Material for Education ( )

2010.3.29
2012.12.14 maksgym

Type of Corrosion ( )
Type

(1)
Corrosion

General

(Uniform Corrosion

(2)

Crevice
Corrosion

Outline
Countermeasure

This is the type of corrosion which Painting is general

the surface of the metal is
countermeasure
corroded almost uniformly.
against this type of
This type of corrosion is usually corrosion.
caused on carbon steel such as

SS400 etc.
Basically, the corrosion which
occurs on materials of FC and Niresist cast iron is this type of
corrosion.

SS400
FC

This type of corrosion occurs

mainly at the parts of seawater
pump, such as the matching surface
of flange and the gap of joint
portion.
In addition, there is the case that
this type of corrosion occurs at
the metal surface to where marine
organisms attached.
The countermeasure against this
corrosion is one of the important
problems to be solved for seawater
pump made of stainless steel.

(3)

Galvanic
Corrosion

Prevent invasion
of seawater into
gap by applying
filling
material
(Applying KE-45
etc.)
Adoption
of
high
grade
material
Adoption
of
cathodic
protection
(sacrificing
anode, external
power method)

Remarks

Duplex
stainless
steel has
excellent
crevice
corrosion
resistance
.

KE-45

This is the phenomenon that less- Do not use lessnoble metal is corroded due to noble
formation
of
galvanic
cell
metals as much as

Trivia about Corrosion.doc

(4) Pitting

(5)
Intergranular
Corrosion

(corrosion battery) in the water,

when
different
materials
are
contacting each other.
This type of corrosion is called
galvanic corrosion, and it is easy
to occur on seawater pump.

possible for small

parts.

Avoid
direct
contact
of
different
materials
by
inserting
insulation
material between
those
different
metals.

Adopt cathodic
protection.

This is the phenomenon that the

surface of metal is eroded such as
apertures. This pitting is caused
because film of passive state of
the surface of stainless steel is
destroyed locally by chloride ion
(Cl ). This pitting is observed
often at impeller and shafts etc.
which are made of SCS13 (SUS304) of
seawater pump.

Cl

SCS13 SUS304

This is the corrosion that erosion

occurs along the boundary of
crystal gain inside of material.
As the result of separate out of
carbide at gain boundary, the film
of passive state of the surface of
stainless
steel
cannot
be
maintained due to shortage of Cr.
There is a case leading to crack.
The status that shows sensitivity
to intergranual corrosion is called
sensitization.

Trivia about Corrosion.doc

When handling liquid

is seawater, it is
hard
to
prevent
completely
the
occurrence
of
pitting.

Duplex
stainless
steel has
excellent
pitting
resistance
.

Carry
out
appropriate
heat
treatment.
(If heat treatment
is
insufficient,
phase or separate
out of carbide is
easily caused.)

(6) Stress Corrosion

Cracking (SCC)

Cr

This is the phenomenon that crack

occurs under the conditions of
tensile stress and the corrosive
circumstance.
This stress corrosion cracking has
to be noted for stainless steel of
seawater pump.
It is said that three major reasons
for the occurrence of SCC are:
Stress
-

Existence of chloride ion Cl

Temperature

SCC 3
Cl

(7)

Selective
Corrosion

(8)
Cavitation
Erosion

Decrease
of
design
stress
(adoption
of
shape
and
dimension that
do not cause
large
tensile
stress)
Decrease
residual stress
in
material
(carry
out
appropriate heat
treatment)

This is the phenomenon that some

component of alloy is selectively
liquates out.
As a typical example, there is
dezincification
corrosion
that
occurs on cupper alloy.

This is the corrosion accompanies

erosion due to cavitation.
Mainly, this cvitation erosion is
observed at inlet of impeller.

Trivia about Corrosion.doc

Avoid occurrence of
cavitation.

Material for Education ( )

2010.3.31

Trivia about Corrosion (

2012.12.19 maksgym
)
Extracted from various documents.

Cl

nm

Cr
11% Cr
11% Cr

Cl

Trivia about Corrosion.doc

Description
In general, the corrosion is the phenomenon
caused by electro chemical reaction.
(The corrosion of metal is the process that the
metal atom leaves from crystal lattice and moves
to water as the metal ion.)
The
corrosion
is
broadly
separated
into
General Corrosion (Uniform Corrosion)and
Local Corrosion.
The typical type of Local Corrosionis
Crevice
Corrosion,
Galvanic
Corrosionand Stress Corrosion Cracking.
The reason why corrosion is easily caused in
seawater than fresh water is that seawater
contains much chloride ion (Cl ) and has higher
electrical conductivity.
The reason why stainless steel is hardly corroded
is that film of passive state is formed on the
surface of stainless steel.
The thickness of film of passive state is in
the order of nm, therefore, it cannot be seen by
naked eye.
The element that forms this film of passive state
is chromium.
More than 11% of chromium is required to form the
film of passive state.
Therefore, stainless steel is iron base alloy
which contains more than 11% of chromium.
The film of passive state can resist to high
velocity, however, there is a case that pitting
or crevice corrosion is caused in seawater due
to partial destruction of the film of passive
state by chloride ion (Cl ). ( = Local
Corrosion )
When the different metallic materials are
contacting each other in seawater, less-noble
metal in respect of corrosion potential becomes
anode and is corroded preferentially, and noble
metal in respect of corrosion potential becomes
anode and its corrosion progress is suppressed.
This corrosion phenomenon is called Galvanic
Corrosion.

10

11

12

13

In general, the corrosion potential of each metal

in seawater is in the order as below:
(noble side: hardly corroded)
(less
noble side: easily corroded)
titanium > stainless steel > copper alloy > Niresist cast iron > steel & cast iron > aluminum >
zinc > magnesium

There is a case that Cathodic Protectionis

used for seawater pump as one of corrosion

protection method.

In cathodic protection, there are Sacrificing
Anode methodand External Power method.

Aluminum alloy or Zinc alloy is often used as

sacrificing anode because corrosion potential is

at less-noble side comparing with the other

metals.
As to steel and cast iron, corrosion speed in
seawater will be increased with increase in

velocity.
This phenomenon is due to diffusion promotion

action of dissolved oxygen by increase of
velocity.
(The dissolved oxygen acts as oxidizing agent to
promote corrosion.)

Cl
However, in the aqueous solution which contains

0.5m/s low concentration of chloride ion (Cl ),

the
corrosion
speed
increases
with

increase in velocity same as in seawater

Cl
if velocity is less than 0.5m/s

however, the corrosion speed decreases

with increase in velocity if velocity is

more than 0.5m/s

Because, in the aqueous solution which contains
low concentration of chloride ion (Cl ),
supply amount of dissolved oxygen to surface of
metal increases with increase in velocity, and
forms protective oxide film.

If velocity increase more and exceed some value

of velocity, oxide film on material surface is

destroyed, therefore, protective effect is lost

and corrosion speed increase remarkably.

This phenomenon, that corrosion is accelerated by

destruction of oxide film by mechanical action of

flow, is called Erosion Corrosion.

The critical velocity in seawater, that type of

corrosion shifts to erosion corrosion, cannot be

presented precisely, however, it is said that it

20m/s
is about 20m/s in case of cast iron.

Trivia about Corrosion.doc

14

15m/s

15

S2

10 100

16

17

18

2 4% C 2%
Si

7 10

Trivia about Corrosion.doc

The corrosion erosion of copper alloy is caused

at lower velocity than that of the cast iron.
It is confirmed that corrosion speed of various
bronze castings increase rapidly due to erosion
corrosion if velocity exceed about 15m/s.
However, aluminum bronze casting resist well to
high velocity.
Form the above, there are experiences in adoption
of aluminum bronze castings for the casing and
impeller for seawater pump.
In contaminated seawater which contains sulfide
ion S2 or ammonium ion, there is a case
that the corrosion speed of copper alloy will
increase 10 to 100 times.
Steel is not sensitive like copper alloy to
contaminated seawater, however, it is said that
the corrosion speed is promoted to about two
times.
In general, the corrosion speed of steel and cast
iron in seawater will increase with increase of
velocity.
However, if un-uniformity of velocity is caused
inside of equipment such as pump and valve, there
is a case that the relationship between velocity
and corrosion velocity will be reversed.
This corrosion phenomenon is caused for the
following sequences and is called velocity
difference corrosion:
1) The supply of dissolved oxygen to surface of
material becomes more active when velocity
becomes high.
2) As the result, electric potential becomes
noble at the portion of high velocity, and
oxygen concentration cell will be formed
because low velocity portion becomes anode
and high velocity portion becomes cathode.
3)
Consequently, low velocity portion will be
corroded.
(However, it is said that there is rare case that
velocity difference corrosion will be the cause
of serious trouble.)
Graphitic
corrosionis
characteristic
corrosion of cast iron.
In general, cast iron contains 2% to 4% of C
(carbon) and about 2% of Si, its metallographic
structure contains dispersed graphite in ferrite
base or in perlite base.
The density of graphite carbon is low, therefore,
its ratio of existence accounts for 7% to 10% in
volumetric ratio.
Ferrite base or perlite base is changed to iron
6

19

20

21

22

oxide (rust), and graphite carbon is remained as

it is.
The corrosion layer is formed as the result of
capture of corrosion product by the remained
graphite carbon.
This corrosion layer is called graphitized
layer, and the type of corrosion that forms
graphitized
layer
is
called
graphitic
corrosion.
The graphitized layer can be easily removed with
tool such as screw driver because its strength is
very low.
When mixture use of different metals is
inevitable for seawater pump, the most important

point to be noted in order to mitigate galvanic

/ corrosion is to make small ratio of area of
cathode / anode.
(Namely, increase area of less-noble potential
material.)
For example, when area of cast iron (anode) is

smaller than area of stainless steel (cathode),

cast iron is corroded remarkably.
In order to mitigate such damage due to galvanic
corrosion, there is a case that it will be

preferable to paint the metal of cathode side or

the metals of both sides of cathode and anode
rather than to paint the metal of anode side.

Cr Mo The addition of Cr, Mo and N is effective in

N
order to improve corrosion resistance of

stainless steel.
Cr Mo N From the above, the corrosion resistance of
PRE stainless steel under environment of chloride is

PRE Cr%
defined with pitting index (PRE)that is
3.3Mo% 16N%
calculated from the content of Cr, Mo and N.

SUS304

PRE (PRE Cr% 3.3Mo% 16N%)

18

SUS316

PRE For example, the corrosion resistance increase

25 SUS329J4L PRE 38 PRE with increase in value of PRE in order of

SUS304
PRE
18
SUS316
PRE
25 SUS329J4L PRE 38 .
PRE 40 The duplex stainless steel which is higher than
PRE40 is called super duplex stainless steel,

and has excellent resistance to pitting and
crevice corrosion.
There is report which is introducing speed of
Cl SUS304
crevice corrosion resistance of stainless steel

SUS316L 2 under the condition of Cl concentration level
SUS329J4L
of natural seawater as follows:
100 Comparing with crevice corrosion resistance

speed of SUS304,
SUS316L has about two (2) times of SUS304
SUS329J4L (duplex stainless steel) has

Trivia about Corrosion.doc

23

24

SCC

SCC 3
Cl

SCC 50 60

SCC

25

SCC
SCC
Type D2

Type
2
Type D2
SCC

26

SCC SCC

27

Trivia about Corrosion.doc

crevice corrosion resistance about one

hundred (100) times of SUS304
Stress Corrosion Cracking (SCC)is the
phenomenon that cracking is caused due to tensile
stress under corrosion circumstance. (SCC in not
caused due to compressive stress.)
It is said that three main causes of SCC of
stainless steel is stress, existence of Cl and
temperature.
If metallographic structure of stainless steel is
sound, it is said that SCC will not be problem
for pump which handles natural seawater because
SCC is not caused at temperature of less 50
60.
(The occurrence of SCC is promoted if there is
deposition of carbide, nitride and etc. at grain
boundary of metallographic structure.)
When controlling of environment is difficult, it
is necessary to reduce design stress of equipment
and residual stress of material.
Ni-resist cast iron is adopted to seawater pump and
brine pump because the following features are
preferred:
Comparing with normal cast iron, uniform
corrosion speed is low.
Crevice corrosion or pitting which occurs
on stainless steel is not caused.
However, Ni-resist cast iron has sensitivity to SCC even
in seawater at normal temperature.
In order to prevent SCC of Ni-resist cast iron, it is
effective way to adopt nodular graphite type (Type
D2), to decrease stress or to adopt cathodic protection.
(SCC resistance of nodular graphite type (Type D2) is
much superior than that of graphite flake (Type 2).)
When metal receives repeated stress under
corrosion
circumstance,
fatigue
strength
decreases remarkably.
This phenomenon is called fatigue corrosion.
Meanwhile, the influence of coexistence of SCC
and fatigue corrosion shall be considered
because Stress Corrosion Cracking (SCC)
will be problem depending on material and
circumstance.
The first prevention measure against fatigue
corrosion is to perform appropriate structural
design.
The appropriate structure design mainly means
that execution of decrease of design stress
amplitude by deceasing stress concentration and
selection of appropriate shape.
In order to decrease stress concentration,
especially, careful attention shall be paid to
8

SCC

1.8

Trivia about Corrosion.doc

the portion where section is changed suddenly.

The second prevention measure against fatigue
corrosion
is
adopt
together
appropriate
corrosion protection.
As the third prevention measure against fatigue
corrosion, appropriate selection of material,
appropriate manufacturing method and appropriate
maintenance are raised.
As to manufacturing method, it is expected to
improve resistance to SCC and strength of fatigue
corrosion, if compressive residual stress is
remained on the surface layer by shot peening,
sandblasting and etc.
It is reported there is a case that by adoption
of shot peening strength of fatigue corrosion is
improved to about 1.8 times of that of finished
with paper.

Japan Stainless Steel Association

http://www.jssa.gr.jp/contents/faq-article/q8/

Pitting

Crevice Corrosion

Intergranular Corrosion
Caused at heat affected area by welding

Trivia about Corrosion.doc

10

Stress Corrosion Cracking

Wikipedia
http://ja.wikipedia.org/wiki/%E3%82%AD%E3%83%A3%E3%83%93%E3%83%86%E3%83%BC
%E3%82%B7%E3%83%A7%E3%83%B3

Hydraulic Turbine

Cavitation

Trivia about Corrosion.doc

11

 Trivia about Corrosion.doc

12