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Chapter -I

Corrosion and Corrosion Theory

1.Q 1.0.1 What is Corrosion. Or Define Corrosion .

Corrosion is a process of decaying or detoriation or rusting of steel

/ metals / materials due to the reaction with the environment.
Almost all metals (materials) should be expected to detoriate with time
and when exposed to Elements

2.Q 1.1.1 What kind of process is Corrosion.

Corrosion is an Electro Chemical Process - Electrolysis - An Anodic

reaction ie.Destruction of the Anode (Metals) due to Corrosion.

3.Q 1.0.2 What is an Electrolytic Cell. Or what is an Electrolysis process.

Or what is Galvanic series

Electrolytic Cell or Electrolysis process comprise of an Electrolyte –a

liquid or corrosive medium, major water base contains Ions (+ve & -ve charged)
capable of conducting electricity, an Anode
(-Ve-Ignoble ie.more reactive or unstable), Cathode (+ve-Noble ie.less reactive or
stable) and a metallic path way (to close the electrical circuit or to complete the
the electro chemical reaction / process). These are the four essential elements of
a Galvanic series.
In the Electrolytic Cell the current flows from the cathode through the
metal to the Anode and returns through the electrolyte when connected through
the external metallic path way i.e. the wire- results the destructive corrosion of the
anode area whilst the cathode remains protected.
The Galvanic Series is a table of named metals given in their ability to
resist corrosion.

4.Q 1.1.2 What factors influencing or Affecting the rate of Corrosion. Or Why
Corrosion occurs.

1. Temperature of the both metal substrate and Corrosion Environment ie.

Surrounding Atmosphere.
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2. Relative Humidity (R.H.) ie. above 60% is Critical.-R.H. above 60% is

the amount of water vapour more in the air.
3. Variation in Oxygen Content on steel surface (Wet / Dry).Less Oxygen
spots – the Anode ie. Oxygen Concentration cells (OH-ve Hydroxyl ion)
and more Oxygen the cathode, results more corrosion at anode.
4. Presence of Impurities in the Environment .ie. the atmosphere (air) such
as acids, alkalis, salts ie. sodium chloride including common table salt,
sulphide, chloride, chemicals and gases.
5. Higher nobility metals (materials) in contact with steel, such as Mill scale
– results bimetallic corrosion.

4.Q 1.1.3.1. What is Mill Scale

The Mill scale is a thin black flaky layer of Iron Oxides which is formed
during steel making process, when steel exists at 1000 deg.C and in contact with
air (Oxygen).The Mill Scale is nobler than the steel, acts as a barrier coating
temporarily.
5.Q 1.1.3.2 Why the Mill scale is the particular problem when
attempting to protect steel .

The Mill Scale is nobler (Cathode) than the steel (Anode), acts as a
barrier coating temporarily.
When Mill scale breaks away (loosen) and exposed to air then the area of steel
sacrifice and preserve the more nobler mill scale.
Before coating the Mill scale are to be removed, since they are
loosely adhered and flaky. The Mill scales are the active corrosion cells and should
not be buried underneath the coating, results bimetallic corrosion.

6.Q 1.0.3 Describe the methode of arresting corrosion Or Describe the

ways of corrosion control.

The Corrosion can be controlled or arrested by the following ways.

1.By the Proper selection of Materials.

Example. Dissimilar metals when tested in presence of sea water,

have order of nobility
ie. The ability to corrode or not. Gold-Nobler, Steel-Noble, Zinc-Ignoble. The
dissimilar metal nobler than steel should not be contacted together, results
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bimetallic corrosion Ignoble steel corrode to protect noble metals such as gold,
silver, copper, Mill scale.

2.By the Proper selection of Design Criteria.

Selection of Proper design avoids entrapment of moisture,

Chemical salt and dirt. Also proper designing allows access for coating system
operation.

3.By providing Cathodic Protection to steel. (The sacrificial

principle-the Galvanic series)

i. The sacrificial Anodes- Bimetallic corrosion.

Two different metals (Bimetal) attached close together. Example
Zinc-Ignoble (Anode) attached to steel-Noble(cathode).Zinc, the sacrificial anode
will sacrifice itself to protect steel from corrosion.

ii. The Sacrificial Coatings.

The process of making a coating to steel substrate, whose

metallic pigment particles are Ignoble than steel. Example. Zinc 0r Aluminum rich
pigments particles coating to steel.

iii. Hot Dip Galvanizing.

The process of dipping the steel components in to a hot molten

zinc (Ignoble-Anode) bath at 450 deg. C. Hot Dip Galvanizing leaves a Zinc coating
about 85 to 135 microns on steel surface.

iv. Sheradising.

The process of tumbling of small component of steel in to a hot

Zinc dust(Ignoble-Anode).
Sheradising leaves a Zinc coating about 15 to 30 microns on steel surface.

v. Metal Spraying.
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The process of spraying molten Zinc or Aluminum powder

(Ignoble-Anode) on to steel

Substrate. Metal spraying leaves a Zinc or Aluminum Powder coating more than
150 microns on to the metal substrate.

4. By Providing an Impressed Current.

Impressed current is an electric current to oppose the current of

the corrosion cells.
Impressed current is an alternative form of Cathodic protection.
The D.C. current supplied between the metal (Pipe) and ground
lead to control the corrosion rate.

5. By providing a Protective Coating.

i. Sacrificial (Principle) Coating. Or Galvanic

The process of making a coating to steel substrate, whose metallic

pigment particles are Ignoble than steel. This type of coating provides Electro
mechanical protection to steel. Even if the steel is exposed due to small
discontinuities such as breaks, scratches etc. a self sealing in the damaged area by a
corrosion reaction which is by produced zinc salts if Zinc rich or Zinc metal coating
is applied as a primer.
Example.
a. Zinc or Aluminium rich pigment coatings.
b. Zinc or Aluminium molten metal spraying.
c. Hot Dip Galvanizing.
d. Sheradising.

ii. Barrier (Principle) Coating.

A process of making a Coating with the pigments of low

permeability system which keeps away the moisture and isolates the substrate
from the environment.
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By keeping the moisture (An Electrolyte) away (remove one

element among four of the Galvanic series) from the metal substrate results
prevention of corrosion.

iii. Inhibitive ( Principle ) Coating.

A process of making a coating usually only primer acting both

as barrier and Inhibitor principle.
Corrosion inhibitors are the substance added in to Small
amounts to the coating or corrosion environments such as acids, cooling water,
steam etc ., which decrease the rate of corrosion.
This Inhibitive coating reacts with both absorbed moisture in
the coating and with the steel to form a passivation layer, which decrease the rate
of corrosion.
Passivation is a chemical reaction between rust inhibitive
pigments in the primer coating and the substrate.
Example : Red Lead or Zinc Phosphate Primer on Metal
Substrate.
Passivation Layer -For steel – Lead or Zinc phosphate.
For Stainless Steel – Iron oxide.

6.Mill Scale.

The Mill scale is a thin black flaky layer of Iron Oxides which is
formed during steel making process, when steel exists at 1000 deg.C and in
contact with air (Oxygen).The Mill Scale is nobler than the steel, acts as a barrier
coating temporarily.

7. Inhibitors or Corrosion Inhibitors.

Corrosion inhibitors are the substance added in to Small amounts to

the coating or corrosion environments such as acids, cooling water, steam etc .,
which decrease the rate of corrosion.

8. Alteration of Environment.
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The process of making alteration of environment by reducing

Relative Humidity% to less than 50%.
This can be achieved by the use of dehumidifiers to dry and
remove moisture from air in the tank that is abrasive blasted. Dehumidifiers can
possible to reduce the R.H. even 10 to 15 %.

7.Q 1.0.4 Describe the Corrosion process on steel structure.

i. Steel conduct Electricity – act as a metallic pathway.

ii. Steel surface wet from dew or rain or fog or moisture and
chemicals present in atmosphere combines – creates a stronger
electrolyte.
iii. Steel is not a homogeneous ie. not perfectly uniform ,slight
variation in the chemical elements forms many tiny Anodic and
Cathodic areas / Spots over its surface differs in electrical
potentials- Form Anodes and Cathodes spots.
The essential elements of a galvanic series, completes an Electrolytic
cell ie. A Corrosion cell. Results the Corrosion of steel (Anode-Ignoble).

8. Q 1.0.4. Describe the formation of Corrosion Product the Iron Oxide

on Steel Surface.

Under normal condition,

At Anode:
Iron atom at anodic surface of steel releases electrons as the part of
corrosion circuit. These atoms becomes positive ferrous ions.
Fe (Solid)  Fe(2+) Ferrous ions + 2e(-ve) electrons.
At Cathode:
The oxygen in air combines with moisture (water) surface and electrons
liberated at anode forms hydroxyl ions.
O2 + 2H2O +4e  4OH(-ve) (Hydroxyl Iron)

Corossion Product.
The ferrous ions librated at the anode and the Hydroxyl Ions librated at the
cathode reacts (combines) in the electrolyte forms a surface layer (Rust) of
Iron Oxide on the steel surface.

2Fe(2+)Ferrous Ions + 4OH(-ve) Hydroxyl Ions  2Fe(OH)2

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2Fe(OH)2 + 2O2  2FeO3 (Iron Oxide) + H2.

9. Q.1.0.5. What are the various form of Corrosion

Various forms of Corrosions are.

1. Surface Corrosion.
2. Pitting Corrosion.
3. Stress Corrosion Cracking.
4. Fretting Corrosion.
5. Crevice Corrosion.
6. Corrosion between Dissimilar Metals (Bi-Metallic).
7. Bacterial Corrosion.
8. Corrosion in acidic and alkaline Environment.

10. Q 1.1.4. What particular problems related to the maintaining of an

effective coating system in the splash Zone.

The Splash zone area is expressed as the area of Lowest

Astronomical Tide (L.A.T.)between -2.5 m. and + 12m.The Mid Tide Level(M.T.L.)
is 12 feet above high tide.
The following problems occurs relate to maintain an effective coat
systems in the Splash Zone.

1. Tidal Changes.
2. Presence of rich moisture ie. High Relative Humidity %( R.H. %)
3. Salt Laden atmosphere and Salt spray.
4. High winds and wave’s impact.
5. Erosion of paint systems and steel itself from wave action and high wind
velocity.
6. Rapid weather changes.
7. High Ultra Violet light energy.
8. Problem with working areas(accessibility to various levels)

11. Q.1.0.6. What is Ferrous metals and Non ferrous metals.

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Ferrous Metals are those which have iron (Fe) content.

Non-Ferrous Metals are those which do not have Iron content.