Chemical Engineering Course (undergraduate)

Bahan Konstruksi dan Korosi

(Construction Material and Corrosion)

Presented by:
Achmad Chafidz M. S., S.T., M.Sc.
Department of Chemical Engineering, Universitas Negeri Semarang

Universitas Negeri Semarang (UNNES)

Semester Ganjil 2016/2017
Corrosion Prevention
Mechanism Of Electrochemical Corrosion

Anodic Reaction:
Dissolution of metal takes place.
As result metal ions are formed with the liberation of free electrons.
M M+n + e-
Metal Ion
Cathodic Reaction
(i) Hydrogen Evolution :- Occurs usually in acidic medium
2H+ + 2e- H2 (g)
(ii) Oxygen Absorption :- occurs when solution is aerated sufficiently.
O2+ 4H+ + 4e- 2H2O (In acidic medium)
1
O+ H2O + 2e- 2OH- (In basic medium)
2 2

Galvanic Corrosion:- When two different metals are present in contact with each other
in conducting medium e.g. Electrolyte
 Factors Affecting Corrosion
1. Nature of the Metal 2. Nature of the environment.

1. Nature of Metal
(i) Position in Galvanic Series:
If two metals are present in in electrolyte, the metal with less reduction potential
undergoes corrosion.
- Greater the difference faster the corrosion.
(ii) Over Voltage:
Hydrogen evolves into gas and reacts at different rates for each type of metal. Thus,
it can be said that the rate of corrosion varies in every kind of metal.
The key here is to elevate the hydrogen overvoltage in order to slow down or halt
the corrosion reaction. For instance, there are corrosion inhibitors that can make
hydrogen overvoltage increase and at the same time make dissolution current
decrease as it inhibits both cathodic and anodic processes.
(iii) Area and Distance:
When anodic metal area is smaller than cathodic area, rate of corrosion at anode
is higher because of demand of electron by cathodic area.
(iv) Physical and Mechanical properties of Metal:
(a) Pure metals are more corrosion resistant.
(b) Smaller grain size metal have high solubility and corrosion.
(c) Uniform distribution of stress on metal reduces rate of corrosion.
(d) Passive metals shows higher corrosion resistance because of formation of
protective oxide film on their surface.
(e) Polycrystalline forms are more sensitive.

2. Nature of Environment
(i) Temperature: directly proportional
(ii) Humidity: faster in humid conditions
(iii) pH : If less than 7 rate is high. Al, Zn, Sn, Pb, and Fe are affected by both acid and
bases.
(iv) Impurities and Suspended Particles: When these will get dissolved in moisture,
provides electrolyte for conductivity and hence corrosion increases.
 Corrosion Control:
1. Selection of material

2. Proper design of metal

3. Cathodic protection / galvanic corrosion protection

4. Modifying environment

5. Protective coating

6. Proper design of construction

 Corrosion Control:
1. Selection of material:
Selection of proper material for a particular corrosive service
Metallic Using pure and noble metals are practically not possible
because of low strength of pure metal. Use of metal alloys which are
homogeneous
Nonmetallic rubbers (natural and synthetic), plastics, ceramics, carbon
and graphite, and wood

2. Proper design of metal:

Minimal contact with medium
Prevention from moisture
Adequate ventilation and drainage
Welding
Avoid cervices b/w adjacent parts
Bend should be smooth
Bimetallic contacts should be avoided
Paint cathodic portion
Prevent uneven stress
(b) Alloying the metal
Alloying the metal is to produce a more corrosion resistant alloy, e.g.
stainless steel, in which ordinary steel is alloyed with chromium and nickel.
Stainless steel is protected by an invisibly thin, naturally formed film of chromium
sesquioxide Cr2O3
In general, the corrosion behavior of alloys depends on the interaction of:
1. The alloy of specific chemical composition and metallurgical structure.
2. The film on the alloy surface.
3. The environment, whether it is sufficiently aggressive to break down the
protectiveness of the surface film, thereby initiating localized corrosion.
4. The alloy/environment combination, controlling whether the film self
repairs after breakdown and, if not, the type and rate of corrosion that
propagates after initiation has occurred
Stainless Steels

Stainless steels are iron

base alloys that contain

Dissolution rate, cm/sec

a minimum of
approximately 11% Cr,
the amount needed to
prevent the formation
of rust in unpolluted
atmosphere.

wt.% Cr
Alloying of Fe with Cr

A protective Cr2O3 layer forms on the surface of Fe

(Cr2O3) = 0.001 (Fe2O3)
Upto 10 % Cr alloyed steel is used in oil refinery components
Cr > 12% stainless steels oxidation resistance upto 1000oC
turbine blades, furnace parts, valves for IC engines
Cr > 17% oxidation resistance above 1000oC
18-8 stainless steel (18%Cr, 8%Ni) excellent corrosion resistance
Kanthal (24% Cr, 5.5%Al, 2%Co) furnace windings (1300oC)

Other oxidation resistant alloys

Nichrome (80%Ni, 20%Cr) excellent oxidation resistance

Inconel (76%Ni, 16%Cr, 7%Fe)
Metals and Alloys

No Environment Proper material

1 Nitric acid Stainless steels
2 Caustic Nickel and nickel
alloys
3 Hydrofluoric acid Monel (Ni-Cu)
4 Hot hydrochloric acid Hastelloys (Ni-Cr-
Mo) (Chlorimets)
5 Dilute sulfuric acid Lead
No Environment Proper material
6 Nonstaining atmospheric Aluminium
exposure
7 Distilled water Tin

8 Hot strong oxidizing Titanium

solution
9 Ultimate resistance Tantalum

10 Concentrated sulfuric Steel

acid
 Alloying elements of stainless steel :
Other than Ni, Cr and C, the following alloying elements
may also present in stainless steel: Mo, N, Si, Mn, Cu, Ti,
Nb, Ta and/or W.

Main alloying elements (Cr, Ni and C):

1. Chromium
Minimum concentration of Cr in a
stainless steel is 12-14wt.%
Structure : BCC (ferrite forming element)

* Note that the affinity of Cr to form Cr-carbides is very

high. Chromium carbide formation along grain
boundaries may induce intergranular corrosion.
2. Nickel

Structure: FCC (austenite forming element/stabilize

austenitic structure)
Added to produce austenitic or duplex stainless
steels. These materials possess excellent ductility,
formability and toughness as well as weld-ability.
Nickel improves mechanical properties of stainless
steels servicing at high temperatures.
Nickel increases aqueous corrosion resistance of
materials.
3. Carbon

Very strong austenite forming element (30x more

effective than Ni). I.e. if austenitic stainless steel
18Cr-8Ni contains 0.007%C, its structure will
convert to ferritic structure. However the
concentration of carbon is usually limited to
0.08%C (normal stainless steels) and 0.03%C
(low carbon stainless steels to avoid sensitization
during welding).
3. Carbon

Very strong austenite forming element (30x more

effective than Ni). I.e. if austenitic stainless steel
18Cr-8Ni contains 0.007%C, its structure will
convert to ferritic structure. However the
concentration of carbon is usually limited to
0.08%C (normal stainless steels) and 0.03%C
(low carbon stainless steels to avoid sensitization
during welding).
Minor alloying elements :
Manganese
Austenitic forming element. When necessary can be used to
substitute Ni. Concentration of Mn in stainless steel is usually
2-3%.

Molybdenum
Ferritic forming element. Added to increase pitting corrosion
resistance of stainless steel (2-4%).
Molybdenum addition has to be followed by decreasing
chromium concentration (i.e. in 18-8SS has to be decreased
down to 16-18%) and increasing nickel concentration (i.e. has
to be increased up to 10-14%).
Improves mechanical properties of stainless steel at high
temperature. Increase aqueous corrosion resistance of material
exposed in reducing acid.
 Tungsten
Is added to increase the strength and toughness of
martensitic stainless steel.

Nitrogen (up to 0.25%)

Stabilize austenitic structure. Increases strength and corrosion
resistance. Increases weld ability of duplex SS.

Titanium, Niobium and Tantalum

To stabilize stainless steel by reducing susceptibility of the
material to intergranular corrosion. Ti addition > 5x%C.
Ta+Nb addition > 10x%C.
 Copper
Is added to increase corrosion resistance of stainless steel
exposed in environment containing sulfuric acid.

Silicon
Reduce susceptibility of SS to pitting and crevice corrosion
as well as SCC.
Influence of alloying elements on pitting
corrosion resistance of stainless steels
Influence of alloying elements on crevice
corrosion resistance of stainless steels
Influence of alloying elements on SCC
resistance of stainless steels
Five basic types of stainless steels :

Austenitic - Susceptible (rentan) to SCC. Can be hardened

by only by cold working. Good toughness and formability,
easily to be welded and high corrosion resistance.
Nonmagnetic except after excess cold working due to
martensitic formation.
Martensitic - Application: when high mechanical strength
and wear resistance combined with some degree of
corrosion resistance are required. Typical application include
steam turbine blades, valves body and seats, bolts and
screws, springs, knives, surgical instruments, and chemical
engineering equipment.
Ferritic - Higher resistance to SCC than austenitic SS. Tend
to be notch sensitive and are susceptible to embrittlement
during welding. Not recommended for service above 3000C
because they will loss their room temperature ductility.
 Duplex (austenitic + ferritic) has enhanced resistance to
SCC with corrosion resistance performance similar to AISI
316 SS. Has higher tensile strengths than the austenitic
type, are slightly less easy to form and have weld ability
similar to the austenitic stainless steel. Can be considered as
combining many of the best features of both the austenitic
and ferritic types. Suffer a loss impact strength if held for
extended periods at high temperatures above 3000C.

Precipitation hardening - Have the highest strength but

require proper heat-treatment to develop the correct
combination of strength and corrosion resistance. To be
used for specialized application where high strength
together with good corrosion resistance is required.
Stress Corrosion Cracking of Stainless Steel
Stress corrosion cracking (SCC) is defined as crack
nucleation and propagation in stainless steel caused by
synergistic action of tensile stress, either constant or slightly
changing with time, together with crack tip chemical
reactions or other environment-induced crack tip effect.

SCC failure is a brittle failure at relatively low constant

tensile stress of an alloy exposed in a specific corrosive
environment.

However the final fracture because of overload of

remaining load-bearing section is no longer SCC.
 Three conditions must be present
simultaneously to produce SCC:
- a critical environment
- a susceptible alloy
- some component of tensile stress
 Pure metals are more
resistance to SCC but not
Tensile stress immune and susceptibility
is below yield increases with strength
point

Susceptible
Tensile
material
stress

Stress
Corrosive corrosion
Corrosive environment
environment is cracking
often specific to
the alloy system
Control/prevention :

Reduce applied stress level

Remove residual tensile stress (internal stress)
Lowering oxidizing agent and/or critical
species from the environment
Add inhibitor
Use more resistant alloys
Cathodic protection
 Corrosion Control:
1. Selection of material

2. Proper design of metal

3. Cathodic protection / galvanic corrosion protection

4. Modifying environment

5. Protective coating

6. Proper design of construction

3. Cathodic Protection:
Force the metal to be protected to behave like cathode.
(i) Sacrificial anodic protection (Galvanic Corrosion Protection)
- Metal to be protected from corrosion connected to more anodic metal
- Commonly used metals Mg, Zn, Al and their alloys
(ii) Impressed current method:
- Direct current is applied in opposite direction to nullify the corrosion current
- Converts the corroding metal from anode to cathode.
(iii) Galvanized steel
 Cathodic protection
Sacrificial Anode Applied Voltage
 Cathodic Protection (CP)
Cathodic protection (CP) is a technique to control the corrosion of a metal surface by
making it work as a cathode of an electrochemical cell. This is achieved by placing in
contact with the metal to be protected another more easily corroded metal to act as the
anode of the electrochemical cell. Cathodic protection systems are most commonly used to
protect steel, water or fuel pipelines and storage tanks, steel pier piles, ships, offshore oil
platforms and onshore oil well casings.
Types of CP:
sacrificial anodes (zinc, magnesium or aluminum): The sacrificial anodes are more
active (more negative potential) than the metal of the structure theyre designed to
protect. The anode pushes the potential of the steel structure more negative and
therefore the driving force for corrosion halts. The anode continues to corrode
until it requires replacement,
Impressed current CP: done for large structures (pipes, offshore platforms, etc)
where a galvanic (or sacrificial) anode can not economically deliver enough current.
Galvanized steel (see previous slide): again, steel is coated with zinc and if the zinc
coating is scratched and steel exposed, the surrounding areas of zinc coating form a
galvanic cell with the exposed steel and protects in from corroding. The zinc
coating acts as a sacrificial anode.
 CATHODIC & ANODIC
PROTECTION
Cathodic protection: Make the structure more cathodic by
Use of sacrificial anodes

Impressed currents

Galvanized steel

Anodic protection: Make passivating metal structures more

anodic by impressed potential. e.g. 316 s.s. pipe in sulfuric acid
plants.
 Anodic protection Passivation

Some materials, such as

Aluminum or Stainless Steel,
form oxide barrier coatings
that prevent oxidation at
active surface this is called
passivation

Surface can be coated with protective layers: painted,

anodized, plated (Caution!!! Cracks in plating or paint can
lead to crevice corrosion!)
 Sacrificial Anode
When metals such as magnesium or zinc are
placed in the environment in contact with a
more noble metal such as steel, a current flows
from the more active anode to the noble
cathode (corrosion cell).

37
 Anodes Used for Sacrificial
Anode
Magnesium Magnesium is often used in soil to
protect small electrically isolated structures, such
as underground storage tanks, and well coated
pipelines.
Zinc Zinc is often used in marine
environments. They are commonly found on
boats.
Aluminum Aluminum can be used for a variety
of marine applications.

38
 STANDARD EMF SERIES
EMF series Metal with smaller
o
Vmetal o
metal Vmetal corrodes.
Au +1.420 V
Cu +0.340 Ex: Cd-Ni cell
Pb - 0.126
Sn - 0.136
Ni - 0.250 o
Co - 0.277 DV =
Cd - 0.403 0.153V
Fe - 0.440
Cr - 0.744
Zn - 0.763
Al - 1.662
Mg - 2.262
Na - 2.714
K - 2.924
5
Aluminium anodes mounted on a steel jacket
structure using galvanic corrosion for
corrosion control! Called cathodic protection
(aka sacrificial anode)
42
 Applications of Cathodic Protection

Galvanized Steel
Zinc coating

Sacrificial Anodes
Ship Hulls
Subs (free flooding areas)

Los Angeles Class Sub

Arleigh-Burke Destroyer
 Keys to obtaining enough
cathodic protection
Determine amount of current required
Theoretical calculations based on coating quality

and environment
Or, perform current requirement testing

Calculate output expected from anode and

determine number of anodes required.

44
 Sacrificial Anode
Pros of Sacrificial Anode
Inexpensive

Little Maintenance cost

No external Power source

A variety of install methods can be used. For

example, many USTs are shipped with anodes
attached.

45
 Sacrificial Anode
Cons of Sacrificial Anode
Typically work best with electrically isolated structures.

No external power source, limited driving potential

(driving potential based on the galvanic series)
Limited output makes it ineffective when trying to
protect large uncoated surfaces.
Require a low resistivity electrolyte to function well.

46
 Impressed Current CP
Utilize an external power source to develop a
high potential difference between the surface to
be protected and an anode.

47
 Impressed Current CP

IMPRESSED CURRENT SYST

Anode Groundbed

Positive Cable
Rectifier
AC Power Supply
Negative Cable

Pipeline
 Impressed Current CP
Pros of Impressed Current CP
Unlimited driving potential.
Capable of protecting large steel structures
when designed properly.
Requires less anodes then a galvanic system.
Output can be controlled using a permanent
reference electrode, desirable when the
electrolyte resistivity is known to change.

49
 Impressed Current CP
Cons of Impressed Current CP
Initial costs can be more expensive.

Requires an external DC power source along

with an AC supply.
System requires routine maintenance and
monitoring.
Anode wires can be susceptible to damage.

50
Impressed Current CP Rectifier
A rectifier converts available AC power to low
voltage DC power. Most cathodic protection
rectifiers are provided with a means to vary the
DC output voltage in small increments, or in
some cases offer complete control from zero to
100% of rated DC output.

51
52
 CP System Testing
A CP system can be evaluated by obtaining a
reference cell potential. This potential
determines the amount of cathodic polarization
the structure is receiving.
Adequate protection is indicated by obtaining a
value more negative then the established criteria.
This criteria is specific to the reference cell used
to obtain potentials.

53
4. Modifying Environment
(i) Eliminating dissolved oxygen:
- De-aeration
- By using chemical substances like sodium sulphite and hydrazine. Also called
Deactivation.
(ii) Reducing Moisture:
- Dehumidification by using silica gels
(iii) Reducing Acidity:
- Neutralizing the acidic environment by adding lime, NaOH, Ammonia
- Commonly used in refineries
5. Protective coating:
- Application of coating
- Coating material should be chemically inert under particular temp and pressure.
Upaya pengubahan lingkungan yang menjadikannya kurang agresif akan
bermanfaat untuk membatasi serangannya terhadap logam.
Dalam hal ini ada 3 situasi yang akan kita pelajari :
1. Lingkungan berwujud gas : udara dengan rentang T = -10oC +30oC.
Beberapa metode yang digunakan untuk mengurangi laju korosi di udara bebas :
- menurunkan kelembaban relatif
- menghilangkan komponen-komponen mudah menguap yang dihasilkan
oleh bahan-bahan di sekitar
- mengubah temperatur
- menghilangkan kotoran-kotoran (termasuk partikel-partikel padat yang
abrasif), endapan-endapan yang akan membentuk katoda (misalnya jelaga) dan
ion-ion agresif
2. Bahan terendam di air bebas yang cukup mengandung ion untuk
menjadikannya sebuah elektrolit. Modifikasi terhadap elektrolit meliputi :
- menurunkan konduktivitas ionik
- mengubah pH
- secara homogen mengurangi kandungan oksigen
- mengubah temperatur
3. Logam terkubur dalam tanah dan mineral-mineral yang terlarut
membentuk elektrolit. Pengendalian biasanya melalui proteksi katodik atau
pelapisan permukaan, tetapi lingkungan tersebut dapat dibuat kurang agresif
dengan mengganti tanah urugan yang tidak menahan air, mengendalikan pH dan
mengubah konduktivitasnya.
6. Use of corrosion Inhibitor
Berdasarkan bahan dasarnya
Inhibitor inorganik
Inhibitor organik

Berdasarkan reaksi yang dihambat

Inhibitor Katodik
Inhibitor Adsorpsi
Inhibitor Anodik

(i) Anodic Inhibitor:

- They combine the anodic metal forming an oxide film which reduce corrosion
(ii) Cathodic inhibitor:
- Organic inhibitors like amines, mercaptans, urea and thiourea reduces the H ion
diffusion by adsorption
- Mercury, arsenic and antimony deposits films at cathodic area which raise the
hydrogen over volume.
- Eliminating Oxygen from the medium by adding sodium sulphate and hydrazine.
 Inhibitor Penggunaan Logam yang Konsentrasi
dilindungi umumnya
Air pendingin Baja 0,05%
Larutan garam Baja Up tp 5%
Natrium nitrit
Air laut Baja 0,5%
Pendingin mesin Baja Hingga 1%
Natrium nitrat Mencegah instrumen Baja
peretakan kaustik
Air pendingin Baja 1%
Natrium hidrogen Ketel Baja, tembaga, seng 10 ppm
fosfat
Air laut (+ Na nitrit) Baja 10 ppm
Pendingin mesin Baja 1%
Boraks
Sistem pendingin glikol Baja 1%
Air minum Baja, tembaga, seng 10 20 ppm
Natrium silikat Air garam ladang minyak Baja 0,1%
Air laut Baja 10 ppm
Ion arsenat Kebanyakan asam pekat Baja 0,5%
Kondensat uap dalam ketel Baja
Amina organik Asam Baja Variabel
Air garam ladang minyak Baja
Hidrasin Pemakaian oksigen Baja Sesuai
(temperatur tinggi) kebutuhan
Natrium sulfit Pemakaian oksigen Baja Sesuai
(temperatur rendah) kebutuhan
 Inhibitor Korosi dalam Baja Tulangan

Syarat inhibitor adalah :

Dapat menginhibisi korosi baja tulangan dalam
campuran beton yang terkontaminasi ion klorida dan
gas CO2
Tidak mempunyai efek-efek yang merugikan pada sifat-
sifat kuat tekan beton, kekuatan lekat baja tulangan,
waktu curing, dan pencampuran.
Inhibitor korosi secara umum membentuk suatu lapisan
tipis protektif yang dapat menghambat air kontak
dengan baja tulangan beton.
Protective Coatings / Wrapping
Provide barrier between metal and environment.
Coatings may act as sacrificial anode or release substance
that inhibit corrosive attack on substrate.
Metal coatings :
Noble silver, copper, nickel, Cr, Sn, Pb on steel.
Should be free of pores/discontinuity coz creates
small anode-large cathode leading to rapid attack
at the damaged areas.
Sacrificial Zn, Al, Cd on steel. Exposed substrate
will be cathodic & will be protected.
Application hot dipping, flame spraying, cladding,
electroplating, vapor deposition, etc.
 Surface modification to structure or composition by use
of directed energy or particle beams. E.g ion implantation
and laser processing.
Inorganic coating : cement coatings, glass coatings, ceramic
coatings, chemical conversion coatings.
Chemical conversion anodizing, phosphatizing, oxide
coating, chromate.
Organic coating : paints, lacquers, varnishes. Coating liquid
generally consists of solvent, resin and pigment. The resin
provides chemical and corrosion resistance, and pigments
may also have corrosion inhibition functions.
 Protective Coating
Surface preparation for Coating:
1. Cleaning:
- To prepare for suitable condition. Adhesion is the most important attribute of a
coating. A clean surface with the proper profile provides a surface to which a
coating can adhere.
- Removing contaminants to prevent detrimental reaction product
- A clean steel surface should be free of all: oil, grease, dust, dirt, mill scale, rust,
coating, oxides, corrosion products, other foreign matter
- E.g. de-greasing, sand blasting, vapour degreasing, pickling and alkaline cleaning.
2. Solvent Cleaning:
- Must be non-inflammable and nontoxic
- Trichloro trifluoroethane which has low toxicity are costlier
- Vapour de-greasing is economical and advantageous because of continuous
cleaning with small quantities of solvent.
3. Electrolyte Pickling:
- Provides better and rapid cleaning by increasing hydrogen evolution resulting in
agitation and blasting action
- Sand blasting is mechanical cleaning.
4. Alkaline Cleaning:
- Cheaper and less hazardous
- Used in conjunction with surface active (wetting) agent
- Ability depends on pH, rapidly decreases below 8.5
- Other abilities are rinsability, detergent properties, sequestering, wetting etc.

5. Acid Cleaning
- Acid such as HCl, H2SO4, H3PO4 is very effective.
- 5-10% H2SO4 and HCl used to remove inorganic contaminants.
- Pickling are performed at high temp. (60 C)
- Is effective for removal of grease, oil , dirt and rust.

Note: Mill scale is the blue/black oxide layer that forms on hot rolled steel during the
cooling process. Mill scale is cathodic to the steel.
Mill scale is cathodic to the steel. If mill scale is left on the surface, and painted over,
the steel will rust and sacrifice itself trying to protect the mill scale.
 Methods of Application of Metallic Coating

1. Hot Dipping:
- Metal is kept in molten state and base metal is dipped into it.
- Used for producing a coating of low M.P
- E.G. Tinning (Tin coating on Iron)
- Process is followed by cooling the coating through a palm oil to prevent oxidation
of tin plate to its oxide.
- Palm oil layer is removed by alkaline cleansing agent.

2. Metal Cladding:
- The surface to be protected is sandwiched between two layers of the coating
metals and pressed between rollers.
- E.g. Alclad Sheeting Plate of duralumin is sandwiched between 99.5%pure
aluminum
3. Electro Plating:
- Pure metal is made as cathode and base metal as anode.
- Electrochemically coat metal is deposited on base metal.
- This metal gives smooth, fine and uniform coating
- It depends on
(i) Temperature (ii) Current density (iii) Electrolyte Concentration
(iv) Nature of base metal (v) Time

4. Electroless Plating:
- Nobel metal is deposited catalytically on less noble metal by using reducing agent
without using electrical energy.
- Advantage over Electro plating
(i) More economical since no electricity required
(ii) Irregular shape can be plated uniformly
(iii) Plating on plastics can also be done
5. Metal Spraying:
- Coating is applied by means of spraying device
- E.g. Aluminum is plated in this way on Aircrafts.

Chemical Conversion Coating

These are formed on metal surface by chemical reaction b/w metal surface and
inorganic salt solution
Coating base metal is converted into one of the resultant protective film.
These films are insoluble, adherent, crystalline or amorphous in nature.
Can be done in 3 ways
1. Phosphate coating
2. Chromate coating
3. Anodized coating
1. Phosphate Coating

- Produced by chemical reaction b/w base metal and aq. H3PO4, Zn or

Fe or Mn Phosphate
- Phosphate coating are applied Iron, Steel, and Zinc
- Film formed on base metal after coating consist of Zn-Fe, Mn-Fe
Phosphates.

2. Chromate Coating

- Produced by dipping the base metal in Potassium chromate (acidic)

followed by immersion in neutral chromate bath.
- Resulting film consist of trivalent and hexavalent chromium.
- Used as base for paints, lacquers and enamels.
3.Anodized Coating
- Formed by anodic oxidation process
- This is produced on non-ferrous metals like Al, Zn, Mg
- In this method base metal is made as anode
- Process is carried out by passing moderate direct current through a bath in which
the metal is suspended as anode.
- Coating are formed as a result of Progressive oxidation starting at surface of base
metal.
Sifat-sifat ideal bahan pelapis dari logam :
1. Logam pelapis harus jauh lebih tahan terhadap serangan lingkungan
dibanding logam yang dilindungi
2. Logam pelapis tidak boleh memicu korosi pada logam yang dilindungi
seandainya mengalami goresan atau pecah dipermukaannya
3. Sifat-sifat fisik seperti kelenturan dan kekerasannya, harus cukup memenuhi
persyaratan operasional struktur atau komponen bersangkutan
4. Metode pelapisannya harus bersesuaian dengan proses fabrikasi yang
digunakan untuk membuat produk akhir
5. Tebal lapisan harus merata dan bebas dari pori-pori.

Tahapan paling penting sebelum suatu logam menjalani proses

pelapisan adalah tahap penyiapannya yaitu untuk :
1. Membuang semua kotoran pada permukaan seperti gemuk, minyak, debu
dan serpihan dari proses produksi
2. Membuang produk-produk korosi yang sudah terbentuk pada permukaan
3. Mengatur karakteristik fisik permukaan
Design Dos & Donts
Wall thickness allowance to accommodate for corrosion
effect.
Avoid excessive mechanical stresses and stress concentrations
in components exposed to corrosive mediums. Esp when
using materials susceptible to SCC.
Avoid galvanic contact / electrical contact between dissimilar
metals to prevent galvanic corrosion.
Avoid sharp bends in piping systems when high velocities
and/or solid in suspension are involved erosion corrosion.
Avoid crevices e.g weld rather than rivet tanks and other
containers, proper trimming of gasket, etc.
 Avoid sharp corners paint tends to be thinner at sharp
corners and often starts to fail.
Provide for easy drainage (esp tanks) avoid remaining
liquids collect at bottom. E.g steel is resistant against
concentrated sulfuric acid. But if remaining liquid is
exposed to air, acid tend to absorb moisture, resulting in
dilution and rapid attack occurs.
Avoid hot spots during heat transfer operations localized
heating and high corrosion rates. Hot spots also tend to
produce stresses SCC failures.
Design to exclude air except for active-passive metals and
alloys coz they require O2 for protective films.
Most general rule : AVOID HETEROGENEITY!!!
DESIGN for
Corrosion
DESIGN for
Corrosion

Bracket easier to
replace than
pipe!