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CORROSION OF
METALS AND ALLOYS
3 units
CHE 431Course Instructors: Dr. Ayoo! A.A.
Mr. O"un#iyi A.T.
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Mode of Assessment
Quiz = 5%
Test = 10%
Grp. Assig. = 15%
Cont. Ass. 30%
Exam. 70% Total 100%
06/05/16 COVENANT UNIVERSITY GEC 210 2
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MODULES
Introu!tion
"rin!iples o# Corrosion
$orms o# CorrosionCorrosion Testing
Corrosion Control & Anoi! '
Cat(oi! "rote!tion
06/05/16 COVENANT UNIVERSITY GEC 210 3
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MODULES
Corrosion Control & )aterials
*ele!tion
Corrosion Control & "rote!ti+e
Coating an ,se o# In(iitors
-is!ussion on GroupAssignment
06/05/16 COVENANT UNIVERSITY GEC 210 4
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GROUP ASSIGNMENT
G/," 1: Corrosion in Automobile Industries.
G/," : Corrosion in Chemical
Industries.
G/," 3: Corrosion in Petroleum
Industries.int2 Discussion should centre around the mode of
operations, nature and effects of corrosion, and
remedies in a parti!ular inustr&.
06/05/16 COVENANT UNIVERSITY GEC 210 5
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06/05/16 6
MODULE ONE:
INTRODUCTION
Corrosion2 A atural "ro!ess
FI$%RE 1: T&e Corrosion Cyce o' Iron
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Two m!o" f#to"s of Co""os$on
)etal material an
An en+ironment.
• The corrosion #e&!(ior o' !)!teri! cannot be described unlessthe environment in which the materialis exposed to is i*enti+e* !n**e+ne*.
•T&e corrosi(ity or !""ressi(enesso' !n en(iron)ent cannot bedescribed unless the material that isto be exposed to that environment is
i*enti+e*.
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%&AT IS CORROSION'
Corrosion can be defned as achemical or electrochemical reaction
between a
material, usually a metal, and itsenvironment that produces
deteriorationand alteration o the material and its
properties.
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T(e m$n f#to"s )sed to des#"$*e
t(e en+$"onment "e:
• Physical state
• Chemical composition
•Temperature
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06/05/16 10
,ORMS O, CORROSION
•ni!orm or "eneral corrosion•Pittin# corrosion
•Cre$ice corrosion
•"al$anic corrosion
• %rosion corrosion
•&nter#ranular corrosion
•'ealloyin#
•%n$ironmentally assiste( crac)in#
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C-ss$f$#t$on of ,o"ms of Co""os$on
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,ACTORS IN,LUENCING METAL
CORROSION
1. NATURE O, T&E METAL
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,ACTORS IN,LUENCING METAL CORROSION
/Contd
2. NATURE O, ENVIRONMENT
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06/05/16 15
MODULE T%O:
PRINCIPLES O, CORROSION
T&EORIES O, CORROSION
1 'irect Chemical ttac) Theory
2 The %lectrochemical Theory
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06/05/16 16
CORROSION REACTIONS
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Co""os$on Re#t$on /Contd
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06/05/16 18
Co""os$on Re#t$ons /Contd
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06/05/16 19
Ct(ode Re#t$ons
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Co""os$on of met- s)"f#e
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06/05/16 21
Mes)"ement of Co""os$on Rte
O#,ecti(es o' Corrosion r!te
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06/05/16 22
Mes)"ement of Co""os$on Rte
-A /EI$HT 0 LOSS METHOD
- MICROSCO2IC
EAMINATION
-C MEAS%REMENT OFELECTRICAL RESISTANCE
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06/05/16 23
1. Un$fo"m Co""os$on: uni!orm thinnin# o$erthe entire sur!ace
MODULE T&REE:
,ORMS O, CORROSION
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2. P$tt$n4 Co""os$on:
characterise( y sharply (e!ine( holes
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C"e+$#e Co""os$on:
This is a !orm o! localie( attac) that occurs at narroopenin#s or spaces #aps eteen metaltometal or
nonmetaltometal components
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6. G-+n$# Co""os$on:occurs hen a metal or alloy is electrically couple( to
another metal or con(uctin# nonmetal in the same
electrolyte
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7. E"os$on Co""os$on:
&s the accelerate( or increase in the rate o! (eterioration
or attac) on a metal ecause o! mechanical ear or
arasi$e contriutions in comination ith corrosion
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8. Inte"4"n)-" Co""os$on:
selecti$e (issolution o! #rain oun(aries: or closelya(;acent re#ions: ithout appreciale attac) o! the
#rains themsel$es
&n a((ition to the presence o! impurity atoms:
metals contain many atom $acancies: that is: sites
here atoms shoul( e present ut are not
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9. De--o5$n4 Co""os$on:
is a corrosion process in hich the more acti$e metal isselecti$ely remo$e( !rom an alloy: lea$in# ehin( a
porous ea) (eposit o! the more acti$e nole metal
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ALLOY ENVIRONENT ELEENT REOVE!
"rasses#$inc %ater& especiall' sta(nant
water
$inc )de*inci+cation,
-ra' Iron .oils& water Iron )(raphic orrosion,
Aluminium bron*es /'dro0uoric acid& acids
containin( chloride ions
Aluminium )dealumini+cation,
.ilicon bron*es /i(h temperature steam and
acidic species
.ilicon )desiliconi+cation,
1opper nic2els /i(h heat 0ux and low water
velocit' )re+ner' condenser
tubes,
Nic2el )denic2eli+cation,
Tin bron*es /ot brine or steam Tin )destanni+cation,
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. St"ess Co""os$on C"#;$n4:
.tresses that causes crac)in# result !rom el(in#:hammerin#: thermal treatment or applie( loa(s (urin#
ser$ice &n such cases: the metal un(er stress ecomes
more ano(ic an( ten(s to increase the rate o!
corrosion
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MODULE ,OUR:
CORROSION TESTING
P)"oses of Co""os$on Test$n4
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Stes $n Co""os$on Test P"o4"m
1 'e!ine The Test -;ecti$es
2 &(enti!y the Time n( Cost/
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C-ss$f$#t$on of Co""os$on Test$n4
T(e"e "e t("ee 4ene"- #te4o"$es of
#o""os$on tests:
L*o"to"5 Tests
P$-ot -nt Tests
,$e-d Tests
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MODULE ,IVE: CORROSION
CONTROL
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Ct(od$# P"ote#t$on:
Catho(ic protection is achie$e(
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Ct(od$# P"ote#t$on
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Ct(od$# P"ote#t$on
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Anod$# P"ote#t$on
• achie$e( y maintainin# an acti$e > passi$e metal or
alloy in the passi$e re#ion y an e?ternally applie(
ano(ic current The potential o! the metal to e
protecte( is ma(e more positi$e to shi!t the
con(itions !rom a re#ion o! acti$e corrosion to are#ion o! passi$e eha$iour
• no(ic protection is use( to passi$ate stora#e tan)s
an( process $essels containin# hi#hly corrosi$e
electrolytes
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Anod$# P"ote#t$on
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@ Potential sensin# (e$ice: < @ Potential controller: C @ 'C poer source:
' @ ,e!erence %lectro(e: % @ Catho(e: A @ Tan) no(e
Ad f A d$ P $
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Ad+nt4es of Anod$# P"ote#t$on o+e"
Ct(od$# P"ote#t$on
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D$sd+nt4es of Anod$# P"ote#t$on
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MODULE SI= CORROSION
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MODULE SI=: CORROSION
CONTROL
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Mte"$-s Se-e#t$on
>A? Re@)$"ements To
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Mte"$-s Se-e#t$on
>
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Info"mt$on on Est$mt$n4 Co""os$on
Pe"fo"mn#e
>A? Co""odent V"$*-es%n$ironment type marine: in(ustrial: internal !lui(
etc
=ain constituents i(entity an( amount
Temperature
p
'e#ree o! aeration
Delocity or a#itation
Pressure
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I f t$ E t$ t$
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Info"mt$on on Est$mt$n4
Co""os$on Pe"fo"mn#e
>
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Info"mt$on on Est$mt$n4
Co""os$on Pe"fo"mn#e
>C? T5e Of A-$#t$on
Ehat is the !unction o! part or e*uipmentF
re sie chan#e: appearance or corrosion pro(uct
prolemFEhat e!!ect ill localie( corrosion ha$e on use!ulnessF
Eill there e stresses presentF
&s (esi#n compatile ith the corrosion characteristics o!the materialsF
Ehat is the (esire( ser$ice li!eF
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Info"mt$on on Est$mt$n4
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Info"mt$on on Est$mt$n4
Co""os$on Pe"fo"mn#e
>D? Ee"$en#e
as material een use( in an i(entical situationF
Ehat ere the resultsF
as material een use( in a similar situationF Ehat
as the per!ormanceF
Eas there any pilot e?perienceF
re there any plant corrosion test (ataFEhat literature or (ataase in!ormation is a$ailaleF
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%(t to #ons$de" *efo"e se-e#t$n4
mte"$-s
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Mte"$-s #ommon-5 )sed
Met--$# mte"$-s:>A? STAINLESS STEELS
=artensitic types
Aerritic types'uple? Aerriticustenitic types
Precipitationar(enin# types
ustentic types>
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Mte"$-s #ommon-5 )sed
on )etalli! materials2
[A] PLASICS
[!] C"#A$ICS[C] C%&C#""
[D] '%%D
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MODULE SEVEN CORROSION
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MODULE SEVEN: CORROSION
CONTROL
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COATING
Coatin#s an( linin# may protect
metals/alloys throu#h three asic
mechanisms+
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IN&I
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T5es of In($*$to"s
Commonly use( inhiitors are+
Anod$#
Ct(od$#O(m$#
P"e#$$tt$onVo)" (se
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A-$#t$on of In($*$to"s
&nhiitor application techni*ues inclu(e+
Cont$n)o)s $n!e#t$on
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CORROSION IN AUTOMO