Corrosion is a natural process that converts a
refined metal into a more chemically stable form
such as oxide, hydroxide, or sulfide. It is the
Corrosion gradual destruction of materials by chemical
and/or electrochemical reaction with their
environment.
Causes of Corrosion
Consequences of corrosion
Dry corrosion occurs when there is no moisture or
water to aid corrosion. The metal in such a situation
oxidizes with only the atmosphere. This process is
Dry corrosion very sensitive to temperature, as can be
demonstrated by holding a piece of metal to a
flame and observing the layer of oxide that forms.
Wet corrosion occurs in the presence of a liquid containing
ions, an electrolyte. Problems with wet corrosion attacks in
Wet corrosion stainless steels occur in mineral acids, process solutions,
seawater and other chloride containing media. Examples of
wet corrosion forms are: Erosion corrosion.
Mechanism
Rusting Pure
metal
# Dry (or) Wet(or)Electro Chemical Corrosion
Chemical Corrosion
1. It occurs in dry state It occurs in presence of moisture (or) electrolyte
2. It follows adsorption mechanism It follows the mechanism of electro chemical reaction.
3. Corrosion product accumulate on the same spot, Corrosion occurs at anode while products gather at
where corrosion occurs. cathode
4. Uniform corrosion behaviour is seen, i.e., either Localised corrosion occurs. i.e., one metal surface alone
the whole surface of the metal in contact with is corroding even though both metal surfaces are in
the medium corrodes, or it does not. contact with the medium.
5. Only heat evolution can be observed. Due to electron flow from the site of oxidation to site
of reduction, current flow can be observed.
Differences between chemical and electro
chemical corrosion
Causes of corrosion
Uneven surface
Differential orientation of grain boundaries
surface
Differential heating of metal
Due to impurity presence in pure metal
Galvanic corrosion is
an electrochemical
Galvanic corrosion process in which one
metal corrodes
preferentially when it
is in electrical contact
with another, in the
presence of an
electrolyte. A similar
galvanic reaction is
exploited in primary
cells to generate a
useful electrical
voltage to power
portable devices.
Mechanism of crevice
corrosion
Mechanism of crevice corrosion is
like that of pitting corrosion:
dissolution of the passivating film
and gradual acidification of the
electrolyte caused by its insufficient
aeration (Oxygen penetration).
Fe = Fe2+ + 2e-
1/2O2 + H2O + 2e- = 2(OH-)
Corrosion control methods
Sacrificial Anodic Protection Method
In this method, the metallic structure to be protected is made cathode by
connecting it with more active metal (anode metal). So that all the corrosion will
concentrate only on the active metal.
Avoid galvanic corrosion
If two different metals are joined , galvanic corrosion will occur. In such a case
galvanic corrosion is prevented by
a) Selecting the metals as close as possible in the electrochemical series.
b) Providing smaller area forRusting
cathode andPurelarger area for anode.
metal
Corrosion control methods
Avoid sharp corners and bends
Sharp corners and bends should always be avoided, and hence erosion corrosion
can be avoided by smooth corners or curved pipe bends
Coating of paints
Through the coating of suitable paints, corrosion can be controlled. Pits and
uneven surface can cover by paints, so metal can be protected by atmospheric
moisture attack, that can cause corrosion or rusting of iron.
Rusting Pure
metal
