away metal May produce hydrogen with subsequent absorption and cracking in steel 5. Selectively attacks grain boundaries and less noble phases of multiphase microstructures, weakening adjacent metal. 1. 2. 3. 4.

Forms of corrosion
The various forms of corrosion are as follows: 1. 2. 3. 4. 5. Uniform or general corrosion Galvanic corrosion Pitting corrosion Crevice corrosion Erosion corrosion

6. Dealloying 7. Environmentally assisted cracking including stress corrosion cracking, corrosion fatigue and hydrogen damage.

Methods of corrosion protection

y Altering the metal by alloying i.e using a more highly alloyed and expensive stainless steel rather than a plain carbon steel. y Changing the environment by dessication or the use of inhibitors y Controlling the electrochemical potential by the application of cathodic or anodic currents y Applying organic, metallic or inorganic coatings.

Surface coatings
Coating methods or materials used to avoid corrosion are as follows:             Organic coatings and linings Ceramic coatings Hot dip metallic coatings Electroplating Electroless plating Thermal spraying Cladding Chemical vapour deposition Physical vapour deposition Weld overlays Thermoreactive deposition Mechanical plating

Surface coatings/treatments and benefits

Surface coatings/treatments Organic coatings benefits

Improved corrosion, wear resistance, aesthetic appearance. Ceramic coatings Improved corrosion resistance Slip/sinter ceramic coatings Improved wear resistance and heat resistance Hot dip galvanizing (zinc Improved corrosion resistance via coatings) sacrificial steel substrate. Hot dip aluminizing Improved corrosion and oxidation resistance of steel substrate electroplating Improved corrosion and wear resistance and aesthetic appearance Electroless plating Improved corrosion resistance and wear resistance Weld overlays Dimensional restoration, corrosion resistance and wear resistance. Thermal spraying Oxidation resistance, wear resistance , corrosion resistance, dimensional restoration. Improved corrosion resistance Improved wear resistance Improved wear , erosion and corrosion resistance. Improved optical and electronic properties, improved wear and corrosion resistance and decorative applications. Improved corrosion resistance Improved corrosion resistance Improved corrosion resistance

cladding Laser cladding Chemical vapour deposition Physical vapour deposition

Mechanical plating Zinc nickel alloy plate Tin plate

Case study : corrosion in the underground pipelines and its prevention by surface coating.
The underground corrosion of pipelines and other structures is often the result of differential corrosion cells of which a variety of different types exist. These include differential aeration of cells, where different parts of pipe are exposed to different oxygen concentration in the soil, and cells created by differences in the nature of the pipe surface or the soil chemistry.

Here we shall discuss the corrosion in the underground pipelines. Corrosion in the pipe acts in the same manner as in the battery. A negative area of metal (anode) is connected to the positive area of metal (cathode) by the pipe wall itself as shown above. As a result electrons can flow from anode to cathode. The conducting solution electrolyte in this case is the water in the pipe with its dissolved salt. The electrolyte accepts the electrons from the cathode, making the cathode maintain a positive charge which draws more electrons to it. In the case of corrosion of a pipe the anode, cathode and the conducting material are all found in the pipe wall with electrolyte as water present within the pipe. If any of these elements which make up the corrosion cell, are absent or are not touching each other then corrosion cannot occur. Cast iron is the old principle pipe material used in the underground pipelines for the transportation of water and waste water service. Ductile iron is commonly used for the transportation of sewage water , oils , gases , slurries and process chemicals.

Effects of corrosion in the underlying pipelines:

y It causes decrease in the pipe diameter resulting in decrease in the flow of water , oil or slurries etc. y The metal particles corrode and may get carried away with the water making the water polluted. y It may lead to leaking of the oils , sewage water , or the gases flowing through the pipelines.

Effects of various types of soils:

Soil type
Gary clay with sand inclusions, wet Sandy loam, dry Clay mixed with organic matter, wet Dense blue and brown clays, moist Sand loam, moist Loam with over lay of white clay, dry Loam and clays, wet Heterogeneous red clay with sand, moist

pH
6.5-6.9 6.5-6.9 6.2 6.8-6.9 6.1-8.1 7.8-7.4 3.6-5.2 6.3-7.2

Relative corrosivity
Corrosive Mildly corrosive Very corrosive Very corrosive Mildly corrosive Mildly corrosive Moderately corrosive Moderately corrosive

The above figure gives the picture of a corroded pipe.

The figure above illustrates the stages of corrosion in a pipe

Method of corrosion detection in an underground pipe

Potential measurements are commonly used on on the underlying pipelines to detect corrosionan electrical connection is made to the pipe,and the potential of the pipe is measured with respect to a reference electrode placed over the pipe. Normally the reference electrode is connected to a negative lead of a digital voltmeter.

Most potentials in soils are negative. With this type of measurement, the most negative regions of the structure are anodes anda are undergoing accelerated corrosion due to differential corrosion cells. Current measurements also can be made to detect differential corrosion cells . IF THE ANODES AND CATHODES ARE LARGE.THESE LONG CELLS CREATE LONG LINE CURRENTS THAT CAN BE DETECTED BY MEASUREMENTS MADE OVER THE PIPEOR OTHER UNDERGROUND STRUCTURE. THROUGH OHMS LAW I.E V=IR WE KNOW THAT CURRENT FLOW IN THE SOIL WILL CREATE A VOLTAGE GRADIENT. THIS GRADIENT CAN BE MEASURED BY PLACING IDENTICAL REFERENCE ELECTRODE OVER THE PIPE AND MEASURING THE VOLTAGE DIFFERENCE.THE VOLTAGE MEASUREMENTS CAN BE USED TO INDICATE THE DIRECTION OF THE DIFFERENTIAL CURRENT.THE ANODIC AND CATHODIC SITES ON THE PIPELINE CAN BE LOCATED BY PERFORMING A SERIES OF CELL TO CELL POTENTIAL MEASUREMENTS TAKEN ALONG THE PIPELIne.

Surface coating for the corrosion control

A coating material is the most effective method to control corrosion if the coating material is y An electrical insulator y Can be applied with no breaks and will remain during the back filling process y Constitutes an initially perfect film that will remain with time. y Good adhesion to the pipe surface y Non toxic interaction with the environment In addition to the above characteristics, the following factors should be considered when selecting a pipe coating y y y y y y y Type of environment Accessibility of pipeline Operating temperature of pipeline Geographical and physical location Pipe surface preparation requirement Handling and storage Costs

Based on the above characteristics a suitable coating called as crossheadextruded polyolefin with asphalt adhesive was selected.

Characteristics and limitations of the above coating:

characteristics 40+ years of use Low current requirement Excellent resistance to cathodic disbondment good adhesion to steel Ease of application Non polluting limitations Difficult to remove coating Limited applicators

Introduced years ago, this thick dense mixture of select graded sand, crushed limestone, and glass fibre bound with an air blown asphalt proved to be a prominent pipe coating.

Conclusion:
y The corrosion of the underlying pipeline can be avoided by using the method of surface coating. y The coating selected for the pipe should have the necessary characteristics , should be cost effective and should give the required performance.

References:

1) J.P. Gossner and K.B. Tator, Painting, Surface Engineering, VoI ASM Handbook ASM International, 1994, p 421-447 2) K.B. Tator, Organic Coatings and Linings, Corrosion, VoI 13, ASM Handbook, ASM International, 1987, p 399-418 3) Corrosion Control by Protective Coatings and Inhibitors, Corrosion: Understanding the Basics, J.R. Davis, Ed., ASM International, 2000, p 363-106 4) J.C. Oliver et al., Porcelain Enameling, Surface Engineering, VoI 5, ASM Handbook ASM International, 1994, p 456^68 5) D. Wetzel, Batch Hot Dip Galvanized Coatings, Surface Engineering, VoI 5, ASM Handbook, ASM International, 1994, p 360-371 6) J. Foct, The Morphology of Zinc Coatings, The Physical Metallurgy of Zinc Coated Steel, A.R. Marder, Ed., TMS, 1994, p 1 7) D.CH. Nevinson, Corrosion of Zinc, Corrosion, VoI 13, ASM Handbook, ASM International, 1987, p 755-769 8) H.E. Townsend, Continuous Hot Dip Coatings, Surface Engineering, VoI 5, ASM Handbook, ASM International, 1994, p 339-348