Introduction to Corrosion

Paint School
1

Former Tank

1243-0019

Paint School
2

Definition of Corrosion
Corrosion is a reaction between Material and Surrounding environment under formation of corrosion products

Paint School
3

Production and degradation of steel

Reaction between the material and the surrounding environment takes place Plates, pipes, profiles, etc.

Raw material Iron ore

Rust

The presence of water / humidity and Oxygen is a pre-requisite for corrosion of steel
Paint School
4

The corrosion process. A galvanic cell

Materials exposed to seawater
will obtain different electrochemical potentials If two differently charged metals are brought in contact a current will start to flow between them Electrons will transport current between the metals and ions in the electrolyte
CP and corrosion: Corrosion_cell1

Paint School
5

A galvanic cell
2e-

Cathode: Steel
O2

Zn = Zn + 2 e

2+

Anode: Zinc

O2 + H2 O + 2e - = 2OH -

In seawater, a calcareous deposit is formed on the steel surface

Paint School
6

Galvanic potentials in seawater

Paint School
7

Steel in Seawater
Potential versus Zinc & Ag/Ag Cl ref. electrodes
Ag / Ag Cl

Potentials in volt
Rapid corrosion

Zinc

Cu / CuSO4

- 0.55

+ 0.50

- 0.60

General corrosion
- 0.80

Some corrosion 100% Cathodic protection

+ 0.25

- 0.85

-1.05

Increasing polarisation Overprotection Possible coating damage

+ 0.0

-1.10

- 1.30

- 0.25

- 1.35

Paint School
8

How fast will a metal corrode ?

The speed of a corrosion process depends on:

The properties of the material The surrounding environment

Paint School
9

pHpH-scale
Acidic

Neutral

Alkaline

Paint School
10

The pH of the solution will affect the corrosion speed

Steel Corrosion increases at lower pH. (Acidic solutions, pH 6 p lower) Strong alkaline solutions prevent corrosion (pH 10 p higher) Zinc and Aluminium Slow corrosion at close to neutral solutions Heavy corrosion in acidic and alkaline solutions

Paint School
11

Corrosion speed differ when exposed to the same environment

In a strong alkaline environment Aluminium and Zinc will corrode rapidly, while steel will be passive
Aluminium Zinc Steel

Protective Iron oxide

pH > 10

Paint School
12

Elements influencing the corrosion speed of metals

Submerged materials

y Temperature y Salinity y Oxygen content y Water velocity y Acidity (See below) y Type of electrolyte ( e.g. cargo or chemicals) y Content of contaminants / pollution that
promotes corrosion y Micro-organisms.
Paint School
13

Parameters influencing the corrosion speed

Atmospheric corrosion

y Humidity y Temperature y Concentration of salts y Amount of air pollution,

including acid rain, soot and dust particles

Paint School
14

Atmospheric corrosion corrosion rate depends on humidity

Corrosion rate

0
Paint School
15

20

40

60

80

100

Relative Humidity, %

Several paints protect the steel by forming a barrier to the surrounding environment

A barrier will
increase the resistance in the galvanic circle A thick barrier will give better protection than a thin

CP and corrosion: Cell_paintprotection1

Paint School
16

Types of corrosion
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.
Paint School
17

Uniform corrosion Galvanic corrosion Selective (preferential) corrosion Pitting corrosion Crevice corrosion Micro biological corrosion (bacteria) Corrosion fatigue Stress corrosion cracking Erosion corrosion Cavitations Stray current corrosion

Most frequently occurring types of corrosion

On carbon steel

Uniform corrosion Uneven corrosion (deep pits) Galvanic corrosion Stress corrosion cracking

Paint School
18

General corrosion
General corrosion is uniform by nature Still, deep pits or uneven areas are found

CD 0026-001

CD 4911-0004

Paint School
19

Most frequently occurring types of corrosion

Stainless steels Titanium

Crevice corrosion Pitting corrosion Stress corrosion cracking

Aluminium

Hydrogen embrittlement Fatigue

Copper based alloys

Pitting corrosion Galvanic corrosion

Erosion corrosion

Paint School
20

How to prevent or reduce corrosion

1. Improve the construction y Design y Position 3. Use corrosion protection y Paint y Cathodic protection y Metallic coatings y Erosion resistant coatings y Rubber or plastic y Anodic protection
Paint School
21

2. Make the optimal selection of materials 4. Change the environment y Inhibitors y Remove Oxygen y Reduce water flow velocity y Change pH y Change temperature y Reduce relative humidity, % RH

Systems with flowing water must be designed to avoid turbulent flow

Erosion corrosion will develop at sharp bends and intrusions

Paint School
22

Avoid stagnant water at bottoms of tanks and containers

Unfortunate Better Best solution

Paint School
23

Avoid solutions where dust / humidity collects

Unfortunate Better Best solution

Humidity is trapped
Paint School
24

Apart from using paint and CP: How to protect against corrosion ?
Corrosion protection can be achieved in many ways

Paint School
25

Good design Avoid corrosion traps Improved accessibility - maintenance Proper materials selection Insulate between dissimilar materials Change the surrounding environment Remove water / humidity Apply metallic coatings Use corrosion inhibitors (closed systems)

Questions?

Paint School
26