Introduction to Corrosion


Corrosion is a natural process and is a result of the inherent tendency of metals to revert to their more stable compounds, usually oxides. Most metals are found in nature in the form of various chemical compounds called ores. In the refining process, energy is added to the ore, to produce the metal. It is this same energy that provides the driving force causing the metal to revert back to the more stable compound.

Forms of Corrosion

General/Uniform Corrosion:     Corrosive attack dominated by uniform thinning due to even regular loss of metal from the corrosion surface Atmospheric corrosion or degradation of material exposed to the air and its pollutants rather than immersed in a liquid
Galvanic corrosion that occurs when a metal or alloy is electrically coupled to another metal or conducting nonmetal in the same electrolyte
Stray-current caused by an externally induced electrical current
General biological corrosion of metals generally over the entire exposed surface in aqueous environments
Molten salt corrosion of metals due to molten or fused salts
Liquid metals types of corrosion found in liquid metal / containment / component combinations
High-temperature Oxidation corrosion by direct reaction of exposed metals to oxidizing agents at elevated temperatures
Sulfidation
Carburization
Other forms
Localized Corrosion:     all or most of the metal loss occurs at discrete areas Filiform occurs on metallic surfaces coated with thin organic film, typically .1 mm thick, characterized by the appearance of fine filaments in semi-random directions from one or more sources
Crevice corrosion in narrow openings or spaces in metal to metal or non-metal to metal component sites
Pitting extremely localized corrosion marked by the development of pits
Localized microbiological cases where biological organisms are the sole cause or an accelerating factor in the localized corrosion
Metallurgically influenced corrosion:     form of attack where metallury plays a significant role Intergranular occurs when the corrosion rate of the grain boundary areas of an alloy exceeds that of the grain interiors
Dealloying a form of corrosion characterized by the preferential removal of one constituent of an alloy leaving behind an altered residual structure
Mechanically assisted degradation:     form of attack where velocity, abrasion, hydrodynamics etc. play a major role Erosion removal of surface material by the action of numerous individual impacts of solid or liquid particles
Fretting combined wear and corrosion between contacting surfaces when motion between the surfaces is restricted to very small amplitude oscillations
Cavitation & Water drop impingement occurs on a metal surface in contact with a liquid, pressure differentials generate gas or vapor bubbles which upon encountering high-pressure zones, collapse and cause explosive shocks to the surface
Fatigue occurs in metals as a result of the combined action of a cyclic stress and a corrosive environment
Environmentally induced cracking:     forms of cracking that are produced in the presence of stress Stress cracking service failures in engineering materials that occur by slow environmentally induced crack propagation
Hydrogen damage results from the combined action of hydrogen and residual or tensile stress
Liquid metal embrittlement brittle failure of a normally ductile metal when coated with a thin film of a liquid metal and subsequently stressed in tension
Solid metal embrittlement occurs below the melting point of the solid in certain liquid metal embrittlement couples


Methods of Corrosion Prevention

Change of Materials complete or partial change of materials used
Change of Environment either a complete change in environment or a partial alteration by modification of pH etc
Barrier Films either organic coatings or electroplating etc.
Electrochemical Techniques sacrificial coatings, cathodic or anodic protection etc.
Design allowances for general corrosion and control of factors such as temperature, velocity etc.

Related Links:
> Introduction to Corrosion
General/Uniform Corrosion
Atmospheric Corrosion
Galvanic Corrosion
Liquid Metal Attack
High Temperature Corrosion
Crevice Corrosion
Pitting Corrosion
Microbiological Corrosion
Fretting Corrosion
Corrosion Fatigue
Hydrogen Embrittlement
Cracking
Failure Analysis
Material Selection
Cathodic Protection
Corrosion Control