Fahmi Mubarok ST, MSc , PhD

Departemen Teknik Mesin ITS

Kampus ITS Keputih Sukolilo-Surabaya 60111
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New art?
ADVANTAGE OR
DISADVANTAGE?

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Frekuensi penyebab khusus kegagalan dari komponen
permesinan yang ada di dalam dunia industri

(Brooks R.C., Failure Analysis of Engineering Materials. New York : McGraw-Hill. 2002)
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Serangan eletrokimia menyebabkan degradasi material

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 Pengolahan

Logam/
Mineral paduan

Oksida Metal
Natural

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CONTOH KERUSAKAN AKIBAT KOROSI

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• Two reactions are necessary:
-- oxidation reaction: Zn  Zn2  2e
-- reduction reaction: 2H  2e  H2 (gas )

• Other reduction reactions:

-- in an acid solution -- in a neutral or base solution
O2  4H  4e   2H2O O2  2H2O  4e  4(OH) 
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 --Metal sample mass

--Metal is the anode (-)

o
Vmetal  0 (relative to Pt)

Standard Electrode Potential 4

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• EMF series • Metal with smaller
o
Vmetal o
metal Vmetal corrodes.
Au +1.420 V • Ex: Cd-Ni cell
Cu +0.340
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
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 Cathode Anode
Cu +
-
H+ Zn
H+ Zn2+

reduction 2e - oxidation
2H  2e  H2 (gas )
H+
O2  4H  4e   2H2O H+
Acid H+
H+ H+

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• Ranks the reactivity of metals/alloys in seawater

Platinum
Gold
Graphite
Titanium
Silver
316 Stainless Steel
Nickel (passive)
Copper
Nickel (active)
Tin
Lead
316 Stainless Steel
Iron/Steel
Aluminum Alloys
Cadmium
Zinc
Magnesium
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Shows what changes in the
environment (pH and potential) that
are necessary to prevent corrosion
 ’Active (corrosion) region
 ’Passive region
 ’Immune region
„Does not say anything about
corrosion rates  we need to include
electrode kinetics

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 Korosi Baja
 Water present
 A metal with Anodic and Cathodic reactions
Anodic : Fe => Fe2+ + 2e- Cathodic = O2 + 2H2O + 4e- => 4OH-
 Anodic reaction = Cathodic

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 Korosi Baja
1. Corrosion potential (Open circuit potential)
The electrochemical potential of a metal freely exposed to a corrosive
environment. Often denoted Ecorr or OCP
2. Corrosion current (or current density)
The anodic current Icorr (current density) at the corrosion potential

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• Uniform Attack
Oxidation & reduction
occur uniformly over
surface.
• Selective Leaching
Preferred corrosion of
one element/constituent
(e.g., Zn from brass (Cu-Zn)).
• Stress corrosion
Stress & corrosion • Erosion-corrosion
work together Break down of passivating
at crack tips. layer by erosion (pipe
elbows).
• Pitting
Downward propagation
of small pits & holes.

• Intergranular
Corrosion along
grain boundaries,
• Galvanic
often where special
Dissimilar metals are
• Crevice Between two
phases exist. pieces of the same metal.
physically joined. The
more anodic one Rivet holes
corrodes.(see Table
17.2) Zn & Mg
very anodic.

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 Bentuk Korosi (2)

Bentuk-bentuk Korosi

Korosi Merata Korosi Lokal

Murni interaksi dengan Hasil interaksi dengan lingkungan dan

lingkungan ada faktor gaya luar yang bekerja

Korosi Korosi Korosi Batas Korosi Stress corrosion

Hydrogen Selective Sumuran/pitting Korosi Fatigue
Celah/ butir/ Erosi/ Fretting
damage leaching Galvanik cracking corrosion
corrosion crevice Intergranular Erosion
corrosion corrosion corrosion

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Prevention:
 Pengecatan
 Metal coating
(pelapisan)
 Anoda tumbal (sacrificial
anode)

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Korosi Galvanic

Penyebab:
Material berbeda
Elektrolit
Ada penghantaran arus (tersambung)

Pencegahan :
Choose metals close in galvanic series
Have large anode/cathode ratios
Insulate dissimilar metals
Use “Cathodic protection”

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Korosi Galvanic (electron flow)

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Korosi Galvanic (Titanium vs CuNi 90/10)

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Korosi Galvanic (Titanium vs CuNi 90/10)

1. Always coat the noble metal!

2. Use Distance Spool to avoid galvanic corrosion

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Korosi sumuran (pitting) and celah (crevice)

Penyebab: Terjadi perbedaan

konsentrasi di electrolyte (cause
some areas high in ion concentrations Prevention:
that accelerate oxidation) Weld – don’t rivet
Use non-absorbing gaskets
Polish surfaces
Add drains – avoid stagnant water
Adjust composition; e.g., add Mo to SS
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Korosi sumuran (pitting)
AISI 316 In piping system transporting seawater
AIS 316 Chloride containing electrolyte

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Korosi crevice

CONDITION:
 Seawater
 High chloride content
 Temperature 31 C
 22% Cr duplex stainless steel
 Corrosion beneath rubber

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Korosi batas butir
Terjadi umumnya di stainless steel /material yang mengalami precipitasi
e.g. : Chromium carbide forming in SS, leaving adjacent areas depleted in Cr

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Cross section of area shown above.

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PENCEGAHAN/perbaikan :
Perlakuan panas ( heat treat to redissolve carbides)

Gunakan stainless yang kadar karbon rendah atau

Alloy with a material that has stronger carbide formation
(e.g., Ti or Nb)

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Korosi - Erosi
Penyebab : abrasive fluids impinging on
surfaces
Banyak dijumpai dalam piping, propellers,
turbine blades, valves and pumps

Pencegahan:
•Change design to minimize or eliminate
fluid turbulence and impingement effects.
•Use other materials that resist erosion
•Remove particulates from fluids

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KOROSI EROSI

Korosi erosi adalah kenaikan laju kerusakan atau serangan pada logam
yang dikarenakan adanya gerakan relatif antara fluida yang korosif
dengan permukaan logam. Umumnya gerakan ini relatif cepat karena
adanya pola gesekan yang menimbulkan efek aus pada permukaan
logam
Produknya berbentuk groove, gully, wave, rounded hole, dan valley serta
menampilkan bentuk kerusakan yang berpola

Erosion Corrosion pada

Tube Wall Condenser
Fontana, 1967, Corrosion Engineering,

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CONTOH EROSI KOROSI

Erosion corrosion failure of cast 316 Erosion corrosion failure of flange

type stainless steel impeller pipe

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KAVITASI

Kavitasi disebabkan oleh pecahnya gelembung uap dipermukaan logam,

Mekanismenya:
1. Fluida menerjang permukaan logam
2. Tekanan hidrodinamika lokal turun
3. Timbul gelembung dipermukaan logam
4. Aksi mekanik, misalnya adanya putaran, menyebabkan tekanan hidrodinamik
lokal naik
5. Gelembung pecah, timbul gaya tekan yang besar pada permuk. Logam
6. Terjadi deformasi plastik pada logam

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 Occurs in alloys in which one
element is preferentially removed –
e.g., in Brass, Zinc is electrically
active and is removed, leaving
behind porous Copper
 Occurs in other metals, such as Al,
Fe, Co, Cr

Pencegahan:
• Use protective coating to protect surfaces
• Use alternative materials

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Stress Corrosion Cracking

Aka: stress corrosion cracking

Retak sepanjang batas butir atau
memotong butir kareana pengaruh
lingkungan dan tegangan (biasanya
akibat sisa pengerjaan)
Stainless steel pada
Heat exchanger etc

Solutions: Reduce stress levels

Heat treatment
Atmosphere control

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 Metals loose strength when Hydrogen is absorbed
through surface, especially along grain boundaries and
dislocations
 Often occurs as a result of decorative plating
 High strength steels particularly susceptible
 Can be removed by “baking” the alloy

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Perlindungan Korosi
Sacrificial Anode Applied Voltage

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 Pelapisan& Pasifasi
Beberapa material
membentuk lapisan oxide
yang stabil, dan tahan
terhadap korosi (pasifasi)

Surface can be coated with protective layers: painted,

anodized, plated (Caution!!! Cracks in plating or paint can
lead to crevice corrosion!)

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Pengamatan KOROSI

Muyac. Handbook Of Corrosion Engineering. Mc Graw Hill

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 • Self-protecting metals!
--Metal ions combine with O
to form a thin, adhering oxide layer that slows corrosion.
• Reduce T (slows kinetics of oxidation and reduction)
• Add inhibitors
--Slow oxidation/reduction reactions by removing reactants
(e.g., remove O2 gas by reacting it w/an inhibitor).
--Slow oxidation reaction by attaching species to
the surface (e.g., paint it!).
• Cathodic (or sacrificial) protection
--Attach a more anodic material to the one to be protected.

Adapted
from Fig.
17.14,
Callister
6e.
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