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CHAPTER 5 : CORROSION & NON-FERROUS METAL ,[object Object],5.0 What is Corrosion? ,[object Object],[object Object]
Corrosion can occur in a gaseous environment (dry corrosion) or a wet environment (wet corrosion).
Importance of corrosion: 1. Economic – direct or indirect losses ,[object Object],2. Improved safety – failure of critical component ,[object Object],3. Conservation of resource – wastage of metal or energy.,[object Object],[object Object],1. General or uniform corrosion ,[object Object],2. Localised corrosion ,[object Object]
5.1 General or Uniform Corrosion ,[object Object],[object Object]
This type of attack is mostly found where a metal is in contact with an acid, a humid atmosphere or in a solution.
Example 1: ,[object Object]
Prevention : Proper material selection, change the environment, Cathodic protection. ,[object Object]
5.2.1 Galvanic Corrosion ,[object Object], Occur when 2 different metals are electrically connected in the same electrolyte. ,[object Object], The less active (more noble) metal corrodes slower and will be protected. ,[object Object], The galvanic series will predict which metal will corrode. ,[object Object], The galvanic series is similar to the “emf” but is for alloys in real environment. ,[object Object]
[object Object],i. A zinc electrode connected to a cuprum electrode and immerse in an electrolyte such as salt water, acid or alkaline ,[object Object],ii. The cuprum acts as cathodic and the zinc as anodic ,[object Object],iii. Zinc will be corrode caused by the electrochemical ,[object Object],corrosion ,[object Object],iv. Time to time the zinc will continue to corrode and became embrittle, fragile and weakening. ,[object Object]
[object Object],1. Size of exposed areas of the anodic metal relative to that of cathodic metal. ,[object Object],i. Smaller cathode relative to anode will cause small increase in corrosion of anode. ,[object Object],ii. Smaller anode will suffer severe corrosion. ,[object Object]
5.2.2 Crevice Corrosion ,[object Object], Crevice corrosion occurs at shielded areas that contain small volume of aqueous solution. ,[object Object], Crevice can be a hole, a space between the surface and a poorly adherent coating. ,[object Object], Principle : ,[object Object],1. Liquid entry but stagnant ,[object Object],2. Corrosion rate of crevice is higher than that on bulk (outside) ,[object Object],3. Crevice corrosion is initiated by changes in local chemistry within the crevice; ,[object Object],i. Depletion of oxygen in the crevice ,[object Object],ii. Depletion of inhibitor in the crevice ,[object Object]
 Oxygen concentration can develop when there is a difference in oxygen concentration on a moist surface of a metal that can be oxidized. ,[object Object], Example : ,[object Object],1. a drop of water/ moisture on the surface ,[object Object],2. the oxygen concentration are lesser on the surface ,[object Object],3. the surface that low in oxygen concentration are cathodic,[object Object],4. the surface that has higher oxygen concentration are anodic ,[object Object],5. because there is anodic and cathodic, the surface below the water drop are corroded (anodic) ,[object Object],6. the water drop act as electrolyte ,[object Object], Usually occurs at a bad gasket pipe flange, under bolt head and connections that soaked in liquid. ,[object Object]
5.2.3 Intergranular Corrosion ,[object Object], Is a localised attack along the grain boundaries, or immediately adjacent to grain boundaries, while the bulk of the grains remain largely unaffected. ,[object Object], It is occur when different potential between atoms at the grain-boundaries and create the boundaries of anode and cathode. ,[object Object], It is usually starts from the surface and accelerates internally causing by bad internal structure. ,[object Object]
5.2.4 Stress Corrosion Cracking (SCC) ,[object Object], It is refers to cracking caused by the combined effects of tensile stress and specific corrosion environment acting on the metal. ,[object Object], Usually occurs in alloys not in pure metals and in certain environment, examples : copper cracked in ammonia or aluminium alloy cracked in chloride solubility. ,[object Object], The stress in the materials must has its compressive component and the presence of both stress and corrosion environment which causing the cracks to form and spread. ,[object Object], The stress corrosion cracking usually occurs between crystals. ,[object Object]
5.3 Corrosion Control ,[object Object], Cathodic protection is the protection of a metal by connecting it to a sacrificial anode or by impressing a direct current voltage to make it a cathode. ,[object Object], Anodic protection is the protection of a metal which forms a passive film by the application of an externally impressed anodic current. ,[object Object], Example (steel hulls of ships adjacent to the bronze propellers) : ,[object Object],i. steel is an anode and bronze is a cathode and both are in sea-water which act as electrolyte ,[object Object],ii. the steel (hulls) will be corroded because of its anodic, so a more anodic material than steel and bronze is used as corrosion sacrificial which it is zinc ,[object Object],iii. zinc blocks are fitted to hulls so that the electrochemical corrosion process will occur only to the zinc ,[object Object],iv. the zinc blocks must be replace time to time because its worn out of corrosion as shown below ,[object Object]
5.4 Material Selection ,[object Object], There are few combination between metal and good corroded environment and economical are shown below : ,[object Object],i. stainless steel – nitrite acid ,[object Object],ii. nickel and alloy nickel – caustic ,[object Object],iii. monel – hydrofluoric acid ,[object Object],iv. hastelloi (chlorimet) – hot hydrochloric acid ,[object Object],v. plumbum – liquidifysulphuric acid ,[object Object],vi. aluminium – unpolluted atmosphere exposion,[object Object],vii. tin – distillation water ,[object Object],viii. titanium – hot oxidation liquid ,[object Object],ix. tantalum – definite resistant ,[object Object],x. steel – sulphuric acid ,[object Object]
5.5 Coating ,[object Object], Plastic and oil are non metal material use mainly for coatings. ,[object Object], Metallic coatings which differ from the metal to be protected are applied as thin coatings to separate the corrosive environment from the metal. Metal coatings are sometimes applied so that they can serve as sacrificial anodes which can corrode instead of the underlying metal. ,[object Object], Metallic coatings : ,[object Object],1. Noble coating ,[object Object],it is a coating where higher potential electrode compared to the base metal will be protected.,[object Object],base metal coating such as cuprum, nickel and chromium as the coating and entering the holes in material.,[object Object],it cannot protect the base metal if there is holes in the coating because the base metal will become anode ,[object Object]
2. Sacrificial coating ,[object Object],the base metal protected by sacrifice it and the coated acts as anode,[object Object],the organic and inorganic material are used to protect the surface from contacting with oxygen or giving the basic protection by coated with stable material which cannot be penetrated by humidity/ moisture,[object Object],organic coating such as paint, tar, oil and varnish ,[object Object],inorganic coating is enamel, plastic. Plastic is the main inorganic materials used as coating by hot dipping and spraying of corrosion resistant material ,[object Object]
5.6 Design ,[object Object], Designing rules : ,[object Object],1. considering corrosion penetration with the need of mechanical strength when determining the thickness of a metal used. It is important for piping and tank with liquid contents ,[object Object],2. welding is better than riveting for contena to reduce crevice corrosion. ,[object Object],3. use one type of material only for the whole structure to prevent galvanic corrosion. ,[object Object],4. avoid extra stress and stress concentration in corroded environment to prevent from crack-stress corrosion. Sharp edges of component need to be avoided because it can caused the stress ,[object Object],5. designing simple attachable system or changeable component if predicted it is easier to break or fail in the service ,[object Object]
5.7 Painting ,[object Object], Paint the surface of metal to avoid corroded material from contacting the surface. ,[object Object], Paint may be applied by brushing, spraying and dipping. ,[object Object], It may be dried naturally or by stoving. ,[object Object],5.8 Electroplate Metal ,[object Object], Electroplating is the process of using electrical current to reduce cations of a desired material from a solution and coat a conductive object with a thin layer of the material such as a metal using electrolysis. ,[object Object], Electroplating and metal finishing processes include copper plating, nickel plating, zinc plating, silver plating, tin plating, brass plating, cadmium and chrome finishes. ,[object Object], Metals plated include brass, copper, bronze, chrome, nickel, and black nickel, silver and gold. ,[object Object]
 The process : ,[object Object],i. the metal/ components to be plated are immersed in a solution called electrolyte ,[object Object],ii. electrolyte allows the passage of an electric current ,[object Object],iii. the parts that require coating, are then placed in the solution and given a negative charge/ terminal (as cathode) ,[object Object],iv. anodes are connected to the positive terminal ,[object Object],v. upon the passage of an electric current metal ions are transferred from the electrolyte onto the surface of the cathode ,[object Object], Electroplating allows for increased corrosion resistance, scratch resistance, decorative finishes and high temperature protection. ,[object Object], Examples : tin plating and tin alloys for food container and food contact applications. ,[object Object]

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Chapter 5

  • 1.
  • 2. Corrosion can occur in a gaseous environment (dry corrosion) or a wet environment (wet corrosion).
  • 3.
  • 4.
  • 5. This type of attack is mostly found where a metal is in contact with an acid, a humid atmosphere or in a solution.
  • 6.
  • 7.
  • 8.
  • 9.
  • 10.
  • 11.
  • 12.
  • 13.
  • 14.
  • 15.
  • 16.
  • 17.
  • 18.
  • 19.
  • 20.
  • 21.
  • 22.
  • 23.
  • 24.