DR Rao Corrosion Management Presentation
DR Rao Corrosion Management Presentation
DR Rao Corrosion Management Presentation
By
Why is it a problem?
Recipe for corrosion
Active metal
Water
Oxygen
(atmospheric corrosion)
Acid
(chemical corrosion)
Salt
High temperature
1.1 Basic corrosion
METALLURGY
2.1 Galvanizing fundamentals
• Galvanization, or galvanisation is the process of applying a
protective zinc coating to steel or iron, to prevent rusting.
• Hot dip galvanizing is a method of submerge steel or iron
in a bath of molten zinc.
• Galvanizing protects:
– corrosive substances from reaching the more delicate part of
the metal.
– in a way if the coating is scratched, the exposed steel will still
be protected by the remaining zinc.
– base metal by corroding before iron.
2.1 Galvanizing fundamentals
FAILURE ANALYSIS
3.0 Failure analysis
• There are 5 methods of corrosion mitigation:
– Materials selection
– Coatings
– Inhibators
– Cathodic protection
– Design
3.1 Material Selections
• Metal and alloy has unique and inherent
corrosion behaviour.
• The corrosion resistance of a metal depends
on the environment to which it is exposed,
that is:
– the chemical composition
– Temperature
– velocity
3.1 Material Selections
• When the corrosion resistance of the material
increases, the rate of corrosion decreases (given
corrosivity of the environment)
1975 1995
All industries
Total 82 296
Avoidable 33 104
Motor vehicles
Total 31.4 94
Avoidable 23.1 65
Aircraft
Total 3 13
Avoidable 0.6 3
Other industries
Total 47.6 189
Avoidable 9.3 36
Table 2. The results of the 1978 and 1995 Battelle/NIST studies (Source: Economic Effects of
Metallic Corrosion in the United States, Battelle Columbus Laboratories and the National
Institute of Standards and Technology (NIST), 1978, and Battelle estimates)
4.3 Factors influencing corrosion
Reduce corrosion costs • Lower maintenance and repair • Identify all corrosion costs by
costs review of total processes,
• Extended useful lives of equipment, and buildings
equipment and buildings • Quantify corrosion costs
• Reduction of product loss from • Implement plan to reduce
corrosion damage costs
Lower risk of failure • Safety • Review process and products
• Product liability for exposure to risk
• Avoidance of regulation • Evaluate risk and
• Loss of goodwill consequences of failure
• Lower exposure by technology
change
Develop new and expanded • Coatings • Apply emerging technology
markets • Alloys • Develop competitive
• Inhibitors advantage by more corrosion-
• Corrosion monitors resistant product
• Transfer existing technology to
other industries