CORROSION

LESSON TOPIC: 60C-104

CORROSION

Q: WHY IS CORROSION CONTROL SO

IMPORTANT ONBOARD NAVY SHIPS?

A: AN EFFICIENTLY OPERATING
CORROSION CONTROL SYSTEM SAVES
THE NAVY MILLIONS OF DOLLARS IN
HULL REPAIRS AND/OR REPLACEMENT.

Types of Corrosion
Galvanic
General
Oxygen Pitting
Intergranular
Stress Corrosion Cracking
Erosion

CORROSION

GALVANIC CORROSION

REQUIREMENTS:
TWO DISSIMILAR METALS
ELECTRICAL CONTACT BETWEEN THE
METALS(They can be touching)
AN ELECTROLYTE(Seawater)

GALVANIC SERIES
ANODE(corroded end)
MAGNESIUM
ZINC
ALUMINUM
IRON
COPPER
NICKEL
STAINLESS STEEL
CATHODE(protected end)

CORROSION

GALVANIC CORROSION

PREVENTION METHODS:
SACRIFICIAL ANODES
IMPRESSED CURRENT CATHODIC
PROTECTION
SEPARATION(of dissimilar metals)
PROTECTION

CORROSION

SACRIFICIAL ANODE CATHODIC

PROTECTION:
Simplest form of cathodic protection
using zinc anodes.
Zincs have a more positive potential in
respect to the steel(ships hull),
causing current to flow from the zincs
into the steel.

CORROSION

SACRIFICIAL ANODE PROTECTION

ADVANTAGES
1. No external electrical power required
2. Little or no maintenance needed
3. Easy to install(zincs bolted or welded to
the ship)
4. No monitoring required
5. Inexpensive

CORROSION

SACRIFICIAL ANODE PROTECTION

DISADVANTAGES

1. Requires frequent replacement

2. Covers limited area
3. Zincs add weight to the ship
4. No increased protection as paint fails

CORROSION

SACRIFICIAL ANODE APPLICATION

BECAUSE OF THESE
DISADVANTAGES ZINC ANODES
ARE PRIMARILY USED IN
CONDENSERS, HEAT
EXCHANGERS, AIR EJECTORS,
AND OTHER MACHINERY EXPOSED
TO SEA WATER.

CORROSION

IMPRESSED CURRENT CATHODIC

PROTECTION :
Uses a dc voltage potential applied to
the hull through platinum anodes
The ideal voltage potential to reverse
the corrosion of seawater is
approximately 0.85VDC.

CATHODIC PROTECTION

Impressed Current Cathodic Protection

SYSTEM OPERATION
The system supply power is aligned
to the anodes (positive
potential)
The reference cells measure the value
of the difference between
the hull and
the cells.

CATHODIC PROTECTION

Impressed Current Cathodic Protection

SYSTEM OPERATION(cont.)
The resultant signal is sent to the
controller, a proportional signal is
developed to react or counter-balance
the signal sent, and system output is
adjusted to the proper level.

BASIC ICCP SYSTEM

SHIPS POWER
Alt. Current

CONTROLLER
Reference
Electrode

POWER SUPPLY
DC Current

HULL
Anode

CATHODIC PROTECTION

Impressed Current Cathodic Protection

Propeller Shaft Grounding Assembly
Electrically connects the rotating shaft

and propeller to the hull

Allows the anode current which flows
through the water to enter the propeller
and shaft and return to the hull.

MOUNTING SHAFT

MAGNETIC AMPLIFIER CONTROLLER

Magnetic Controller
34650 Mod III
0

6 .9 1.2
.3 .

U.S. Navy Property

1.5

Output Check

Control Auxiliary
Reference Cell Check

Operating
OperatingInstructions
Instructions

Power On

Warning
Disconnect Power
before opening

CATHODIC PROTECTION

Impressed Current Cathodic Protection

IS ALWAYS ENERGIZED AND
OPERATIONAL CHECKS MADE
DAILY, except for the following;
Deenergize and tagged out :
Divers are in the water near the ship
For preventive/corrective maintenance
When the ship is in drydock

Impressed Current Cathodic

Protection

Advantages:
No significant wear/replacement
Less maintenance
Provides continuous protection, regardless of
changing evironmental conditions and paint
failure
Streamlined, no significan drag
Covers large areas of hull - complete
protection

Impressed Current Cathodic

Protection

Disdvantages:
Requires trained technicians
Expensive to install
Requires DC power supply
Affects ships magnetic signature
Can be improperly adjusted, causing paint
to deteriorate

CORROSION
GALVANIC CORROSION SEPARATION
METHODS:
Obvious solution: dont use dissimilar metals
Next best: try to separate them

GASKETS
BIMETALLIC STRIPS

CORROSION

Control with dissimilar metals:

Sometimes, they cant be separated

Use grounding straps
Keep clean, free of debris metal

copper debris in gun barrels

Chemical treatment

Boiler and condensate systems

CORROSION

Large Anode/Small Cathode

Relative size of the anode and cathode
affects the extent of corrosion
Anodic base metal, Cathodic bolt

Base metal threads corrode, enlarging the hole

Anodic bolt, Cathodic base metal

Fastener corrodes and gives way

CORROSION

Separate the Metal From the

Environment - Keep the electrolyte
away from the surface

Painting
Cladding or Galvanizing
Flame Spraying
DEHUMIDIFYING(Remove the Water)

CORROSION

GENERAL CORROSION
Occurs Across the Entire Surface of the
Metal

Example: Rust Is a General Corrosion Product

of Iron

Slight changes in composition of the metal

occur, causing migration of the galvanic cell
across the surface

CORROSION

Factors Affecting General Corrosion:

pH: the Electrolyte Around the Metal
Affects the Corrosion Rate
Oxygen: the Presence of Oxygen in the
Electrolyte Increases the Corrosion Rate

CORROSION

GENERAL CORROSION
PREVENTIVE METHODS:
Same as galvanic, however there are additional
methods for general corrosion.
Pacifying
Corrosion resistant oxide layer
Anodizing: commercial production of the protective oxide
coating on metals

Alloying

CORROSION

OXYGEN PITTING:
Can occur in a metal when the metal is
exposed to an environment which has
different chemical compositions. The
electrochemical attack on the metal is
localized (the galvanic cell does not
migrate).

CORROSION
Oxygen Pit
++++++++++

SCAB

++++++++++

Fe++

e-

e-

Cathode

Cathode
Anode

CORROSION

Intergranular Corrosion:

Corrosion which proceeds along the grain

boundaries of a metal. There are three
metals in current shipboard use which
have intergranular corrosion problems:
stainless steel, aluminum-magnesium
alloys, and nickel alloys.

CORROSION

Stress Corrosion Cracking - Some

metals, when under stress and exposed
to a particular environment, will develop
cracks. These cracks occur along the
grain boundaries.
Examples:
Caustic stress corrosion cracking
Chloride stress corrosion cracking

CORROSION

Erosion
Destructive attack caused by physical
means
Removes passive oxide layer, increases
corrosion too
Solutions:
Use an appropriate alloy
Limit turbulence in fluid systems

CORROSION
REVIEW & SUMMARY