Combating with corrosion is very important. So in this article, we will look at the methods that can be considered in combating corrosion.
Select proper material:
Keeping in view the environmental conditions and possible corrosion phenomena, water flow rate and temperature, etc. right metal should be chosen to avoid incoming problems. Moreover, the cost of the material will also be considered. The following tests must be done for the proper selection of material.
- Galvanic effect
- Stress Test
- Corrosion test
Proper Design:
Proper design Consideration should be kept in view to minimize the corrosion difficulties as an important factor. The ease of cleaning should be provided in the design.
The use of dissimilar metals should be avoided. Foundation should be made in such a way that vibration must be absorbed.
Inhibitors
The use of various inhibitors as additives to decrease corrosion of metal in the environment is an important means of combating corrosion. Inhibitors are effective as the result of their combating influence on the cathode or anodic reactions.
Examples are chromate, Phosphate, and silica. Inhibitors that minimize corrosion by inhibiting anodic polarization are called anodic inhibitors.
Inhibitors are organic types used to control the control cathode polarization and are called cathodic inhibitors. Some inhibitors that act as anode as well as cathode are called mixed inhibitors. Example Zinc Chromate
Cathode Protection:
These are the two methods generally we use for cathodic protection.
- Sacrificial Anode method
- Impress EMF method
Sacrificial Anode Method:
In the sacrificial anode method zinc, Hg, etc. are used as anode in electrical contact with material to be protected. So, the anode material is eroded and the cathode is protected. Due to the sacrifice of anodic material, is called the sacrificial anodic method.
Impressed EMF method
In the case of impressed emf the direct current is provided by an external device and passed through the system by use of a non-sacrificed anode such as carbon, or platinum.
Anodic Protection
Still, there is another method called anodic protection in which corrosion control involves providing the metal by applying the external current.
Coating and Lining
The use of metallic and non-metallic coating and lining is an important influence for combating corrosion. Coating thick layers of plastic, rubber, glass, or ceramics. Coating such as organic paints of aromatics lignin derivatives forms a protective insoluble film on the metal surface.
Metallic Coating:
The perfect coating can be accomplished by base metal with a continuous non-porous layer of noble metal. This is expected on a large scale and forms the resistant self-protecting metal. Copper, zinc, cadmium lead, and chromium are exclusively employed. Metallic coating is usually in these ways
Dipping
Electrolytic deposition
Spraying
Galvanizing
This is a coating of zinc on iron or steel in passing the cleaned iron through a layer of flux into molten zinc.
Chromium Coating:
This involves chromium casting on the base metal.
Cadmium Casting
It behaves like zinc and is applied as a coating to Fe and steel.
Factors Influencing Corrosion:
There are several factors which influence the rate of corrosion. These factors are divided into two categories.
- Physical Factors
- Chemical Factors
Let’s discuss the physical factors first.
Grain density
Differences in the grain density of the metal surface cause one area to be anodic while the surrounding area will be cathodic. Thus, two adjacent grains of different densities create a corrosion cell.
Temperature
The rate of corrosion increased with rising temperature. Any temperature variation within a piece of metal will cause the warmer portion to become anodic. Also, some metals are charged and cause corrosion if they are galvanized at rising temperatures and potential.
Velocity
The higher velocity of water increases corrosion by transporting oxygen to the metal by carrying away corrosion products. Higher velocity also causes the corrosion of metal surface protecting oxide film. When velocity is low, deposition of suspended solids is established in localized corrosion cells thereby increasing the corrosion rate.
Dissimilar Metals
The direct contact of two dissimilar metals in a conductive solution may cause a potential difference between them (the metal of lower potential becomes anode) and result in the formation of an active galvanic cell with subsequent corrosion of the anodic metal.
Relative area of anode and cathode
The relative area of the anode and cathode is an important factor in corrosion. The rate of corrosion increases in proportion to the ratio of the cathode area to the anodic area.
Now Let’s discuss some chemical factors.
PH
The effect of PH on corrosion generally depends upon the behavior of metal oxides. If the metal oxide is soluble in acid, then the metal will corrode rapidly. Some oxides dissolved in both alkaline and acidic media are called amphoteric oxides. Some metals that are not dissolved in any acid or base are called noble metals.
Dissolved salts
Corrosion rate for metals increases as dissolved salt concentration increases. The mineral constituents fixed in water have various effects on the rate of corrosion. Out of these chloride ions penetrate protective metal oxide film and promote highly active localized attack.
Conversely, hardness-producing salts like Ca, and Mg may be precipitated to form a protective film to inhibit corrosion.
Dissolved Gases
Several gases are normally found dissolved in water. These include CO2, etc. CO2 reduces PH and promotes acid attack. O2 on the other hand acts as a depolizer and promotes corrosion. Similarly, Cl2 promotes active corrosion.
Suspended Solids
Mud, sand, silt, dirt, and other particles may enter the system and settle down. They form deposits that promote differential aeration corrosion.
Micro Organism
Some micro-organisms are acidic producers and decrease the PH of the system resulting in promoting corrosion.
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