CORROSION Meta Fitri Rizkiana, S.T.

,
M.Sc.
PASSIVITY

Some normally active metals and alloys, under

particular environmental conditions, lose their
chemical reactivity and become extremely inert.
 This phenomenon, called passivity
 Example: chromium, iron, aluminium

Passive behavior results from the formation of a

highly adherent and very thin oxide film on the
metal surface, which serves as a protective barrier
to further corrosion.
Stainless steels are highly resistant to corrosion in a
rather wide variety of atmospheres as a result of
passivation.
 They contain at least 11% chromium that, as a solid-solution
alloying element in iron, minimizes the formation of rust;
 A protective surface film forms in oxidizing atmospheres.
 Stainless steels are susceptible to corrosion in some
environments, and therefore are not always “stainless.”
Aluminum is highly corrosion resistant in many
environments because it also passivates.
If damaged, the protective film normally reforms very
rapidly.
However, a change in the character of the environment
alteration in the concentration of the active corrosive
species may cause a passivated material to revert to an
active state.
CATEGORIES AND FORMS OF
CORROSION (MECHANIC OF
ATTACK) Original surface

Group I: readily identified

by visual examination.
1. General corrosion
2. Localized corrosion
pitting
– Crevice corrosion
3. Galvanic corrosion

Noble metal
Base metal
 erosion flow
Group II: may require
supplementary means of
examination.
Cavitation bubbles
5. Velocity effect
• Erosion-corrosion
• Cavitation
• Fretting load
vibration
6. Intergranular attack (IGA)
7. Dealloying (parting
corrosion) Exfoliation Weld decay
HAZ Weld

Layer Plug
 Stress corrosion cracking (SCC)
GROUP III
Static stress
Usually should be verified by
microscopy (optical or SEM),
although sometimes can be Corrosion fatigue
observed visually.
8. Cracking phenomena Dynamic stress
– Stress Corrosion Cracking
(SCC)
– Hydrogen-Assisted Cracking Internal attack
(HAC), Sulfide Corrosion
Cracking (SSC) Fissure (celah)
– Liquid Metal
Cracking/Embrittlement
(LMC/E)
Scaling
9. High-temperature corrosion
scale
I-(1) GENERAL
CORROSION
Characterized by an even, regular loss of metal from the corroding
surface.
 Apply to all metals at some conditions
 Atmospheric rusting
 Zinc dissolution by dilute acid
 Tarnishing silver
 It is the most desirable form of attack
 Easy and reliable to predict the life of equipment.
 Observed in single metal or bimetallic metal corrosion.
I-(2) LOCALIZED
CORROSION
All or most of attack occurs at discrete areas.
 To be a “pit” its depth => wide
 Pitting may cause brittle crack failure
 Unwanted form of corrosion attack
 Usually attack corrosion resistant metals
Crevice corrosion:
 occurs in crevices and recesses.
 Usually due to oxygen concentration cell effects.
I-(3) GALVANIC
CORROSION
Known as bimetallic or two metal corrosion
 Accelerated attack by electrical contact between
dissimilar conductor in an electrolyte.
 Anodic member of the couple suffers the most
 Lower ratio of anodic area to cathodic area increases
the damage.
 Farther apart the relative positions between the anodic
and the cathodic in the galvanic series, more higher the
potential of corrosion.
 II-(4) VELOCITY
EFFECT
Comprise of
 Erosion-corrosion
 Cavitations
 Fretting
Erosion-corrosion
 Attack by high-velocity flow or impingement
 Two mode of attack:
 Purely mechanical: abrasion and wear
 Corrosion related: protective film is removed by the flow
 Identified distinctively by flow pattern
Cavitations
 Attack by implosion of bubbles formed where local pressure
drops below the vapor pressure.
 Observed frequently on ship propellers, pump impellers.
Fretting
 Associated with motion
 Tearing away of small particles between the facing surfaces.
II-(5) INTERGRANULAR
ATTACK (IGA)
 Attack at the grain boundaries of metal
 The whole grain may fall out
 Caused by
 improper heat treatment
 Heat affected zones (HAZ) of weld
II-(6) DEALLOYING
CORROSION
Or parting corrosion
 Selective removal of one metallic constituent of an
alloy.
 Dezincifation of yellow brass.
 Layer-type: removal occur uniformly
 Plug-type: removal localized to form pit
Selective leaching
Weakens structure seriously without changing the
apparent physical dimension.
III-(7) CRACKING
PHENOMENA
Environmental cracking
a) Stress Corrosion Cracking (SCC)
– An anodic process
 Chloride SCC of stainless steel
b) Hydrogen-Assisted Cracking (HAC)
– A cathodic process
 Sulfide stress cracking (SSC) of hardened steel by H2S.
c) Liquid Metal Cracking (LMC) or Liquid Metal
Embrittlement (LME)
– A fissuring process by liquid metal
 Action of Hg on cold-worked brass
 Action of molten Zn on austenitic SS.
 III-(8) HIGH TEMPERATURE
CORROSION

Phenomena involving conversion of the metal to a metallic

compound
 Metal  oxide
 Metal  halides, sulfides, carbides, nitrides, etc.
Reaction may occurs
 At surfaces or
 Within the metal structure
CORROSION PREVENTION:
INHIBITORS
Substances that, when added in relatively low
concentrations to the environment, decrease its
corrosiveness.
The specific inhibitor depends both on the alloy and on
the corrosive environment.
INHIBITORS
Several mechanisms:
a) React with and virtually eliminate a chemically
active species in the solution (such as dissolved
oxygen).
b) Inhibitor molecules attach to the corroding surface
and interfere with either the oxidation or the
reduction reaction, or form a very thin protective
coating.
Inhibitors are normally used in closed
systems such as automobile radiators and
steam boilers.
CATHODIC PROTECTION
One of the most effective means of corrosion prevention,
Can be used for all eight different forms of corrosion,
May, in some situations, completely stop corrosion.
Cathodic protection technique employs a galvanic couple:
 the metal to be protected is electrically connected to another
metal that is more reactive in the particular environment.
 The latter experiences oxidation, and, upon giving up electrons,
protects the first metal from corrosion.
 The oxidized metal is called a sacrificial anode,
 Mg and Zn are commonly used because they lie at the anodic
end of the galvanic series.
CREVICE CORROSION
Korosi celah didfinisikan sebagai korosi local yang disebabkan oleh
adanya celah yang terbentuk dari dua permukaan dimana paling tidak
satu permukaannya adalah logam
Perbedaan konsentrasi oksigen pada celah
Perbedaan konsentrasi larutan
PENCEGAHAN
Kurangi atau buat seminimal mungkin adanya kemungkinan
terjadinya celah
Hindari dalam perencanaan suatu peralatan adanya kemungkinan-
kemungkinan untuk membuat bentuk-bentuk yang mempunyai sudut
tajam dan daerah-daerah yang menyebabkan adanya aliran stagnan
Berikan inhibitor
Pemberian lapisan pelindung
KOROSI GALVANIS
Korosi yang terjadi karena adanya dua logam atau material yang berbeda
jenis terdapat dalam satu elektrolit
Jenis logam yang lebih anodic akan terjadi korosi

Usahakan tidak terjadi coupling

Hindarkan adanya kemungkinan terjadinya suatu kondisi dimana terjadi
perbandingan luas anode yang lebih kecil terhadap luas permukaan logam
yang lebih bersifat katodik
Buatlah rencana bahwa pada material yang bersifat anodic mudah diganti
Penggunaan sekat tidak porous
Inhibitor
KERUSAKAN KAVITASI
(CAVITATION DAMAGE)
Kerusakan material disebabkan karena adanya kavitasi dari cairan di
dalam aliran fluida pada fase antar muka padat-cair
Terjadinya gelembung-gelembung udara menyebabkan adanya
kerusakan lapisan film pelindung korosi.
Adanya pemecahan gelembung-gelembung uap yang berulang-ulang
pada permukaan logam atau material akan dapat menyebabkan
kerusakan secara fisik pada lapisan film pelindung korosi (cavitation
corrosion), terjadinya deformasi dan keretakan permukaan (cavitation
deformation), atau terjadi kelelahan pada permukaan metal atau material
(cavitation fatigue)
Adanya daerah tekanan rendah yang disebabkan adanya aliran yang
divergen, pusaran air, hambatan-hambatan pada aliran atau karena
vibrasi
PENCEGAHAN
Hindari kondisi yang menyebabkan tekanan absolut turun dibawah
tekanan uap dari media cairnya
Pergunakan perlindungan secara proteksi katodik
Buat perencanaan sedemikian rupa sehingga misalnya di dalam
merencanakan perpipaan dapat diharapkan bahwa adanya kavitasi
atau pembentukan gelembung-gelembung udara tidak ada
Usahakan tidak terjadi endapan pada permukaan material
KOROSI EROSI
Proses korosi yang dipercepat oleh kecepatan aliran dari fluida dan
adanya abrasi fluida
Aliran yang amat cepat dapat menyebabkan rusaknya lapisan film
pelindung korosi dimana kemudian dengan adanya aliran yang tetap
maka permukaan logam seperti terkikis dan terjadilah korosi
PENCEGAHAN
Turunkan kecepatan alir fluida/cairan yang mengalir dan usahakan
adanya aliran yang tenang
Usahakan aliran stream-line, hindari hal-hal yang dapat
menyebabkan aliran turbulen
Memperkecil factor-factor penyebab perubahan aliran atau arah
aliran
Pertebal beberapa bagian yang merupakan daerah kemungkinan
terjadi korosi erosi
Proteksi katodik
FRETTING CORROSION
Kerusakan local antar permukaan material yang berhubungan,
dipercepat adanya gerakan teratur antar permukaan yang
menyebabkan terjadinya gesekan

Berikan lubrikasi pada permukaan yang bergesekan (pilih system

lubrikasi yang tepat dan efisien)
INTERGRANULAR
CORROSION
Korosi yang sangat selective terjadi pada batas antar kristal
(intergranular) pada logam atau alloy

Reaksi chrom carbide (terjadi pada temperature tinggi) 

kekurangan chrom sehingga proteksi menurun

Pilih logam dengan kandungan carbon yang rendah

Penambahan titanium / niobium
SELECTIVE ATTACK
(LEACHING)
Proses ekstraksi dari beberapa komponen suatu logam alloy dengan
meninggalkan logam sisa dalam alloy sehingga kekuatan
mekaniknya berubah

Dezincfication, graphite corrosion

Proteksi katodik
Pemakaian inhibitor
PERUSAKAN KARENA
HYDROGEN
Perusakan logam secara mekanis karena adanya hydrogen hasil
produk korosi atau lingkungan sumber hydrogen yang berdifusi ke
dalam logam
Atom H mudah berdifusi dalam logam

Penggunaan resistant alloy (FCC alloy)

Proteksi katodik
Minimalkan atau hilangkan sumber hidrogen