CORROSION LANGUAGE AND TERMINOLOGY

MODULE 1

OVERVIEW
Cost of Corrosion Fundamental Chemistr y Cells and electrochemistry Forms of Corrosion

WHAT IS CORROSION?
Spontaneous , exothermic reaction of a metal with its environment to form compounds. The metal rever ts back to the natural form found in nature. In order to made metals (smelting, or reduction), chemical energy is given to the ore material to make it a metal. Thus metals contain more energy than rust. The rusting process releases this energy back to the environment.

COST OF CORROSION
Annually, between 3~ 6% of GDP.
The US spends approx. 276 Billion annually (1999 figures).
( equal to the DOD budget!)

In the UAE the GDP in 2008 was 792 Billion Dhs. Cost of corrosion was therefore between 24 and 48 Billion Dhs. But, of these costs, between 20 and 40% is preventable, using current technology and best practices. The UAE economy could therefore save between 5 and 10 Billion Dhs annually if best practices were implemented. Current world annual cost of corrosion: $3.3 Trillion.

DIRECT VERSUS INDIRECT COSTS

Direct costs: Replacement of infrastructure. Product loss. Plant shutdown. Corrosion resistant materials. Cathodic Protection. Coatings. Inhibitors. Manpower. Inspection. Loss of life/ injur y. Loss of reliability (redundancy). Indirect costs: Loss of consumer confidence. Disruption to society. Litigation. Fines. Increased regulation. Failure analysis. Research and development. Education and training.

FORMS OF CORROSION
Uniform Galvanic Dealloying Pitting Crevice Stress Corrosion Cracking Intergranular Corrosion Erosion Corrosion Fretting Microbiological Corrosion High Temperature Corrosion Hydrogen Damage Sulfide Stress Corrosion

CORROSION FUNDAMENTALS

Chemistr y

ATOMS AND IONS

Elements are unique types of atoms. Nucleus containing:
Protons Neutrons

Orbiting electrons Listed in the Periodic Table of elements Chemistr y involves adding and subtracting electrons to atoms. Since electrons are charged, the resulting IONS have electrical charge.

THE PERIODIC TABLE OF THE ELEMENTS

IONS
However, electrons are negatively charged, so removing electrons makes the ion positively charged Compounds are a positive ion and a negative ion held together by electrostatic attraction. Overall the compound is neutral.
Fe 3+ + 3Cl - FeCl 3

In water, some ions are soluble and are surrounded by a solvation sphere of water molecules. State symbol: ( aq)

CHEMICAL REACTIONS AND SPONTANEIT Y

A chemical reaction may be spontaneous or non spontaneous. Spontaneous reactions are exothermic. Reverse the direction of reaction and change the energy changes:
Spontaneous, exothermic

Fe (s)

Fe 2+ (aq) + 2 e -

Non spontaneous, endothermic

CORROSION FUNDAMENTALS

2 Electroche mistr y

ELECTROCHEMISTRY
Corrosion is electrochemical. The transfer of electrons from one substance to another. Spontaneous chemical reactions liberate energy. This energy can be used to push electrons around a circuit, giving them a voltage. The materials proper ties change: Fe (s) Fe 2+ (aq) + 2 e In order for corrosion we need 4 things:
Anode Cathode Electrical path electrolyte

ELECTRODES NEEDED FOR CORROSION

ANODE Oxidation (loss of electrons). Corrosion. Source of electrons. More Active metals. Low [O 2 ]. CATHODE Reduction (gain of electrons). Protection from corrosion. Consumption of electrons. More Noble metal. High [O 2 ].

CONDUCTIVE PATHS NEEDED FOR CORROSION

Metallic path Allows the movement of ELECTRONS. From the anode to the cathode. Must be made of metal. REAL CURRENT. Electrolytic path Allows the movement of IONS. Positive ions flow from the anode. Must be an electrolyte (water or a molten salt). CONVENTIONAL CURRENT.