Uniform, or General Attack. Galvanic, or Two-Metal Corrosion. Crevice Corrosion. Pitting

FORMS OF CORROSION
1. Uniform, or General Attack.
2. Galvanic, or Two-Metal Corrosion.
3. Crevice Corrosion.
4. Pitting.
5. Intergranular Corrosion.
6. Selective Leaching , or Parting.
7. Stress corrosion.
8. Erosion Corrosion.
Under Deposit Corrosion - It is more prevalent at
the bottom of horizontal lines, on lower floors,
and where flow rates are slowest.
The degree of wall loss occurring under deposits
is generally proportional to
the volume or size of the internal deposit.
Condenser water pipe
UNIFORM ATTACK
It is normally characterized by a chemical
or electrochemical reaction which
proceeds uniformly over the entire
exposed surface.
The metal becomes thinner and

eventually fails.
- A piece of steel or zinc immersed
in dilute sulfuric acid will normally
dissolve at a uniform rate over
its entire surface.
- Anodic and cathodic areas keep

shifting , so corrosion is spread
more or less evenly over the
entire surface of the metal.
This 40 year old sample of 8 in. schedule 80 pipe,
while clearly containing deposits of iron oxide,
shows very even wall loss and long remaining
service life. The pipe was cleaned using high
pressure water jet and returned to service with
approximately schedule 40 thickness remaining.
Uniform corrosion of carbon steel
occurs when the surface is not protected
by passive films (formed by reactions of
the metal with the environment), scales
(deposits of minerals from the
environment), or protective coatings
This happens in many acidic
environments. Unfortunately, most
general attack is not uniform and
this can lead to areas of greater and
lesser metal loss.
Similar corrosion patterns are found
in condensate return lines of steam
systems where air leaks cause the
liquid in the lines to become acidic.
This corrosion pattern is sometimes

termed condensate or CO2
channeling.
In this case, the corrosion was
caused by a debonded coating that
led to corrosion by groundwater
seeping underneath the debonded
coating
General corrosion is more likely to
occur in locations where acidic
water collects. This can be at the
bottom of horizontal piping, but it
can also occur in locations where
condensation occurs due to thermal
gradients
It is important to monitor corrosion
rates in the appropriate location
including the bottom of horizontal
flowlines and the top of lines where
uninhibited condensate can collect.
Combating Uniform Attack
General corrosion is normally controlled

by
1. Design, for example, adding thicker

metal corrosion allowances, by
including appropriate drainage and
inspection capabilities.
2. Use of protective coatings or
corrosion inhibitors, or
3. By the selection of corrosion-

resistant alloys (CRAs).
4. Cathodic protection and
modification of the environment, for
example, dissolved gas removal,
can also be effective.
5. The choice of more suitable
materials, inhibitors , protective
coatings , or combinations of
these expedients.
GALVANIC OR TWO-METAL CORROSION
When two dissimilar metals are in

contact with each other (or otherwise
electrically connected) and exposed to a
conductive solution, a potential is set up
between these two metals and a current
flows.
A common example of galvanic corrosion is shown where a
brass valve connected to galvanized steel piping. The
galvanic corrosion on the pipe exterior is obvious.
Standard emf series of metals
Corrosion on the less- corrosion-
resistant metal is usually increased
and attack on the more resistant
material is decreased, compared to the
behavior of these metals when they are
not in contact.
Example:
Galvanized steel hot water tanks failed

where copper tubing , from an external
gas heater , was joined to the tank. Also,
long tubes of aluminum supported by
steel.
In some domestic waters at
temperatures over 180 oF of the
steel becomes anodic and corrodes
while zinc become the cathode.
Note in the galvanic series the more
noble position assumed by the stainless
steels in the passive state as compared
to the higher position of these materials
when in the active condition.
These materials are chromium steels,

and the 18Cr-8Ni stainless steels with
and without 2% molybdenum.
The bracket indicates that in most
practical applications there is little
danger of galvanic corrosion if metals in
a given bracket are coupled or in contact
with each other.
This is so because these materials are

close together in the series and the
potential generated by these couples is
not great.
Area effect
An unfavorable or bad area ratio consists of a
large cathode and a small anode, because the
current density (A/cm2) is greater for a small
electrode than for a larger one.
The greater the
current density of
the current
leaving an anodic
area, the greater
is the corrosion
rate.
Under certain conditions, as shown here, it
may also exist at steel to steel contact
points - where new pipe meets old, and
where different ground potential exists
New sections of pipe are often
anodic to the older pipe either
because the old pipe is covered with
heavy layers of rust that are
cathodic to the new pipe or because
the new pipe is placed in a more
aggressive environment.
Some organizations have adopted
the policy that whenever a new pipe
installation occurs, they will install
galvanic anodes in the location
Another example of the higher corrosion
activity usually existing at direct brass to
iron connections.
COMBATING GALVANIC CORROSION
1. Selecting combination of metals as

close together as possible in the
galvanic series.
2. Avoid combinations where the area of

the less noble material is relatively
small.
•3. Insulate dissimilar metals wherever
practicable. It is important to completely
insulate if possible.
•4. Apply coatings, but with caution. Keep such

coating in good repair.
5. Add chemical inhibitors to the
corrosion solution.
6. Avoid joining materials well apart in

the series by threaded connections,
as the thread will probably deteriorate
excessively.
-Spilled liquid or condensed moisture
can collect and remain in the thread
grooves.
--Welding joints using welds of the same

alloy are even better.
•7. If possible, install relatively small
replaceable sections of the less noble
materials at joints and increase its
thickness in such regions.
For example, attaching replaceable

piece of the less noble material in the
vicinity of the galvanic contact.
8. Control of the water chemistry on
the inside is necessary to prevent
general corrosion of the galvanized
steel, which is seldom galvanized on
the pipe interior.
9. The lack of reducible species is
the main reason why galvanic
corrosion is not common in
downhole oil well equipment, where
there is little oxygen and other
reducible species are unlikely.
10. Filler metals for welding should
always be cathodic to the base
metals being joined.
11. The inherent corrosion
resistance of aluminum in a marine
atmosphere means that the
aluminum is protected by a passive
film, and the effects of joining it to
stainless steel are minimal.

Uniform, or General Attack. Galvanic, or Two-Metal Corrosion. Crevice Corrosion. Pitting

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FORMS OF CORROSION

1. Uniform, or General Attack.

2. Galvanic, or Two-Metal Corrosion.

6. Selective Leaching , or Parting.

The metal becomes thinner and

- Anodic and cathodic areas keep

This corrosion pattern is sometimes

General corrosion is normally controlled

1. Design, for example, adding thicker

3. By the selection of corrosion-

When two dissimilar metals are in

Galvanized steel hot water tanks failed

These materials are chromium steels,

This is so because these materials are

activity usually existing at direct brass to

1. Selecting combination of metals as

2. Avoid combinations where the area of

•4. Apply coatings, but with caution. Keep such

6. Avoid joining materials well apart in

--Welding joints using welds of the same

For example, attaching replaceable

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