Corrosion

1. Corrosion theory
Loss of metal by chemical reactions with the environment or to the electrochemical reaction. Which
caused damage to a number of engineering components. The rate of corrosion depends on the concentration
of the reaction and other factors such as pressure and erosion (Erosion) which contributes to the corrosion.

𝑂𝑥𝑖𝑑𝑎𝑡𝑖𝑜𝑛 ; 𝑍𝑛 → 𝑍𝑛2+ + 2𝑒 −

𝑅𝑒𝑑𝑢𝑐𝑡𝑖𝑜𝑛 ; 𝐶𝑢2+ + 2𝑒 − → 𝐶𝑢

𝐸𝑞𝑢𝑎𝑡𝑖𝑜𝑛 ; 𝑍𝑛 + 𝐶𝑢2+ → 𝐶𝑢 + 𝑍𝑛2+

Corrosion caused by an electrochemical reaction which

comprises the anode and cathode, the anode, which is
losing 𝑒 −
2. Types of Corrosion
Type Example Detail Prevention
Uniform corrosion is normal corrosion - Coating
and easy to calculate corrosion of - Inhibitor
materials lifetime.
Uniform

There are two kinds of metal components. - Coating

Electrode Potential (E.P.) of metal are - Use area anode > cathode
lower as anode and higher as cathode, so - Select E.P. cathode near
Galvanic the electrochemical reaction at the anode anode
side to the corrosion.

Pit corrosion is deep hole in specimen. - Inhibitors

The pit area of the specimen to the - Material select
anode and cathode are outside the pit
Pitting
when electrochemical reaction within
the hole of the specimen so corrosive.

The material that is crevice. Causing - Welding

the formation of a solution within that - Designed to vent
Crevice corrosion.
 2. Types of Corrosion
Type Example Detail Prevention

Intergranular corrosion occurs at grain - Heat treatment

boundaries or grain boundary side. - Alloying element
This is usually the result of improper
Intergranular
corrosion heat treatment.

Selective leaching occurs in any one of - Material select

phase of the alloy. The elements
dissolved in the phase will be less
stable than other elements, thus eroded.
Selective leaching
As a result of corrosion and corrosion - Material select
media flow on effect of the corrosion.
Resulting more severe erosion.

Erosion corrosion
Stress corrosion Stress corrosion caused by metal under - Annealing
tensile load or shear during use or
exposure to the environment. As a result,
the metal is susceptible to cracking.
 3. Prevention corrosion

Corrosion control

Materials Cathodic and Environment

Coatings Design anodic protection
selection control

Metal Metallic and Avoid excessive

Tempurature
purification Inorganic coating stresses

Avoid dissimilar
Alloy Organic coating metal contract
Velocity

Avoid crevices
Oxygen
exclude air

Concentration

Cleaning Inhibitors
Corrosion testing
Salt spray testing
used to check corrosion resistance of materials and surface coatings. Salt spray testing is an
accelerated corrosion test that produces a corrosive attack to coated samples in order to evaluate (mostly
comparatively) the suitability of the coating for use as a protective finish. The appearance of corrosion products (rust)
is evaluated after a pre-determined period of time. Test duration depends on the corrosion resistance of the coating.
Standard of Salt Spray testing : ASTM B117, ISO9227, JIS Z 2371 and ASTM G85.

Cyclic Corrosion Testing (CCT)

has evolved in recent years, largely within the automotive industry, as a way of accelerating real-world
corrosion failures, under laboratory controlled conditions. As the name implies, the test comprises different climates
which are cycled automatically so the samples under test undergo the same sort of changing environment that would
be encountered in the natural world. The intention being to bring about the type of failure that might occur naturally,
but more quickly i.e. accelerated. By doing this manufacturers and suppliers can predict, more accurately, the
service life expectancy of their products.
Cyclic Corrosion Testing, the traditional Salt spray test was virtually all that manufacturers could use for
this purpose.
 Galvanic corrosion
Purpose To study the galvanic corrosion, including ways of preventing such the corrosion.
Equipment and Methods
1. Steel (Fe) 2. Copper Wire (Cu) 3. Aluminum foil (Al) 4. Saline Solution (NaCl)
Start After 20 hr.

Fe Fe+Cu Fe+Al Fe Fe+Cu Fe+Al Fe Fe+Cu Fe+Al

Summary
From the trial will see that galvanic corrosion occurs as a result of two metals come in contact with or connected by
electric chemistry. Because the material has a different value E.P. well as the introduction above.
Weak
Fe Fe+Cu Fe+Al 𝐶𝑢2+ + 2𝑒 − → 𝐶𝑢 + 0.34

Anode
Corrosion throughout Fe -> anode Fe -> cathode 𝐹𝑒 2+ + 2𝑒 − → 𝐹𝑒 − 0.45
NaCl

the surface. Cu -> Cathode Al -> anode 𝐴𝑙 3+ + 3𝑒 − → 𝐴𝑙 − 1.66

Strong
Guidelines for galvanic corrosion-resistant metal is applied to two types of the same power. Choose materials that are
close together or create E.P. the anode to the cathode, to prevent corrosion over a new gallery system. However, need the
structural design and usability.
 Summary

Corrosion is electrochemical process reacts with the environment to cause

deterioration of the object. As a result, the performance of the function or purpose to
decrease.
Types of corrosion
- Uniform attack - Intergranular corrosion
- Galvanic corrosion - Selective leaching
Metal should have good corrosion resistance makes the material can protect yourself
- Pitting corrosion - Erosion
from the environment around it, such as moisture, heat, chemicals.
- Crevice corrosion - Stress corrosion
In order to increase efficiency in the use of materials. Can slow corrosion in several ways,
such Protection
as for the fromGED.
corrosion
Metal should have good corrosion resistance makes the material can protect yourself from the environment
around it, such as moisture, heat, chemicals and etc. In order to increase efficiency to use of materials and can
slow corrosion in several ways, such as Metallic coating, Electrochemical protection, Corrosion inhibitors and etc.
Protection from corrosion
- Salt Spray Testing
- Cyclic Corrosion Testing